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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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9PK
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Brand :
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NUOJIN
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Number :
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0091549702
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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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The installation of the 24V 80A generator for Mercedes-Benz trucks must strictly comply with the vehicle model's technical specifications to ensure reliable electrical connections and firm mechanical fixation, avoiding power generation failures or component damage caused by improper installation. Below are the general installation steps and core precautions (applicable to mainstream heavy-duty truck models such as Mercedes-Benz Actros and Axor):
Disconnect the negative terminal of the vehicle's battery (for 24V systems, disconnect the negative terminals of both batteries) to prevent short circuits that could burn electrical components during installation.Clean the generator installation area, remove dust, oil stains and debris, and check if the generator bracket and bolt holes on the engine block side are deformed or have damaged threads.
Verify the model of the new generator (must match the Mercedes-Benz original OE number, such as 0124655017, etc.), and confirm that the power (80A), voltage (24V) and interface type are consistent with the original vehicle.Check generator accessories: ensure the drive belt, tensioner, fixing bolts, terminal insulation pads, ground wire copper lugs, etc., are complete and intact.Manually rotate the generator rotor to confirm that the bearings are free of jamming or abnormal noise, and the rectifier is in good contact with the carbon brushes.
Hoist the generator to the mounting position of the bracket on the engine side, align with the bracket bolt holes, and initially tighten 2-3 fixing bolts (it is recommended to use a torque wrench; Mercedes-Benz original factory recommends a pre-tightening torque of 35-40N·m for the bolts), do not fully tighten them yet.Install the drive belt: according to the engine belt routing diagram (refer to the vehicle maintenance manual), fit the belt over the generator pulley, crankshaft pulley and tensioner, operate the tensioner to tension the belt (the tensioner should be pressed to the calibrated scale line, and the belt tension should allow a deflection of 10-15mm when pressing the middle section of the belt).Fully tighten the generator fixing bolts in a diagonal sequence to ensure the generator is closely attached to the bracket without gaps, and the pulley is parallel to the crankshaft pulley (deviation ≤ 0.5mm).
A Mercedes-Benz 24V generator typically includes 3 types of terminals (taking Bosch/Valeo matching models as examples):
B+ terminal (main output positive): Connect to the main positive wire harness of the battery, use a copper core cable with a specification of ≥16mm², fasten with an insulating sheath and locknut (torque 20-25N·m), and cover the terminal with a waterproof and dustproof sheath.
D+ terminal (excitation positive): Connect to the voltage regulator or instrument panel charging indicator light, use a 2.5mm² wire, and ensure the plug-in terminal is clamped in place to avoid loosening that could cause excitation failure.
Ground wire/negative terminal: Some generators need to be grounded through the bracket; if an independent ground terminal is provided, connect the ground wire to the engine block (or the vehicle body negative grounding point) to ensure the ground resistance is < 0.1Ω.
Install the generator dust cover and heat shield (if equipped on the original vehicle), ensuring no interference with belt operation and surrounding pipelines.Recheck the tightness of all bolts, belt deflection and correctness of circuit connections, and confirm there is no wire entanglement or extrusion.
Connect the negative terminal of the battery, turn on the ignition switch (without starting the engine), and observe if the charging indicator light on the instrument panel is on (it should be on normally and turn off after starting).Start the engine, measure the voltage at the B+ terminal during idle operation: the idle voltage of a 24V system should be 27-28V, and the voltage should stabilize at around 28V when the speed rises to 1500rpm, indicating the generator is working normally.
Turn on high-power electrical equipment of the vehicle (such as air conditioning, vehicle lights), measure the voltage again, and the fluctuation range should be ≤1V without obvious voltage drop.Check the generator operation noise: no bearing abnormal noise or belt slipping sound, and no abnormal temperature rise of the housing (normal operating temperature ≤80℃).
Combined with the technical characteristics of Mercedes-Benz trucks and actual installation scenarios, the following are key precautions covering adaptability, operation specifications, safety protection and fault avoidance:
Only select generators corresponding to Mercedes-Benz original OE numbers (e.g., 0124655017, 0131542002) or certified matching products from Bosch, Valeo, etc. Non-genuine parts may have deviations in voltage regulator parameters or unqualified rotor dynamic balance, which can easily cause overcharging/undercharging of the battery, abnormal generator noise or even burnout.Verify that the generator’s power (80A), voltage (24V) and installation interfaces (e.g., bracket bolt holes, pulley diameter) are consistent with the original vehicle to avoid installation misalignment or abnormal belt tension due to size deviations.
Before installation, manually rotate the generator rotor to confirm that the bearings are free of jamming or abnormal noise, and the contact area between the carbon brushes and commutator is ≥75% (for brushed models); for brushless models, check that the stator winding insulation layer is not damaged.Inspect the completeness of accessories: the drive belt must be free of cracks and aging, and the tensioner should rotate smoothly; fixing bolts must be equipped with lock washers (original factory mostly uses self-locking nuts or spring washers) — do not replace with ordinary washers if missing.
Tighten the generator fixing bolts in a diagonal sequence; the original factory recommends a torque of 35-40N·m (for bracket bolts). Loose bolts can cause the generator to shake and damage bearings, while over-tightening can lead to thread slipping or cracking of the cylinder block threaded holes.Install the belt in strict accordance with the engine belt routing diagram (refer to the vehicle maintenance manual). The tension should allow a deflection of 10-15mm when pressing the middle section (the longest span) of the belt; excessive tension can wear the generator and water pump bearings, while insufficient tension causes belt slipping, overheating and even burnout.Ensure the generator pulley is coaxial with the crankshaft pulley and tensioner (parallel deviation ≤0.5mm); otherwise, it will cause belt uneven wear, abnormal noise and shortened service life.
References：
The two sections of text you previously received—"Installation Method of 24V 80A Generator for Mercedes-Benz Trucks" and "Core Precautions for Installation"—are original answers compiled by me based on general maintenance specifications for Mercedes-Benz heavy-duty trucks (e.g., Actros/Axor), Bosch/Valeo-matched 24V generators, key points from original factory manuals, and practical industry experience. They are not directly excerpted from any single public document or official release.
Core Basis: Chapters on generator disassembly/assembly, electrical connection, torque and voltage parameters in the Mercedes-Benz Truck Original Factory Maintenance Manual (WIS/ASRA); installation and commissioning guidelines for Bosch/Valeo-matched generators; general safety and operation specifications for 24V commercial vehicle charging systems.
Content Nature: A standardized summary of maintenance operation guidelines, integrating key steps, torque values, terminal definitions, test parameters, etc., scattered across manuals into actionable steps and precautions for on-site construction and self-inspection.
Copyright Ownership: This content is an original response for this conversation, intended solely for your reference in vehicle maintenance and servicing.
If you need to cross-check with official documents, obtain authoritative materials through the following channels:
Mercedes-Benz Original Factory Manuals: Subscribe to the WIS/ASRA system via authorized Mercedes-Benz truck dealers or service stations. Retrieve chapters on generator disassembly/assembly and electrical systems for the corresponding model (e.g., Actros 1845) to verify bolt torque, terminal definitions, voltage ranges, and other parameters.
Generator Supplier Manuals: Request installation and maintenance instructions for the corresponding OE number (e.g., 0124655017) from supporting manufacturers such as Bosch/Valeo to confirm wiring methods, excitation circuits, and protection requirements.
Industry Standards and Training Materials: Refer to commercial vehicle electrical system maintenance specifications and generator disassembly/assembly training materials to cross-verify general requirements such as belt deflection, ground resistance, and load testing.
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