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Type :
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Alternator
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Specification :
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24V 80A
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Pulley :
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8PK
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Brand :
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NUOJIN
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Number :
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0124555017 124555009 17204355
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Quality :
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refurbish
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Delivery time :
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30 days
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The core of installing a Volvo 24V generator lies in prior power-off for safety protection, thorough cleaning and accurate positioning, torque-compliant bolt tightening, standard wiring and belt tensioning, and final functional testing. The key points are ensuring the mounting surface fits perfectly, complying with torque specifications, and achieving correct electrical polarity, so as to avoid short circuits or component damage. Below is the complete operation procedure and key specifications:
Turn off the ignition switch and disconnect the negative battery cable (keep it disconnected throughout the process and reconnect it only after installation is completed) to prevent short circuits or electric shocks.
Prepare socket wrenches, torque wrenches, special tools for belt tensioners, wire brushes, cleaning agents, new O-rings/gaskets (if applicable), thread lockers, insulating tape, terminal crimping tools, etc. Verify that the generator model is compatible with the Volvo vehicle model/engine (e.g., FH/FM series, D13 engine, etc.).
Clean oil stains, rust, and sealant residues from the engine mounting bracket and generator flange surface. Inspect the pulley and bearing for looseness or abnormal noise; check that the rectifier/regulator is intact in appearance; ensure that the wiring harness terminals are free from burn marks.
Loosen the generator belt tensioner and remove the drive belt. Disconnect the main power cable (B+ terminal) and the excitation/signal wiring harness plug, remove the mounting bolts, and take out the old generator smoothly while arranging the parts in the order of removal.
Align the generator flange with the mounting holes on the engine bracket, with the pulley facing the belt path. Insert the mounting bolts and manually pre-tighten them until the flange is fully attached to the mounting surface with no gaps.
Tighten the bolts in a crisscross symmetrical sequence using a torque wrench. The reference torque for common Volvo specifications is 25–35 N·m (refer to the vehicle-specific manual for exact values). Over-tightening is strictly prohibited to avoid thread damage or housing cracking.
Use a tensioner tool to fit the belt onto the generator pulley, crankshaft pulley, and water pump pulley. Release the tensioner to tension the belt. The proper belt deflection is 10–15 mm when pressed with a finger at the midpoint, or calibrate according to the tensioner scale markings.
First, connect the main power cable (thick wire) to the B+ terminal, install a lock washer, and tighten the nut to 20–25 N·m. Then connect the excitation wire (D+ terminal) and signal plug, ensuring they are fully engaged and secured without loosening. Organize the wiring harness to keep it away from high-temperature components (e.g., engine exhaust pipes) and moving parts (e.g., fans).
Refit the protective cover (if equipped), lower guard plate, and other removed components. Confirm that the wiring harness has no interference and the terminals are well-insulated.
Before starting the engine, recheck the belt for slipping or uneven wear, and ensure the tensioner operates without abnormal noise.
Reconnect the negative battery cable, start the engine by turning the ignition key. Verify that the charging indicator light turns off and the voltage stabilizes at 27–29 V (for 24V systems). Use a multimeter to measure the output at the B+ terminal; the voltage should meet standards at both idle and medium engine speeds.
Turn on electrical loads such as headlights and air conditioning. The voltage should remain stable with no significant fluctuations. Run the engine continuously for 10–15 minutes, then check that the generator housing is not overheated, the wiring harness has no abnormal odors, and the bolts are not loose.
If charging is abnormal, inspect the following components in sequence: belt tension, wiring polarity, regulator/rectifier, and generator excitation circuit. If necessary, use a diagnostic tool to read fault codes.
Disconnect the negative battery cable before installation and keep it disconnected until all mechanical and electrical connections are fully completed before reconnecting. It is strictly forbidden to plug or unplug wiring harness plugs or tighten terminal posts when the power is on, so as to prevent short circuits from burning the generator rectifier, regulator, or the vehicle's electronic control unit (ECU).
Thoroughly clean oil stains, rust, and sealant residues from the engine mounting bracket and the generator flange surface to ensure they are fully fitted without warping or foreign objects. Some models require the installation of original equipment manufacturer (OEM) positioning gaskets. Never arbitrarily increase or decrease the number of gaskets; otherwise, it will cause uneven stress on the generator housing, premature bearing damage, or uneven belt wear.
Manually pre - tighten the mounting bolts in a crisscross symmetrical sequence, then use a torque wrench to tighten them to the value specified in the Volvo vehicle manual (the general range is 25–35 N·m; refer to the corresponding engine manual for specific figures). Forced tightening with an air impact wrench is prohibited.
Apply a small amount of thread locker to the bolt threads to prevent loosening due to vehicle vibration. If a bolt hole becomes stripped, repair the thread or replace the mounting seat—do not attempt forced installation.
Connect the main power cable (thick wire) to the generator's B + terminal, which corresponds to the positive terminal of the battery. Install a lock washer on the connection nut and tighten it to 20–25 N·m. Ensure the ground terminal (E terminal) is reliably connected to the engine block without paint or rust obstruction.
Connect the excitation wire (D + terminal) to the instrument charging indicator light or the regulator control terminal, and ensure the signal plug is fully engaged without loosening. Never reverse the connections of the B + and E terminals, as this will instantly burn out the rectifier bridge stack and internal coils.
Secure the wiring harness with cable ties, keeping it away from high - temperature components such as exhaust pipes and moving parts like fans, to prevent insulation aging and wear that may lead to short circuits.
References：
Below is the breakdown of authoritative core sources and supplementary references for the precautions, categorized by content modules. It includes verifiable official documents and universal specification information:
Industry Universal SpecificationsGeneral automotive electrical system standards (e.g., SAE J563), industry consensus on diesel engine charging system maintenance, and service manuals from generator supporting manufacturers (e.g., Bosch, Delphi). These are used to supplement general requirements for wiring and belt installation.
Technical Bulletins & Practical ExperienceTechnical training materials from Volvo authorized dealers and hands-on experience in diesel vehicle generator installation. These cover on-site risk points not detailed in official manuals (e.g., wiring harness anti-interference fixing, terminal anti-loosening treatment).
Compatibility Verification BasisVolvo engine and generator model matching database, and OEM parts catalog (Volvo Parts Catalog). These ensure compliance with model compatibility verification before installation.
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