Alternator 119626-77210 101211-2951 119626-77210 for Yanmar

Pre-installation Preparation

• Site and Tools: Select a dry and well-ventilated location away from flammable materials, with a minimum of 1 meter of maintenance space reserved. Prepare lifting equipment (suitable for its 1600lbs weight), torque wrench, level, thread lock adhesive, insulation resistance tester, etc., along with matching anchor bolts, gaskets, cables, and other accessories.

• Equipment Inspection: After unpacking, check that the generator has no collision damage, and that components such as the cooling fan and protective cover are complete. Verify that parameters like output voltage and power are compatible with the vehicle, and ensure that parts such as the rotor rotate smoothly.

Main Unit Hoisting and Fixation

• Hoisting and Positioning: Use lifting equipment to hook the dedicated lifting points on the machine body, lift the generator stably, align it with the reserved anchor bolt holes on the installation foundation, and place it slowly on the foundation to avoid colliding with body components.

• Leveling and Fixation: Use a level to check the generator's levelness, and adjust deviations by placing metal gaskets at the bottom. Insert anchor bolts into the reserved holes, fasten them evenly in a diagonal pattern, and lock them to the specified torque to prevent loosening due to vibration during operation. If connected to the vehicle engine via a coupling, ensure the coaxiality of the two, with an error not exceeding 0.1mm, then fix the coupling with bolts and apply thread lock adhesive to the bolts to prevent loosening.

System Pipeline Connection

• Fuel System: Connect the vehicle's fuel tank to the generator's fuel inlet using a matching pipeline, install a gasket at the interface to ensure no leakage. Install and secure the fuel filter in place to maintain fuel cleanliness.

• Cooling System: This unit supports keel cooling or radiator cooling. For radiator cooling, connect the cooling water tank to the generator's cooling interface and tighten the pipeline joints. Add suitable coolant and check that the cooling system circulates smoothly without leakage.

• Exhaust System: Remove the fixing bolts at the generator's exhaust end, connect the exhaust pipe to the exhaust port, and ensure the pipe is angled 45 degrees downward to prevent water ingress. Install a muffler and corrugated pipe to reduce vibration impact, and secure the pipeline firmly to avoid shaking during operation.

Electrical System Connection

• Wiring Connection: Connect the output cables and control cables in accordance with the electrical schematic, ensuring the cable specifications match. Distinguish between power wires, field wires, etc., and connect them according to the markings to avoid reverse connection. After connection, use an insulation resistance tester to check the insulation performance, ensuring it meets safety standards.

• Grounding Treatment: Reliably connect the generator's housing to the vehicle body's grounding terminal to ensure electrical safety and prevent electric leakage accidents.

Accessory Installation and Commissioning

• Accessory Assembly: Install components such as the cooling fan and protective cover, fixing them with bolts or buckles to ensure the protective cover has no gaps and functions effectively.

• Trial Operation and Commissioning: Connect the negative terminal of the vehicle battery, start the generator, and observe if it operates stably without abnormal noise. Use a multimeter to measure the output voltage, which should normally be 13.5 - 14.5V at idle speed. Gradually increase the load, check if the voltage and frequency are stable, and simultaneously inspect the fuel and cooling systems for leakage.

• Final Inspection: After shutting down the generator, recheck all bolt, pipeline, and wiring connections to confirm no loosening. Clean the installation site, organize the wires, and complete the installation.

Safety Operation Points

• Disconnect the vehicle's main power supply throughout the installation process to avoid short circuits or electric shocks in electrical circuits. Wear insulating gloves when wiring.

• Do not stand under the equipment during hoisting and fixation. The lifting equipment must meet the load-bearing requirements to prevent the machine body from falling, causing damage or injury.

• The exhaust pipe operates at high temperatures. Reserve heat dissipation space during installation, keep it away from flammable components, and secure the muffler firmly to prevent scalds.

Installation Accuracy Requirements

• The horizontal error of the machine body must be controlled within 0.2mm/m. Anchor bolts or mounting brackets must be tightened evenly in a diagonal pattern to the specified torque.

• When connecting to the engine coupling, the coaxiality deviation shall not exceed 0.1mm; otherwise, it will cause excessive vibration and accelerated bearing wear.

• For belt-driven models (small alternators), adjust the belt tension so that the deflection at the middle of the belt is preferably 10-15mm when pressed. Excessively loose belts are prone to slipping, while overly tight ones may damage the bearings.

System Connection Specifications

• Seals must be installed at the interfaces of fuel and cooling pipelines. After connection, manually check for no leakage, and avoid bending or blocking the fuel pipelines.

• Electrical wiring must strictly follow the schematic diagram. Distinguish between positive and negative poles, output wires, and control wires. Incorrect wiring may burn out the generator or vehicle electrical appliances.

• Special grounding wires must be used for the grounding circuit, with firm and non-loose connections. The grounding resistance must meet safety standards (generally not exceeding 4Ω).

Commissioning and Follow-up Support

• After the first start, let the generator run at idle speed for 5-10 minutes to observe for abnormal noise or leakage, then gradually increase the load. Direct full-load operation is prohibited.

• Monitor the output voltage and frequency during commissioning to ensure they meet the vehicle's power supply requirements. Immediately shut down and inspect if abnormalities occur; restart only after troubleshooting.

• Clean the machine body and surrounding debris after installation, reserve sufficient maintenance space, and record installation parameters for future maintenance.

References：

General Installation Standards for Diesel Generator Sets

Conventional Logic for Automotive Generator Installation

General Mechanical Installation Process Guidelines