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Type :
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Altemator
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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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1976289
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Quality :
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Remanufacture
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Delivery time :
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10 day
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The installation of a DAF 24V alternator (usually an integrated rectifier-regulator unit) must follow the sequence of Power-off → Mechanical Positioning and Alignment → Belt Installation and Tensioning → Electrical Wiring → Testing to ensure operational safety and stable power generation. Below are the universal, actionable steps and key points applicable to belt-driven models of DAF commercial vehicles (e.g., XF/XG/CF series). For the exact torque values, belt models and wiring diagrams, refer to the DAF official manual corresponding to the specific vehicle model.
Disconnect the main vehicle power supply or the negative terminal of the battery, and wait for the capacitors to discharge for at least 5 minutes. Hang a "No Switching On" sign on the negative terminal to prevent short circuits caused by misoperation, which could burn out the regulator, wiring harness or other electrical components.
Confirm that the alternator is rated at 24V, and its power, claw pole and pulley specifications match those of the original equipment. Ensure the mounting bracket, bolts and wiring terminals are compatible with the engine interface. For replacement parts, prioritize DAF OE (Original Equipment) or equivalent specifications.
Socket wrench set, spirit level, torque wrench, belt tensioning tool, sandpaper/wire brush, conductive paste/anti-rust grease, high-temperature resistant gaskets, rated fuses, cable ties and corrugated tubing, insulating tape.
Clean the mounting surfaces, pulleys and wiring terminals. Check that the bearings, rectifier bridge, carbon brushes and belt grooves are in good condition. Ensure the belt is free of cracks, delamination and tooth loss, and the connectors are free of oxidation and ablation.
Fasten the alternator mounting bracket to the pre-drilled holes on the engine block/front end cover, tightening the bolts diagonally in stages to the DAF OEM-specified torque to avoid bracket deformation.
Hang the alternator onto the bracket and hand-tighten the positioning bolts (do not fully lock them yet, leaving sufficient adjustment allowance). Ensure the alternator shaft is parallel to the crankshaft/water pump pulley shaft, and the centerlines of the two pulley widths are aligned (alignment tolerance ≤ 0.5 mm) to prevent belt misalignment and abnormal wear.
After alignment, lock the positioning bolts to the DAF OEM-specified torque (typically 25–40 N·m, refer to the manual for exact values). Recheck the parallelism and alignment.
Use the DAF-specified V-belt/poly V-belt, and route it around the crankshaft, water pump and alternator pulleys in accordance with the engine front-end accessory drive diagram. For models without an automatic tensioner, loosen the alternator adjustment bolt first.
Use a crowbar or belt tensioning tool to push the alternator outward to achieve the standard belt deflection (usually apply a force of 20–30 N at the midpoint of the belt, with deflection around 10–15 mm; or follow the values in the DAF manual). Lock the adjustment bolt and positioning nut, then recheck the pulley alignment and belt deflection.
Install the belt guard to prevent foreign objects from getting entangled.
Connect the alternator’s B+ terminal to the battery positive terminal via a heavy-gauge wire of matching diameter and a main fuse (rated current selected based on specifications, e.g., 60–100 A, as recommended by DAF). Polish the terminal, apply conductive paste, and tighten the bolt to 10–12 N·m. Route the wire away from high-temperature components such as the exhaust pipe and moving parts, securing it firmly with cable ties.
Connect the IG/IGN (power supply when ignition switch is ON), L (charging indicator light) and D+ (excitation) terminals in accordance with the DAF circuit diagram. Clean the connector, plug it in securely, and apply a small amount of anti-rust grease to prevent moisture damage. Never mix up or loosely connect the wires.
Ensure the alternator housing is reliably grounded to the engine block via the mounting bracket. If necessary, install a grounding jumper wire to guarantee low grounding resistance and good electrical contact. Poor grounding in a 24V system can easily cause voltage instability and regulator damage.
Reconnect the negative terminal of the battery. Check that there is no wiring interference, all fuses are in place and the grounding connection is secure. Confirm all connectors are fully plugged in and terminals are tightened.
Start the engine and run it at idle speed. Measure the battery terminal voltage, which should be within the range of 27.6–29.0 V. Turn on high-load accessories such as headlights and heater; the voltage should remain ≥ 26.0 V, with no abnormal noise or odor detected.
Gradually increase the engine speed to the rated value. Observe that the belt does not slip or misalign, the alternator does not overheat, and the charging indicator light turns off normally. Record the voltage, current and temperature rise, and compare the data with the DAF manual.
Power-off Must Be Maintained Throughout the Entire ProcessDisconnect the main vehicle power supply or the negative terminal of the battery before installation, wait for the capacitors to discharge for no less than 5 minutes, and hang a "No Switching On" sign to prevent short circuits caused by accidental power-on that could burn out the alternator regulator, wiring harness, or other electrical components. Reconnect the negative terminal only before power-on testing. Never plug or unplug connectors or wire connections while the power is on.
Strict Control Over Mechanical Positioning and Alignment
Tighten the connecting bolts between the alternator bracket and the engine block diagonally in stages to the torque specified by DAF’s original factory standards to avoid bracket deformation, which would cause misalignment between the alternator shaft and the crankshaft/water pump pulley shaft.
Pulley alignment is a core requirement: The deviation of the centerlines of the two pulley widths must be ≤ 0.5 mm. Otherwise, it will cause abnormal belt wear, slipping, or even breakage. After installation, use a spirit level to recheck the parallelism and alignment.
Do not pry the alternator housing with brute force to adjust belt tension. Always use the bracket adjustment bolts for this operation to prevent housing deformation and damage to internal bearings and windings.
Precise Control of Belt Tension
Adhere strictly to the tension standards: When applying a force of 20–30 N to the midpoint of the belt, the deflection should be controlled within 10–15 mm (or follow the values specified in the DAF original factory manual). An overly loose belt tends to slip and generate heat, while an overly tight belt will accelerate wear on the alternator bearings and water pump bearings.
Install a belt guard after installation is completed to prevent sand, debris, and other foreign objects from getting entangled in the pulleys and causing mechanical jamming or damage.
References：
The two sections of text you referred to, namely Installation Method for DAF 24V Alternator and Installation Precautions for DAF 24V Alternator, are original technical summaries compiled by me based on the general installation specifications, industry practices and safety guidelines for 24V alternators equipped on DAF commercial vehicles (e.g., XF/XG/CF series). They are not directly copied from any single publicly available official manual or third-party document.
The content integrates the common requirements for the front-end accessory drive system of DAF engines (including alignment, belt tensioning and torque control), the electrical wiring standards for 24V charging systems (including B+ fuse configuration, excitation circuit connection and grounding arrangement), the troubleshooting logic for common faults, as well as the safety and testing key points specified in maintenance manuals. The purpose is to provide actionable universal installation steps and prohibited practices.
DAF original factory manuals (such as vehicle-specific installation guides and engine maintenance manuals) provide precise installation positions, torque values, belt models and wiring diagrams tailored to specific vehicle/engine models. However, there are no exact text paragraphs that correspond to the general installation method/precautions you have received. The content I compiled can be used in conjunction with the original factory manuals to improve the safety and success rate of installation operations.
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