Preparation Before Installation

• Tool Preparation: Prepare tools such as screwdrivers, wrenches, and spirit levels.

• Determine the Installation Location: Select a flat, stable, well-ventilated ground free of flammable and explosive materials, and the ground should have sufficient load-bearing capacity.

• Safety Measures: If the generator is connected to the power system of a vehicle or other equipment, the relevant power supply must be disconnected first to prevent hazards such as short circuits during the installation process.

• Inspect the Generator: Check whether the appearance of the generator is intact, all components are complete, the wiring terminals are intact, and the rotor rotates flexibly.

• Inspect the Installation Foundation: Ensure the installation foundation is solid and reliable and meets the generator installation requirements. If necessary, use a spirit level to measure and ensure the foundation is level.

Installation Steps

• Mechanical Fixing: Place the generator at the installation location, adjust it to a horizontal state, and fix the generator to the installation foundation or bracket with screws, but do not fully tighten them to facilitate subsequent fine-tuning.

• Cable Connection

• Identify Wiring Terminals: Locate the positive and negative wiring terminals on the generator; usually, B+ is the positive output terminal, and E is the ground terminal (negative pole).

• Connect Power Cables: Use cables of appropriate specifications to connect the B+ terminal to the positive pole of the power system, and reliably connect the E terminal to the ground terminal. Ensure the cable joints are firm, without looseness or oxidation during connection.

• Other Wiring: If the generator has other control wirings, such as D+, W and other terminals, connect them to the corresponding control circuits or regulators in accordance with the generator manual.

• Install Accessories (if any): According to the specific conditions of the generator, install accessories such as exhaust pipes, fuel pipes (for fuel generators), and cooling systems. Ensure all accessories are correctly connected, well-sealed, and free of leaks.

• Tighten Screws: After completing the cable connection and accessory installation, use a wrench to tighten the fixing screws of the generator to ensure it is firmly fixed.

Post-Installation Inspection

• Electrical Connection Inspection: Check whether all cable connections are firm and the wiring terminals have no looseness or oxidation.

• Accessory Inspection: Check whether accessories such as exhaust pipes, fuel pipes, and cooling systems are correctly installed and free of leaks.

• Startup Test: After confirming all installations and connections are correct, turn on the power, start the generator, and observe whether the generator operates stably without abnormal noise or vibration. Use a multimeter to measure the output voltage of the generator and check if it is within the normal range. For a 28V generator, the normal output voltage is generally around 29-31V.

Core Precautions for the Installation and Use of National VI 28V 80A Generators

I. Safety Precautions for Installation Operations

1. Compliant Power-Off Operation: Before installation, the main power supply and battery negative terminal of the vehicle/equipment must be disconnected. If the original vehicle circuit is involved, the relevant fuse switches must be additionally turned off to avoid short circuits during wiring that may burn the generator rectifier and National VI-specific electronic control modules (such as SCR and DPF control units), causing equipment failures or electric shock risks. After installation, power supply can only be restored after verifying each wiring point for correctness.

2. Enhanced High-Voltage Protection: The 28V system voltage is higher than the conventional 12V system. Insulating gloves and tools must be used during wiring, and direct contact with exposed terminals with bare hands is strictly prohibited. At the same time, avoid accidental contact of tools with positive and negative terminals to prevent short circuits and arcing. A safe operating space must be reserved around the generator, and stacking debris is prohibited.

3. Absolute Prohibition of Polarity Reversal: The B+ terminal of the generator must be connected to the positive pole of the power supply, and the E terminal (ground terminal) must be reliably grounded. Reversing the positive and negative poles is strictly prohibited. Polarity reversal will directly burn the internal electronic components of the generator and the voltage regulator, and may also damage the precision electronic control system of National VI vehicles, resulting in high maintenance costs.

4. Standardized Mechanical Fixing: When tightening the generator's fixing screws, a torque wrench must be used in accordance with the torque specified in the equipment manual (usually 25-35N·m, subject to specific model parameters) to ensure the installation foundation is level and stable. Avoid loose screws that cause operational vibration, damaging the generator bearings or connecting components; excessive tightening may cause thread stripping or deformation of the installation bracket.

II. Precautions for Compliance and Component Adaptation

1. National VI Vehicle-Specific Adaptation: It is necessary to confirm that the generator model is fully compatible with the engine model and electronic control system of the National VI vehicle to avoid excessive emissions or electronic control system errors due to improper adaptation. Priority should be given to original factory or compliant accessories that meet National VI standards; non-standard substitutes are prohibited.

2. Precise Matching of Line Specifications: The connecting cable for the B+ terminal must be suitable for 28V high voltage and 80A current. It is recommended to use a copper core wire with a diameter of not less than 6mm², connected in series with a dedicated 80-100A fuse. The fuse holder should be fixed away from high-temperature components to prevent line overload and short circuits. At the same time, ensure the voltage regulator matches the generator power and vehicle electronic control system (compatibility of built-in regulators must be confirmed, and external regulators should be 28V-specific models).

3. Compliance Requirements for Accessory Installation: For fuel-type generators, the exhaust pipe installation must comply with relevant National VI emission standards to avoid exhaust gas leakage; the fuel pipe and cooling system connections must be tightly sealed without leakage, and kept away from high-temperature components (such as exhaust pipes) to prevent safety hazards. The installation location must ensure good ventilation to meet heat dissipation and exhaust emission requirements.

III. Key Precautions for Circuit Connection

1. Accurate and Standardized Terminal Wiring: Strictly wire according to the markings in the generator manual. Connect B+ to the positive pole of the power supply, E to reliable ground, and control terminals such as D+ and W to the designated control circuits or regulators; confusing terminal functions is not allowed. After wiring, wrap the joints with insulating tape or waterproof heat-shrinkable tubing. Especially in the high-temperature and humid environment of the engine compartment of National VI vehicles, enhanced protection is required to prevent joint oxidation and short circuits.

2. Reliable and Up-to-Standard Ground Connection: The ground wire of the E terminal must be connected to a clean metal surface of the equipment body (with oil stains and rust removed) to ensure the ground resistance is less than 0.5Ω. This avoids unstable generator output voltage, charging failures, and even interference with the normal operation of the National VI electronic control system due to poor grounding.

3. Safe and Reasonable Line Layout: The cable layout must avoid rotating components such as engine belts and gears, as well as high-temperature components such as exhaust pipes. Secure the cables firmly with cable clips to prevent line wear and loosening during vehicle/equipment operation, which may cause poor contact or short circuits.

4. References：
5. Judging from the content, it covers the installation methods and precautions for the National VI 28V 80A generator, and may be derived from relevant generator user manuals, technical guides, or professional books and websites on automobile maintenance. However, since there are no clear identifiers or citation information in the text, its specific source cannot be accurately pointed out.