Generator 1025030FE010, truck spare parts 14V/120A diesel generator set 1025030FE010

Preparation

Removal of the Old Generator

1. Take off the Drive Belt: Use appropriate tools to loosen the belt tensioner and remove the belt from the generator pulley.

2. Disconnect Electrical Connections: Locate the wire connectors on the generator, pull them out carefully, and mark the position of each connector to facilitate correct installation later.

3. Loosen the Generator Fixing Screws: Use a wrench or socket to loosen and remove the bolts and nuts that secure the generator, then take the old generator out of its installation position.

Installation of the New Generator

1. Clean the Installation Position: Use cleaning tools to carefully remove dust, oil stains, and debris from the installation position to ensure the new generator can be installed firmly and make good contact with components such as the engine.

2. Place the New Generator: Place the new generator stably in the installation position and initially fix it with bolts and nuts, but do not tighten them completely to reserve space for subsequent adjustments.

3. Connect the Wires: According to the previously marked positions, connect the wires to the corresponding interfaces of the new generator, ensuring the connections are firm and free of looseness.

4. Install the Drive Belt: Accurately fit the belt onto the generator pulley and adjust the belt tensioner to give the belt appropriate tension. Generally speaking, a deflection of 10-15mm when pressing the middle of the belt by hand is appropriate.

5. Tighten the Generator: Check if the position of the generator and the belt tension are appropriate, make fine adjustments if necessary, and then fully tighten the fixing bolts and nuts to ensure the generator is installed firmly.

Post-installation Inspection

Key Notes on Terminology and Expression

1. Brand Nomenclature: "江淮汽车" is translated as "JAC (Jianghuai Automobile)", where "JAC" is the globally recognized abbreviation of Jianghuai Automobile, balancing professionalism and readability for international audiences.

2. Technical Term Accuracy: "Deflection" is retained as the standard automotive engineering term to precisely describe the belt's elastic deformation parameter, avoiding ambiguous alternative expressions.

3. Sentence Structure Adaptation: Complex Chinese procedural descriptions are split into concise, action-oriented English sentences, in line with the norms of technical documents, ensuring that each operational step is clear and easy to follow.

4. Modal Verb Usage: The use of "may" in "may be working normally" accurately conveys the tentative nature of the preliminary inspection result, reflecting the rigor of technical operations.

Safety Protection Aspects

1. Disconnect the Power Supply: Be sure to disconnect the negative battery cable first to prevent short circuits or accidental electric shocks during installation.

2. Wear Protective Equipment: It is recommended to wear protective equipment such as insulated gloves and goggles to prevent tool slippage from damaging components in the engine compartment and avoid personal scratches or electric shocks.

3. Keep Away from Hazardous Areas: During operation, maintain a safe distance from rotating components (such as pulleys) and high-temperature areas (such as exhaust pipes) in the engine compartment to prevent accidents.

Component Inspection and Preparation Aspects

1. Confirm Model Compatibility: Ensure the new generator model is strictly compatible with the vehicle, including parameters such as the generator's mounting holes, terminal types, and pulley specifications. This avoids installation failures or operational malfunctions caused by mismatched models.

2. Inspect Generator Condition: Carefully check the appearance of the new generator to ensure there is no damage, deformation, or rust on the terminals. Manually rotate the rotor to confirm it rotates flexibly without jamming or abnormal noise.

3. Inspect Related Components: When replacing an old generator, clean oil stains and rust from the surface of the mounting bracket, and apply rust inhibitor if necessary. Meanwhile, inspect auxiliary components such as the bracket, belt tensioner, and drive belt. Promptly repair or replace them if there are issues like deformation, aging, or cracks.

Installation Operation Specifications

Mechanical Installation Details

1. Bolt Tightening Torque: Tighten the fixing bolts to the torque specified in the vehicle maintenance manual. The torque for JAC automobile generator fixing bolts is usually around 20-35N・m, with specific values subject to the corresponding vehicle model manual. It is recommended to use the diagonal step-by-step tightening method to avoid deformation of the generator housing due to uneven force.

2. Belt Installation and Tension Adjustment: When installing the drive belt, strictly follow the vehicle's belt transmission path (refer to the marks on the old belt or diagrams in the maintenance manual). The belt tension should be moderate—generally, a deflection of 10-15mm when pressing the middle of the belt by hand is appropriate.

3. Avoid Collisions and Ensure Heat Dissipation: Handle the generator with care when placing it to avoid collisions with its housing and internal components. Additionally, ensure the generator's heat dissipation area is free of obstacles to guarantee heat dissipation efficiency and prevent overheating failures.

Electrical Connection Requirements

1. Mark and Distinguish Wires: Before disassembling the wires of the old generator, make clear marks (such as taking photos or attaching labels) to specify the connection position and function of each wire. Distinguish between signal lines (such as excitation wires and sensor wires) and the main power line (the thick wire of the B+ terminal); usually, connect the signal lines first, then the main power line.

2. Inspect Wires and Ensure Secure Connections: Before wiring, check if the insulation layer of the wires is damaged or aged. Gently polish the generator terminals and wire connectors with sandpaper to remove the oxide layer and improve conductivity. All connections must be firmly tightened, and plug-in connectors must ensure the buckles are fully locked to prevent poor contact.

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