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Type :
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Alternator
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Specification :
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24V 120A
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Pulley :
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10PK
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Brand :
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NUOJIN
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Number :
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4087421289222
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Quality :
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Remanufacture
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Delivery time :
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30 days
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24V 120A generators are mostly used in heavy-duty vehicles, engineering machinery, or large-scale generator sets. The core principles of installation are secure mechanical fixation, standardized electrical connection, and adequate heat dissipation and protection. The detailed steps are as follows:
Mechanical tools: Wrenches, sockets, torque wrenches, screwdrivers, drilling machines (if hole-drilling is required), bracket welding tools (if custom brackets are needed).
Electrical tools: Multimeters, crimping pliers, insulating tape, heat-shrinkable tubes, cable ties.
Special accessories: Generator brackets compatible with the engine, shock absorbers (to reduce vibration damage), generator belts of 24V 120A specification (matching the pulley groove type), belt tensioners, current-carrying capacity compliant cables (≥16mm² copper-core cables are recommended to meet the 120A rated current), fuses (or circuit breakers with a rated value of 150A for circuit protection).
Disconnect the negative terminal of the battery of the original equipment to prevent short circuits during installation.
Inspect the generator appearance: Ensure no housing cracks, no loose or abnormal noises from bearings, and no oxidation or corrosion on terminals.
Confirm that the rotation direction of the generator is consistent with that of the engine output end (to avoid reduced power generation efficiency or damage caused by reverse rotation).
Install dedicated brackets or custom brackets according to the engine model and installation space. Brackets must be welded or bolted to the load-bearing parts of the engine block; do not fix them on thin-walled or non-load-bearing components.
Install rubber shock absorbers between the generator and the bracket to reduce the impact of engine vibration on generator bearings and the housing.
Place the generator on the bracket and temporarily fix it with bolts (do not fully tighten them yet).
Adjust the generator position to ensure that the center lines of the generator pulley, engine crankshaft pulley, and tensioner pulley are coplanar, with a deviation ≤ 0.5mm (to prevent belt deviation and wear).
Tighten the fixing bolts with a torque wrench according to the torque specified by the manufacturer (generally 25–35 N·m; refer to the generator manual for exact values).
Fit the belt onto each pulley in accordance with the belt routing diagram (provided in the engine or generator manual).
Adjust the belt tensioner: Press the middle part of the belt; the deflection should be 10–15mm under a pressure of 10kg. Excessive tension will wear the bearings, while insufficient tension will cause slipping and overheating.
Tighten the tensioner fixing bolts, start the engine and let it run at idle speed for 5 minutes, and check that the belt runs without deviation or abnormal noise.
Connect the B+ terminal (main output positive terminal) of the generator to the positive terminal of the 24V battery using a ≥16mm² copper-core cable. The cable should be protected with a corrugated tube to avoid contact with high-temperature engine components.
Connect a 150A fuse/circuit breaker in series on the line close to the positive terminal of the battery to prevent circuit burnout due to short circuits.
Connect the housing grounding terminal of the generator to the engine block or frame with a grounding wire (ground resistance ≤ 0.1Ω) to ensure reliable grounding.
IG terminal (excitation control terminal) of the generator: Connect it to the 12V/24V control power supply of the ignition switch or controller. When the ignition switch is turned on, it supplies excitation current to the generator to initiate power generation.
D+ terminal (charging indicator control terminal) of the generator: Connect it to the charging indicator on the instrument panel. When the generator operates normally, the voltage at this terminal rises and the indicator light turns off; when the generator fails to generate power, the indicator light turns on.
Secure all cables to the frame with cable ties to prevent abrasion of the insulating layer due to shaking.
Crimp all terminals firmly with crimping pliers and seal the exposed parts with heat-shrinkable tubes to prevent oxidation and short circuits.
Use a multimeter to measure the resistance between the B+ terminal of the generator and the ground; it should be infinite (no short circuit).
Check that all terminals are tight and all lines are undamaged.
Reconnect the negative terminal of the battery.
Start the engine and let it run at idle speed; use a multimeter to measure the voltage at the B+ terminal, which should be 27–29V (rated charging voltage for 24V systems).
Gradually increase the engine speed to the rated speed (generally 1500–2000r/min); the voltage should stabilize at around 28V, and the output current can reach 120A (load testing is required).
Check the charging indicator light: The light should turn on when the ignition switch is turned on and turn off after startup, indicating that the control circuit is functioning properly.
Run the generator at full load for 30 minutes; check that the generator housing temperature (≤ 80℃), the belt runs without slipping or abnormal noise, and the lines do not overheat.
After turning off the engine, recheck the tightness of the bolts and the connection status of the lines.
The negative terminal of the battery must be disconnected throughout the entire installation process to prevent short-circuit arcing, which may damage the generator rectifier, on-board electronic devices, and cause harm to operators.
It is strictly forbidden to disconnect the battery or main circuit wiring while the generator is in operation. Otherwise, instantaneous overvoltage will occur, damaging the internal components of the generator and precision equipment such as the vehicle ECU.
The generator shall be installed away from high-temperature areas such as the exhaust pipe and engine block with a minimum distance of 10 cm. Cables shall be sheathed with high-temperature-resistant corrugated pipes to avoid insulation melting and short circuits.
Reversing the positive and negative terminals of the battery is strictly prohibited. Doing so will directly burn out the generator’s diodes and excitation windings, resulting in irreversible damage.
The generator pulley, engine crankshaft pulley, and tensioner pulley must be coplanar with their center lines, with a deviation ≤ 0.5 mm. Failure to meet this requirement will cause belt deviation, abnormal wear, or even belt detachment.
Belt tension must be strictly controlled: Press the middle part of the belt with a pressure of 10 kg; the deflection should be 10–15 mm. Excessive tension will accelerate bearing wear, while insufficient tension will lead to belt slippage, overheating, and reduced power generation efficiency.
References：
The core source notes of the text "Installation Precautions for 24V 120A Generator" are as follows:
This content is an original technical summary compiled based on the general technical logic of 24V 120A generator installation, combined with industry standards and practical experience. It does not correspond to the original text of any single public document, nor is it directly reproduced from a specific instruction manual or web page.
GB/T 15548-2023 General Technical Requirements for Three-phase Synchronous Generators Driven by Reciprocating Internal Combustion Engines: It specifies technical indicators such as insulation, voltage withstanding, and voltage stability of generators after installation.
GB 50171-2016 Code for Construction and Acceptance of Installation Engineering of Electrical Devices - Panel, Cabinet and Secondary Circuit Wiring: It provides guidance for operations such as terminal crimping, insulation protection and circuit fixing in electrical wiring.
GB/T 2820 Series Standards Generator Sets Driven by Reciprocating Internal Combustion Engines: It clarifies requirements for mechanical installation including bracket load-bearing capacity, shock absorption, and pulley coplanarity.
24V generator installation manuals of mainstream manufacturers (e.g., Bosch, Delphi, Cummins, etc.): They provide core data such as torque parameters, belt tension, and terminal definitions.
Electrical installation manuals for heavy-duty vehicles/engineering machinery: They cover practical key points including cable selection for 24V systems (≥16mm² copper core suitable for 120A current) and fuse matching (150A overload protection).
Standards such as power-off operation in vehicle electrical maintenance, reverse wiring protection, and grounding resistance requirements are industry-recognized safe operation guidelines, widely applied in installation scenarios of various electrical equipment.
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