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Type :
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AIternator
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Specification :
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24V 50A
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Pulley :
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3PK
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Brand :
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nuojin
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Number :
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8971865511, 8973666120
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Quality :
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Renovate
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Delivery time :
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10DAY
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This installation method is formulated in accordance with the Isuzu Original Service Manual and the Industry Standard for Installation of Commercial Vehicle Electrical Systems (QC/T 413-2002). It is applicable to the replacement and installation of 24V generator assemblies for Isuzu series commercial vehicles.
Special Tools: Socket wrenches (10mm, 12mm, 14mm), torque wrench, belt tension gauge, Phillips/flathead screwdrivers.
Materials: Generator mounting bolts (original equipment manufacturer (OEM) specification), lock washers, generator drive belt, insulating tape, thread locking adhesive.
Protective Equipment: Insulated gloves, safety goggles, anti-slip work gloves.
Disconnect the negative cable of the vehicle battery to prevent short circuits during installation.
Check that the model of the new generator matches the original one of the vehicle, focusing on verifying the voltage rating (24V), mounting hole positions and pulley specifications.
Clean oil stains and rust on the surface of the generator mounting bracket to ensure tight fit.
Place the generator on the engine-side mounting bracket and align it with the mounting holes.
First install the locating bolts (do not tighten them completely), then install the remaining mounting bolts to ensure the generator is free from displacement.
Use a torque wrench to tighten all mounting bolts crosswise and symmetrically to the torque specified by the OEM (usually 25–30 N·m).
Apply a small amount of thread locking adhesive to the bolt threads and install lock washers to prevent bolt loosening due to vehicle vibration during operation.
Route the drive belt over the generator pulley, crankshaft pulley and tensioner pulley in sequence in accordance with the engine belt routing diagram.
Adjust the position of the tensioner pulley and use a belt tension gauge to check the belt tension, which shall comply with the OEM standard (the typical tension for a 24V generator drive belt is 80–120 N).
Tighten the tensioner pulley bolts and recheck the belt tension to ensure there is no risk of slipping.
Locate the terminal block on the rear end of the generator and identify the B+ terminal (positive output), D+ terminal (field excitation signal) and ground terminal.
Connect the positive cable of the vehicle wiring harness to the B+ terminal, install a flat washer and a lock nut, and control the tightening torque within 10–15 N·m.
Connect the field excitation signal wire to the D+ terminal and ensure the connector clip is locked securely without loosening.
Verify that the ground terminal is reliably connected to the engine block; remove paint or rust from the contact surface to ensure good electrical grounding.
Connect the negative cable of the battery and ensure the battery terminal is securely fastened.
Start the engine and let it run at idle speed for 5 minutes; observe whether the generator produces abnormal noise or vibration.
Use a multimeter to measure the output voltage of the generator. The voltage shall be 27–28V at idle speed and not less than 25V under full load, which meets the 24V system standard.
Check the operation status of the drive belt for misalignment or slipping; inspect all wiring terminals for overheating or smoke.
These precautions are formulated in accordance with Isuzu Commercial Vehicle Service Manual - Electrical System Volume (2023 Edition) and the industry standard QC/T 413-2002, covering safety specifications and quality control key points throughout the entire installation process.
Before installation, the negative cable of the vehicle battery must be disconnected, and wait for 5–10 minutes to allow the vehicle-mounted capacitor to discharge completely, so as to prevent short circuits from burning out the generator, ECU and other precision components.
It is forbidden to touch the generator terminals without power-off to avoid electric shock or arc burns.
Confirm that the model of the new generator matches the original vehicle, focusing on checking the voltage rating (24V), mounting hole dimensions, pulley diameter and number of grooves. Incompatible accessories will lead to low power generation efficiency or mechanical wear.
Inspect the generator appearance: ensure there is no housing crack, no bearing jamming or abnormal noise, and no oxidation or rust on the terminals; otherwise, installation is prohibited.
The operation area must be clean and dry to prevent oil stains and water from entering the generator interior.
Operators shall wear insulated gloves and safety goggles to avoid injury caused by falling metal debris or tools.
Tighten the generator mounting bolts in a crosswise and symmetrical sequence and strictly follow the OEM torque standard (25–30 N·m). Never use an extended wrench for violent tightening.
Lock washers must be installed on the bolts, and a small amount of thread locking adhesive (recommended: Loctite 243 medium-strength adhesive) shall be applied to the threads to prevent bolt loosening and falling off due to vehicle jolting.
It is forbidden to drill additional holes on the bracket or generator housing to avoid damaging structural strength and grounding paths.
The belt routing must be strictly in accordance with the belt routing diagram in the engine compartment. Reverse installation will cause the generator to rotate in the opposite direction and fail to generate electricity.
The belt tension shall be measured with a special belt tension gauge, with the standard value ranging from 80–120 N. Excessive tension will easily cause early bearing wear, while insufficient tension will lead to belt slipping and fluctuating power generation voltage.
After adjusting the tension, start the engine and run it at idle speed for 3–5 minutes, then recheck the tension to ensure no changes.
Clearly distinguish the functions of generator terminals: B+ terminal (thick cable positive output), D+ terminal (thin wire field excitation signal) and ground terminal. Incorrect or reverse connection is prohibited.
When connecting the B+ terminal, install a flat washer and a lock nut, control the tightening torque within 10–15 N·m, and wrap the terminal with insulating tape for protection to prevent short circuit with the engine block.
The ground terminal must be directly connected to the metal surface of the engine block. Remove paint, rust or oil stains from the contact surface to ensure the grounding resistance is less than 0.1Ω; otherwise, unstable power generation voltage will occur.
The wiring harness shall be routed away from high-temperature areas of the engine (e.g., exhaust pipe) and moving parts (e.g., fan), and fixed with clips to prevent wiring harness wear and aging.
References：
The source of the aforementioned text is specified as follows, including authoritative references and verifiable access channels.
QC/T 413-2002 Basic Technical Requirements for Automobile Electrical EquipmentIt is an automotive industry standard of the People's Republic of China, issued on December 31, 2002, and implemented on March 1, 2003, replacing QC/T 413-1999. This standard specifies the technical requirements, test methods and inspection rules for automobile electrical equipment, serving as a universal basis for the installation and acceptance of automotive electrical systems. It can be retrieved and downloaded from the Ministry of Industry and Information Technology, the National Technical Committee of Automobile Standardization (SAC/TC114) or authorized standard platforms.
Isuzu Original Service ManualMarked as the
2023 Edition of Electrical System Volume in the text, it is an official technical document of Isuzu, designed to guide authorized service outlets in the replacement and installation of generator assemblies. The manual is usually subdivided by vehicle model/engine model (e.g., 4JB1, 4JJ1, etc.) and contains key parameters such as torque values, terminal definitions, belt routing diagrams and test standards.
Key parameters in the text, such as bolt torque (25–30 N·m for mounting bolts, 10–15 N·m for B+ terminal nuts), belt tension (80–120 N) and power generation voltage (27–28 V at idle speed), are all derived from the vehicle-specific data in the Isuzu Original Service Manual. QC/T 413-2002 provides a general framework for safety and electrical performance but does not replace vehicle-specific parameters.
Safety specifications including power-off operation, anti-loosening measures, grounding requirements and wiring harness arrangement comply with both QC/T 413-2002 and the Isuzu Original Service Manual.
For QC/T 413-2002Search for the standard number on the National Standards Full-text Public System, SAC/TC114 or authoritative standard platforms, and download the full text for clause verification.
For Isuzu Original Service Manual
Apply for the Electrical System Volume corresponding to the specific vehicle/engine model from authorized Isuzu dealers or service stations.
Or obtain it through the automaker's after-sales system or professional auto repair databases (e.g., Auto Repair Bible).
It is crucial to verify the vehicle model code, engine model and manual version to avoid misapplication of parameters.
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