Installation Method for MAN 24V 35A Generator

I. Pre-installation Preparation

1. Tools and Consumables

• Special tools: MAN generator bracket torque wrench (torque range: 20-80N·m), terminal crimping pliers, insulated socket

• General tools: 10mm/13mm/16mm socket, Phillips screwdriver, crowbar

• Consumables: High-temperature resistant insulating tape, lock washers (specification: M8/M10), generator-specific grease (Model: MAN 009100200), sealant (Loctite 5910)

• Protective equipment: Insulated gloves, safety goggles, anti-static wristband

2. Safety Pre-inspection

1. Disconnect the negative cable of the vehicle battery (wait 10 minutes after power-off to release residual power in the electrical system);

2. Inspect the generator appearance: no housing cracks, no oxidation of wiring terminals, and the pulley rotates without jamming;

3. Verify accessory models: brackets, bolts, and connectors must match the original MAN accessory numbers (bracket number: MAN 81962100345);

4. Clean the installation station: remove debris in the engine compartment and confirm that the generator mounting surface is free of rust and oil contamination.

II. Installation Steps

1. Fix the Generator Bracket

1. Fit the generator bracket to the engine block mounting surface and insert the M10 positioning bolt (do not tighten);

2. Tighten the bracket fixing bolts to 45N·m in a diagonal sequence with a torque wrench and install lock washers;

3. Check the bracket verticality: the angle error with the engine block shall not exceed ±2°, and there shall be no obvious shaking.

2. Hoist the Generator Body

1. Two people collaborate to hoist the generator to the bracket mounting position and insert the M8 connecting bolt;

2. First pre-tighten the connecting bolt between the generator and the bracket to a torque of 15N·m, reserving allowance for belt tension adjustment;

3. Install the generator ground wire: connect one end to the generator housing ground terminal and the other end to the engine block ground bolt, tighten to a torque of 20N·m; the ground wire shall be free of bending and damage.

3. Install the Drive Belt

1. Mount the multi-ribbed drive belt (Model: MAN 81962010652), routing it around the crankshaft pulley, generator pulley, and tensioner in sequence;

2. Adjust the tensioner screw so that the belt tension meets the specification: when pressing the midpoint of the belt with a force of 10kg, the deflection shall be 10-15mm;

3. Lock the tensioner, tighten the generator fixing bolt to the final torque of 35N·m, and make an anti-loosening mark.

4. Connect the Electrical Circuits

1. Positive power cable: Connect one end of the 25mm² high-temperature resistant cable to the generator B+ terminal (tighten to a torque of 12N·m) and the other end to the main battery positive switch; the cable shall be sheathed with an insulating protective tube and fixed to the wiring harness bracket in the engine compartment;

2. Excitation circuit: Connect the generator D+ terminal to the corresponding terminal of the vehicle voltage regulator (Model: MAN 81259070120), reserve a 50mm allowance for the wiring harness length, and wrap the joint with insulating tape for 3 layers;

3. Signal circuit: Connect the generator W terminal (speed signal) to the vehicle ECU; the plug shall be clamped in place without loosening.

5. Reassembly and Completion

1. Clean oil contamination on the generator surface and apply a small amount of special grease to the pulley bearing;

2. Check that all circuits are free of interference and wear, and all bolts have anti-loosening marks;

3. Connect the negative battery cable and organize tools and consumables.

III. Post-installation Commissioning

1. Start the engine and run at idle for 5 minutes, observe the generator:

• No abnormal noise (such as belt slipping or bearing noise);

• The voltmeter displays a voltage of 27-28V (rated voltage of the 24V system);

2. Load test: Turn on high-power electrical equipment (air conditioner, vehicle lights) of the whole vehicle; the voltage fluctuation shall not exceed ±1V, and the generator shall not overheat;

3. After shutting down the engine, recheck the belt tension and bolt torque to confirm no loosening.

IV. Notes

Electrical Safety

• It is strictly forbidden to plug or unplug generator wiring terminals without power-off to prevent short circuits and ablation of components;

• The ground wire must be reliably connected, otherwise it will cause generator excitation failure or housing electrification.

Torque Specifications

• All bolts must be tightened according to the original factory torque value; loose bolts are prone to vibration and noise, while over-tightened bolts may damage threads or brackets.

Belt Maintenance

• The belt tension must be rechecked every 500km after installation, and the belt and tensioner must be replaced during the first maintenance (10,000km).

Adaptability Requirements

• For non-original MAN generators, it is necessary to confirm the matching of voltage, power, and mounting holes; mixing accessories of different brands is prohibited.

Emergency Handling

• If abnormal voltage occurs after installation, first check the excitation circuit connection, then troubleshoot the voltage regulator and the internal windings of the generator.

• References：

Source of the Installation Method

Key Instructions

Manual Number

Electrical Specifications

Accessory Models

Data Acquisition

• The official manual can be queried through MAN authorized dealers, MAN WIS system or EPC database;

• ISO 16750-2 can be obtained through the official website of the International Organization for Standardization (ISO) or automotive industry databases.

Verification Suggestions

1. Check the vehicle VIN code to confirm that the manual version matches the vehicle model;

2. Verify the accessory models through the MAN EPC system before installation to avoid mixing accessories of different brands;

3. If an electronic version of the manual or specific chapters are needed, contact MAN customer service or authorized service stations for acquisition.