Installation Method for King Long 24V 150A Generator

I. Pre-installation Preparation

1. Tool and Consumable Preparation

• Special Tools: Socket wrenches (10mm, 12mm, 14mm, 17mm), torque wrench (range 0-200N·m), Phillips/flathead screwdrivers, ratchet wrench, terminal crimping tool, multimeter

• Consumables: Lock washers, insulating tape, high-temperature threadlocker, conductive paste, generator-specific gaskets (if applicable)

• Protective Gear: Insulated gloves, safety goggles, non-slip gloves

2. Accessory and Equipment Inspection

• Confirm that the generator model is compatible with the King Long vehicle (verify the part number). Check that the generator has no cracks on its surface, no corrosion on the terminals, and the pulley rotates smoothly without abnormal noise.

• Inspect that the matching accessories (brackets, bolts, terminals) meet the original factory specifications and are free from deformation or damage.

• Use a multimeter to measure the resistance of the generator's excitation winding (reference value: 2-5Ω) to confirm there is no open circuit or short circuit.

3. Pre-vehicle Preparation

• Park the vehicle on a flat surface, engage the parking brake, turn off the engine, and disconnect the negative cable of the battery (to prevent short circuits).

• Clean oil stains and dust from the generator installation area. Check if the engine brackets and belt tensioner are intact; replace damaged components if necessary.

II. Removal of the Old Generator (if replacing)

1. Remove the generator belt: Use a wrench to pry the belt tensioner, remove the drive belt, and record the belt routing (photographs can be taken for reference).

2. Disconnect the wiring: Remove the power cable (B+ terminal), excitation cable (D+ terminal), and ground cable from the generator in sequence, and mark the wiring clearly.

3. Remove the fixing bolts: First unscrew the generator adjustment arm bolt, then remove the generator base fixing bolts, and take out the old generator.

III. New Generator Installation Process

1. Install the Generator Body

1. Place the new generator on the mounting bracket, first pre-tighten the base fixing bolts (do not fully tighten), then install the adjustment arm bolt (in a pre-tightened state).

2. Adjust the generator position to ensure that the pulley, crankshaft pulley, and tensioner pulley are on the same plane (deviation ≤1mm).

3. Use a torque wrench to tighten the fixing bolts according to the original factory specified torque (base bolt torque is generally 35-45N·m, adjustment arm bolt torque is 20-25N·m). Apply a small amount of high-temperature threadlocker to the bolts to prevent loosening.

2. Install the Drive Belt

1. Install the drive belt according to the previously recorded routing, ensuring that the belt is fully seated in the grooves of each pulley.

2. Pry the belt tensioner to achieve the appropriate belt tension (when pressing the midpoint of the belt, the deflection should be 10-15mm). Release the tensioner and confirm that the belt does not slip.

3. Wiring Operation

1. Treat the terminals: Use sandpaper to polish the oxide layer on the terminals and apply conductive paste to improve conductivity.

2. Connect the power cable: Connect the positive battery power cable to the generator's B+ terminal, add a lock washer, tighten with a nut (torque 8-10N·m), and wrap with insulating tape.

3. Connect the excitation cable: Connect the excitation control cable to the D+ terminal, ensuring the connection is firm and free from loosening.

4. Connect the ground cable: Connect the generator housing ground cable to a reliable grounding point on the engine block to avoid poor contact.

5. Organize the wiring harness: Secure the wiring harness with cable ties to prevent contact with high-temperature or moving engine components.

4. Reconnect the Battery

IV. Post-installation Commissioning and Testing

1. Idle Speed Test

1. Start the engine and run it at idle for 5 minutes. Observe if the generator has abnormal noise or odor, and check if the belt slips.

2. Use a multimeter to measure the battery terminal voltage: It should be 27-28V at idle (standard voltage for 24V systems), and not lower than 25V when high-power loads such as headlights and air conditioners are turned on.

2. Load Test

1. Turn on all electrical equipment of the vehicle (headlights, air conditioner, heater, wipers, etc.) in sequence and run for 10 minutes.

2. Measure the generator output current (a current clamp must be connected in series). A 150A generator should reach the rated current within ±10% under full load, and the voltage should remain stable.

3. Visual Inspection

V. Installation Precautions

Electrical Safety

• The negative battery cable must be disconnected throughout the installation process. Do not plug or unplug generator wiring while the power is on.

• Avoid short-circuiting the generator's B+ terminal to the vehicle body ground, as this will burn out the generator stator winding.

Mechanical Installation

• The generator fixing bolts must be tightened to the specified torque. Loose bolts will cause belt slippage and generator abnormal noise, while over-tightening will damage the brackets or generator housing.

• The belt tension must be strictly controlled. Excessive tension will accelerate bearing wear, and insufficient tension will reduce power generation efficiency.

Compatibility Requirements

• Only use original factory or certified generator accessories for King Long vehicles. Incompatible generators may cause charging system failures.

• If replacing the generator, check the status of the voltage regulator and belt tensioner simultaneously and replace them if necessary.

References：

Source Explanation and Traceability of This Installation Method

I. Labeled Sources and Actual Corresponding Relations

II. Traceability of Key Content

1. Installation Process and Torque

• The base bolt torque of 35–45N·m and adjustment arm torque of 20–25N·m are consistent with the Yuchai 6K12 generator bracket torque (35N·m) and industry general values.

• The belt deflection of 10–15mm and B+ terminal torque of 8–10N·m are general specifications for automotive generator installation.

2. Electrical Connection and Safety

• The requirements of disconnecting the negative terminal first, definitions of B+/D+/ground wires, and terminal treatment (conductive paste, insulating tape) comply with GB/T 23642-2022 and general automotive maintenance safety requirements.

3. Testing Parameters

• The idle voltage of 27–28V and load voltage of not less than 25V for the 24V system are the standards for commercial vehicle 24V charging systems; the excitation winding resistance of 2–5Ω is a typical industry reference value.

III. Reasons for Labeling as "Comprehensive Compilation"

• King Long Bus original factory manuals are released by model, and no independent installation chapter for "24V 150A" has been publicly issued; Yuchai specifications focus on engine-side bracket and torque, and electrical details need to refer to industry general standards.

• This article integrates model processes, engine torque, national standard safety, and industry testing into complete steps for direct operation.

IV. Ways to Obtain Authoritative Data

1. King Long Original Factory Manual

• Contact King Long Bus after-sales service or authorized service stations, and provide the VIN to query the maintenance manual for the corresponding model (including the generator installation chapter).

2. Yuchai Engine Specification

• Visit the "Service Support" section of the Yuchai official website, download the maintenance manual for the corresponding model (e.g., 6K12), and check the generator installation part.

3. National Standard

• Log in to the National Standard Full-Text Public System or CNKI, and search for GB/T 23642-2022 to obtain the original text.