Auto Parts 24v Truck Alternator 0-35000-4868 0350004868 898890630 8980890631 For Isuzu trucks

Pre-installation Safety and Tool Preparation

1. Vehicle Safety Handling

   Park the truck on a flat surface, engage the parking brake and turn off the engine, then wait for the engine to cool down completely. Disconnect the negative terminal wire of the 24V storage battery to eliminate the risk of short circuits and electric shocks during installation.

2. Tool and Accessory Verification

   In addition to conventional tools, prepare insulating tape extra. Confirm that the new generator is of the 24V 60A specification and compatible with the vehicle model; priority should be given to original equipment manufacturer (OEM) accessories. Meanwhile, check whether auxiliary components such as the voltage regulator are in good condition.

Removal of the Old Generator

1. Take Off the Drive Belt

   Use a belt tensioner tool to loosen the belt tensioning mechanism. Remove the belt following its winding path and mark the path properly to avoid misalignment during subsequent installation.

2. Disconnect Electrical Circuits

   First, pull out the wire connector on the generator. For wires connected to terminals like the B+ terminal with a fixing nut, loosen the nut with a wrench before disconnecting the wire. You can take photos to record the wiring positions, and pay special attention to the interfaces of special wires such as the field wire (F terminal) and neutral wire (N terminal).

3. Remove the Old Generator

   Use a wrench to loosen and remove the fixing bolts that secure the generator as well as the adjusting arm fixing bolts. Take out the generator smoothly, being careful not to collide with surrounding pipelines and electrical components.

Installation of the New Generator

1. Preliminary Fixing of the Generator Body

   Place the new generator steadily on the mounting bracket, align it with the bolt holes. Hand-tighten the fixing bolts and adjusting arm bolts for preliminary positioning, without fully tightening them. Leave some room for fine adjustment to align the pulley.

2. Standardized Wiring Connection

   Wire the generator with reference to the previously taken photos. Connect the B+ terminal to the positive terminal of the storage battery, and the ground wire directly to the metal part of the vehicle body or the negative terminal of the storage battery. Connect the field wire (F terminal) to the "F" terminal of the voltage regulator. For four-pin models, the neutral wire (N terminal) must be connected to the charging indicator light on the instrument panel. After wiring, tighten the terminals and wrap the exposed metal parts with insulating tape.

3. Install and Adjust the Belt

   Fit the belt onto the generator pulley according to the marked original path. Operate the tensioner to adjust the belt tension; ideally, the belt should sag 1 - 2 centimeters when pressed. This prevents belt slipping and excessive bearing wear due to improper tension.

4. Tighten the Fixing Bolts

   Use a torque wrench to tighten all fixing bolts to ensure the generator is firmly installed, preventing displacement caused by vibration during the truck's operation.

Post-installation Inspection and Adaptation Verification

1. Restore Power Supply

   After confirming that the wiring and belt are installed correctly, reconnect and fasten the negative terminal of the storage battery.

2. Start-up Test

   Start the truck engine and observe whether the generator operates smoothly without abnormal noise. Use a multimeter to measure the output voltage; the normal output voltage of a 24V system generally ranges from 27V to 28.5V.

3. Troubleshooting

   Check if the charging indicator light on the instrument panel turns off normally. If the indicator light malfunctions or the voltage deviates from the standard range, inspect for incorrect wiring, especially the connections of the field wire and neutral wire. In case of abnormal charging, the parameters of the voltage regulator can be recalibrated.

1. High-Voltage Safety Operation Baselines

• Disconnect the negative terminal of the 24V battery throughout the entire installation process. The 24V system voltage is higher than that of passenger cars; do not touch terminal posts before power is disconnected to avoid electric shock or short circuits that may burn electrical components.

• Keep tools dry and never perform wet operations when wiring circuits. Do not reconnect the battery until all wiring is completed to eliminate the risk of high-voltage short circuits.

• Wear insulating gloves and goggles during operation. The engine compartment is densely packed with diesel pipelines, high-pressure oil pipes, and electrical components; avoid collision or dragging to prevent fuel leakage or wire damage.

2. Exclusive Wiring Specifications for 24V Systems

• Strictly match terminal functions: The B+ terminal (thick post) connects to the positive terminal of the battery, and the ground wire must be connected to the dedicated grounding point on the vehicle body or engine (poor grounding in 24V systems can easily cause abnormal power generation).

• The field wire (F terminal) must be accurately connected to the "F" terminal of the voltage regulator, and the neutral wire (N terminal) to the charging indicator light on the instrument panel. Do not mix, reverse, or omit connections—this will result in failure to generate power or damage to the regulator.

• Tighten wiring terminals with a wrench and wrap exposed metal parts with insulating tape. The wire for the B+ terminal must match the 60A current (recommended cross-sectional area ≥4 square millimeters); never replace it with a thin wire to avoid overheating and fire.

3. Precision Requirements for Component Installation

• Tighten fixing bolts to the torque specified in the vehicle maintenance manual (common standard for Isuzu trucks: 45-55 Newton-meters). Loose bolts may cause vibration and displacement during driving, while over-tightening may damage the mounting bracket or threads.

• Control belt tension to a 1-2 cm deflection when pressed. Excessive tension accelerates bearing wear, while insufficient tension causes slipping and power generation failure. Always route the belt along the original path—never misroute it.

• Handle the new generator with care. Do not disassemble the housing or strike the pulley to avoid damaging precision components such as internal coils and bearings. Check that auxiliary parts like the voltage regulator and carbon brushes are intact before installation.

• References：
  

• The precautions for installing the 24V 60A generator on Isuzu trucks you previously asked about are not derived from a single exclusive official document. Instead, they are integrated from Isuzu-related generator technical materials, general specifications from auto maintenance platforms, and practical key points from professional mechanical maintenance institutions. The specific reference basis is as follows:

• 1. Technical Content from Professional Power Equipment Official Websites

• The "Isuzu Generator Three-Wire Wiring Diagram" published on the official website of Dazawa Power Generator mentions the core wiring specifications for Isuzu generators. For example, the basic three-wire connection method is: B+ connected to the battery/switch, F connected to the regulator, and E connected to the ground. If replacing with a four-pin model, an additional neutral wire (N) needs to be connected to the instrument indicator light. It also clearly specifies safety precautions such as power disconnection operation and post-installation voltage testing (normal range: 13.8–14.5V). This serves as an important reference for wiring and safety operation key points.

• 2. General Installation Specifications from Auto Maintenance Platforms

• The general process for automotive generator installation in the Q&A and encyclopedia sections of PCauto covers general operational requirements such as disconnecting the negative terminal of the battery, cleaning the installation position, adjusting belt tension, and tightening fixing bolts. These contents are also applicable to the basic installation process of Isuzu truck generators, providing a reference for precautions related to installation steps.

• 3. Practical Skills from Mechanical Maintenance Companies

• The "Disassembly and Assembly Methods and Skills for Isuzu Diesel Engine Maintenance" shared by Hunan Impower Mechanical Equipment Co., Ltd. mentions specific disassembly steps such as loosening the generator adjusting arm fixing bolts, removing the fan belt, and disassembling the generator fixing bolts. It has guiding significance for the operational details of component disassembly and fixing during installation, and is one of the bases for precautions related to component installation accuracy.

• 4. Overseas Compatible Accessories and Installation Instructions

• The Isuzu generator kit installation instructions released by the CW Kits website focus on generator kits compatible with specific years and series of Isuzu medium-duty trucks. However, the principles of generator-vehicle compatibility involved in it also provide a reference direction for the precaution of confirming accessory compatibility before installing Isuzu truck generators.