IS19_908E

Instruction Sheet
IS-19908E
BOSCH TO DELCO REMY ALTERNATOR INSTALLATION, H3-45
From D-2364 up to J-0184
REVISION : E
Updated electrical schematic. Added instructions for H series GHG17 engine
variant.
05-27-2019
MATERIAL
Order Main Kit IS19908, which contains
Part No.
Description
Qty
0610086
Alternator Mechanical Kit, Right
1
0610089
Adaptation Kit, Right, H3-45
1
IS-19908
Instruction Sheet
1
FI-19908
Feuille d’instructions
1
0610086 Alternator Mechanical Kit, Right
Part No.
Description
Qty
560720
Alternator Remy 55SI 24V-250A Pad Mount
1
069892
Pulley 8PK, 83 DOB
1
069894
Bracket, Alternator Remy
1
506065
Belt Poly V 8PK1435 EPDM QT+Aramide
2
5001308
SCREW CAP HEXF N500 M10-1.5X40 G10.9
4
5002091
SCREW CAP HEXF N500 M10-1.5X120 G10.9
4
5001137
WASHER FL SS .203X.438X.06 (M5,#10)
2
5001180
NUT HEX NYRT SS 10-24
2
500411
WASHER FL SS .260X.697X.05 (M6,1/4)
1
5001341
WASHER FL SS 8.4X17X1.6 (M8,5/16)
1
500685
NUT HEX NYRT 5/16-18 SS
1
Writer: FL

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0610089 Adaptation Kit, Right, H345
Part No.
Description
Qty
1
450580
MODIFIED BRACE, AC COMPRESSOR
5000360
STUD, M10-1.5X52 N500
5001834
WASHER BEL SPR 10.5X23X2.5 N500
1
5001799
SCREW CAP HEXF M10-1.5x70 G10.9 N500
2
5001930
NUT HEXF NYRT M10-1.5 N500 G10.9
1
N55439-02
RING TERMINAL 5MM / 16-14 / DURASEAL
3
N33509-06
Shrink tubing
1
12”
0610052
Power cable RH alternator H345
1
0610034
Ground cable RH alternator
1
NOTE
Material can be obtained through regular channels.
Writer: FL

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TOOLS
680888 CLUTCH EXTRACTOR
METRIC OPEN END WRENCH
SET
RATCHET, SOCKET, HEX BIT
SET – METRIC
LAPTOP W/ RS232 SERIAL
ADAPTER
&
066009
1
CONNECTION
CABLE
TORQUE WRENCH
SOFT FACED HAMMER
1 / 8 OPEN END WRENCH
BELT TENSION GAUGE
½ SQUARE DRIVE BREAKER
BAR
VOLTMETER / MULTIMETER
CUTTING PLIERS
15/16”
THIN
CROWFOOT
WALL
ADAPTER.
5
1
VPG software or a MUX update package may be required on some vehicles. Contact your Prevost
customer service manager for details.
Writer: FL

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PROCEDURE
DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position. Apply vehicle lockout
procedures according to local policies.
Table of contents
OVERVIEW ............................................................................................................................................................. 4
ELECTRICAL SCHEMATICS ....................................................................................................................................... 5
BOSCH ALTERNATORS REMOVAL, RIGHT HAND SIDE ............................................................................................. 6
RIGHT HAND ALTERNATOR INSTALLATION .......................................................................................................... 11
RIGHT HAND ALTERNATOR INSTALLATION (CONTINUED) .................................................................................... 13
RIGHT HAND ALTERNATOR CONNECTIONS .......................................................................................................... 17
ALTMGM PARAMETER CHANGE........................................................................................................................... 22
FUNCTIONAL TESTING.......................................................................................................................................... 22
APPENDIX A – LTD WIRE GUIDELINES .................................................................................................................. 24
LABOR REFERENCE TABLE .................................................................................................................................... 26
OVERVIEW
For vehicles with PRIME battery management, a parameter value must be changed in the vehicle’s
multiplex system. This requires a laptop with the proper serial cable and software. See TOOLS.
Make an appointment with your nearest Prevost service center. If you choose to perform the procedure
yourself, contact your Prevost customer support manager before starting.
The procedure involves removing the existing Bosch alternators, their corresponding brackets and
harnesses and replacing them with a Delco Remy 55SI alternator.
The alternators require new brackets and harnesses.
First time users should read the procedure before starting work on a vehicle. Best viewed in color.
Writer: FL

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ELECTRICAL SCHEMATICS
FIGURE 1: ALTERNATOR CONNECTIONS
Writer: FL

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BOSCH ALTERNATORS REMOVAL, RIGHT HAND SIDE
1.
Loosen bolt A on A/C belt tensioner.
2.
Unscrew B.
3.
Remove the mechanical tensioner assembly.
4.
Remove the A/C compressor drive belts (2
side-by-side belts).
Note: Keep hardware for reuse in next steps
FIGURE 2
450580 BRACE PRE-ASSEMBLY
5.
Install stud 5000360 with Red Loctite 271 on
new modified compressor brace 450580.
6.
Install it so it exceeds by 25mm. Place
5001834 Belleville washer and hand thread
5001930 flange nut.
FIGURE 3
7.
Remove the LANG electromagnetic clutch
assembly.
FIGURE 4
Writer: FL

IS-19908E
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8.
Hold the rotor with the 1 5/8 wrench.
Loosen and remove the M12 rotor
mounting screw.
REMOVING
SCREW
THE
M12
FIGURE 5
For the next step, use rotor extractor
tool #680888.
9.
Screw the extractor tool into the
straining washer only until the rotor pops
off the tapered shaft. Then work the
rotor off the shaft by hand with help from
soft faced mallet as needed.
PULL OFF THE ROTOR WITH
TOOL #680888 (shown)
TAKE OFF THE ROTOR
FIGURE 6
10. Loosen the fastening screws (4x) of the coil
and pull the coil off the retainer.
FIGURE 7
Writer: FL

IS-19908E
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11. Remove the support bracket mounting
screws on the engine. Keep screws for
reuse. See note below.
12. Remove the belt tensioner bolt. Reserve for
re-use.
13. Remove and discard the alternator drive belt.
FIGURE 8
Note 2013 to 2015 vehicles equipped with a
welded brace variant use two 55mm long screws
to secure the tensioner support casting to the
engine.
Discard the 55mm screws, keep the other screw.
FIGURE 9: WELDED BRACE VARIANT (2013-2015)
14. Unscrew and remove two socket cap screws.
15. Discard the reinforcement bracket.
16. Keep hardware for re-use.
FIGURE 10
Writer: FL

IS-19908E
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17. Remove compressor mounting bolts and
reserve. Move compressor slightly aside to
provide additional working space.
FIGURE 11
WARNING
The alternator is connected to the batteries through master relay R1. If the ignition switch is in the OFF
position and the battery master switch (master cut-out) is set to the OFF position, there should not be
electrical power to the alternator terminals. However, a faulty master relay R1 could eventually leave
the battery power circuit closed, thus electrical power would be present at the alternator terminals.
Using a multimeter, probe the alternator B1+ terminal and the ground terminal. Make sure that the
voltage reading is 0 volt before disconnecting the alternator cables.
18. Disconnect the Power, Jumper, Control
Harness and Ground cables from the
alternators.
Discard ground cable.
FIGURE 12
A: (+) POWER CABLE
B: (+) JUMPER CABLE
C: CONTROL HARNESS
D: GROUND CABLE
Writer: FL

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19. Remove the existing alternators. To do so,
unscrew the four (4) mounting bolts identified
on the figure. Discard bolts and alternators.
20. Also remove the idler at the bottom. Discard
idler and hardware.
FIGURE 13
21. Remove the alternator support bolted on the
engine. Discard support and bolts.
FIGURE 14
Writer: FL

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RIGHT HAND ALTERNATOR INSTALLATION
22. Installing the alternator pulley.
Place 560720 alternator flat on a bench with
the shaft horizontal.
Required tools:
•
•
15/16” crowfoot adapter
8mm hex bit
Clean shaft and pulley with brake cleaner.
Slide pulley 069892 on shaft by hand.
Hand thread nut on shaft until snug.
Using 15/16”adapter and 8mm hex bit to
block shaft rotation, tighten to 70-80 lb-ft.
Apply torque seal
Never use power tools to install pulley and
nut.
FIGURE 15
Note: Do not apply any pressure to end of
the shaft. Internal damage may occur if the
shaft is pushed back and turned.
23. Install bracket 069894 on engine with four (4)
5001308 M10x40 bolts.
Apply blue Loctite 243
Tighten to 35 lb-ft.
Apply torque seal.
FIGURE 16
Writer: FL

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24. Install alternator on engine with four (4)
5002091 M10x120 bolts.
Apply blue Loctite 680038
Tighten to 48 lb-ft
Apply torque seal.
FIGURE 17
Writer: FL

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RIGHT HAND ALTERNATOR INSTALLATION (continued)
25. Re-install compressor mounting bolts by
hand. Do not tighten yet.
FIGURE 18
26. Install new compressor brace support
450580.
Assemble with blue Loctite 243.
Follow tightening sequence C-D-E.
Install hardware by hand. Then tighten.
Tighten C to 22 lb-ft
Tighten D to 43 lb-ft,
(use two 5001799 M10 70mm screws)
Apply torque seal.
FIGURE 19
27. Screws E, choose below
Cylindrical head screw:
Tighten 40 lb-ft (use blue Loctite 243)
OR
Button head screw:
Tighten 32 lb-ft (use blue Loctite 243)
Apply torque seal.
Writer: FL
FIGURE 20

IS-19908E
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28. Tighten compressor base mounting bolts
to 82 lb-ft
Apply torque seal.
FIGURE 21
29. Install the alternator belt tensioner with
hardware reserved earlier.
Tighten to 48 lb-ft. (use blue Loctite 243)
Apply torque seal
FIGURE 22
Writer: FL

IS-19908E
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30. Install alternator belt 506065. To do so,
rotate the automatic belt tensioner using
a ½ square drive breaker bar.
Keep the spare 506065 belt in the vehicle.
FIGURE 23
31. Install A/C clutch coil.
Use blue Loctite 243
Tighten to 22lb-ft
Apply torque seal
FIGURE 24
Writer: FL

IS-19908E
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32. Mount the rotor on the shaft end.
The flange and the shaft end of the
compressor must be free from dirt.
Apply high temperature approved assembly
grease on the shaft end for easy dismounting
of the clutch. Lang recommends the use of
Molykote G-rapid-plus or Molykote P 40.
33. Carefully mount the rotor on the shaft
end by hand.
Never use a hammer for pressing the rotor
on.
Align the key on the compressor shaft with
the keyway on the pulley bore. To avoid
damaging the bore of the rotor, feel the
engagement of the key in the keyway and slip
the rotor on the shaft end of the compressor
till reaching the stop.
The Woodruff key on the shaft end and the
groove in the location hole of the rotor must
be flush.
FIGURE 25
34. Fasten the rotor to the shaft end using the
M12 screw and by holding-up with a
wrench on the rotor.
35. Turn rotor by hand and pay attention to
the free run and the generation of noises.
In case of grinding or similar noises,
dismount the clutch and check installation.
Use blue loctite 243 on threads
Tighten to 60lb-ft
Apply torque seal
FIGURE 26
Writer: FL

IS-19908E
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36. Re-install A/C belt tensioner and belt.
A belt strand tension gauge is needed. Belt
tension should be within the following range:
•
90-100 lbs new belts (mean of 2 belt
values)
•
75-85 lbs used belts (mean of 2 belt
values)
37. Apply blue Loctite 243 on B threads and
then hand-tighten B. Adjust belt tension
using bolt A. Use the jam nut at the base
of bolt A to keep proper tension
adjustment.
Note: Once thread locker is applied, do not
wait too long before applying final torque.
When proper tension is achieved, tighten B to
43 lbf-ft. (58 N-m).
FIGURE 27
Apply torque seal
RIGHT HAND ALTERNATOR CONNECTIONS
38. Open the Bosch alternator connectors by
rotating the metal lock and prying open the
plastic cap.
FIGURE 28
Writer: FL

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39. On the upper alternator connector, cut the
white wire at position 2. Crimp ring
terminal N55439-02. Seal connection by
melting shrink Tag and identify “25A1”.
40. Cut the other two red wires at positions 3
and 4. Seal with N55439-01 shrink tube.
41. On the lower alternator connector, cut the
white wire at position 2. Crimp ring
terminal N55439-02. Seal connection by
melting shrink Tag and identify “25A2”.
42. Cut red wire at position 3. Crimp ring
terminal N55439-02. Seal connection by
melting shrink Tag and identify “24ALT”.
43. Cut and seal the wire at position 4 with
N55439-01 shrink tube.
FIGURE 29
44. Connect ring terminals 25A1 and 25A2 (on
Indicator, “I”; 24Alt on Sense, “S”.
Use 5001180 10-24 Nylon lock nut and
5001137 washer.
45. Tighten to the following torque values:
Sense: 25-45 lb-in (3.0 5.0 N-m)
Indicator: 25-45 lb-in (3.0 5.0 N-m)
Note: After completing tests, Apply color guard
684013 on all connections.
FIGURE 30
Writer: FL

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46. Install ground
alternator.
cable
0610034
on
Pre-bend the cable before attempting to
install.
Use the screw and lock washer supplied
with alternator. Add 500411 SS Washer.
Tighten to 50-60 lb-in (5.6-6.8 N-m)
47. Connect ground cable to the engine.
Tighten to 240 lb-in.
FIGURE 31
Note: After completing tests, Apply color guard
684013 on all connections.
FIGURE 32
For all X series vehicles and H series only up to H-3734, we will reuse the vehicle’s existing power cable.
The cable is too short to connect to the new alternator as-is, perform steps below to get the additional
length.
48. Remove cable ties up to the rear junction box cable trough.
49. Take the required extra length in the area circled in figure below.
Writer: FL

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FIGURE 33 TYPICAL CABLE TIE ARRANGEMENT AND CABLE ROUTING (X SERIES GHG14 VARIANT SHOWN)
50. Secure cable with cable ties following the same path. Take care to clear the A/C pressure
transducer located in this area.
NOTE: The cable ties must be rated to withstand the temperature of the engine compartment. Use the
cable ties specified in the shop supplies list of this bulletin.
Special instructions for H series from H-3735 up to
J-0184, only.
51. Remove existing power cable. Route
power cable 0610052 supplied with kit
0610089
from
the
main
power
compartment towards the engine.
52. Dismantle the former cable progressively.
Use the same routing, cable supports and
mounting points for the new power cable.
FIGURE 34: FROM H-3735 UP TO J-0184, ONLY
Writer: FL

IS-19908E
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Special instructions for H series from H-3735 up to
J-0184, only.
53. In main power compartment, connect new
cable to junction block in same location as
previous cable.
Tighten to 96 lb-in
Apply torque seal.
FIGURE 35: FROM H-3735 UP TO J-0184, ONLY
54. Install power cable on alternator.
See NOTE below
Use 500685 Nylon lock nut and 5001341
SS Washer.
Tighten to 80-125 lb-in (9.0-14.0 N-m)
FIGURE 36
Writer: FL

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NOTE on positive stud :
Early versions of the alternator have a shorter
positive stud.
Nut 500685 does not thread fully on the shorter
stud to allow the locking nylon lock to grip on the
threads.
In this situation, use the nut and lock washer
provided with the alternator.
Tighten to: 80-125 lb-in (9.0-14.0 N-m).
FIGURE 37: HARDWARE TO USE WITH EARLY VERSIONS
55. Secure control harness and power cable
together with double loop cable ties as
shown in images below.
56. If the red LTD wire was disturbed by
dismantling of the Bosh wiring, secure it
using the recommendations outlined in
Appendix A “LTD wire guidelines”.
FIGURE 38
ALTMGM PARAMETER CHANGE
Contact your Prevost Customer support manager if your require assistance for this step.
Multiplex parameter ALTMGM value must be No.
FUNCTIONAL TESTING
Writer: FL

IS-19908E
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57. Reset main circuit breakers if applicable. Set the battery master switch (master cut-out) to the ON
position and start the engine. Make sure that the charging system is working normally.
On the instruments cluster, the alternator telltale
Writer: FL
illuminates if the alternators are not charging.

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APPENDIX A – LTD WIRE GUIDELINES
IMPORTANT: It the LTD wire is disturbed; the following guidelines must be followed to secure it properly.
NOTE
Always use double loop cable ties to secure LTD. LTD must be tied alone, with no other cables in the
loop.
NOT ALLOWED
CORRECT
Possible contact or rubbing against screws,
edges, etc.
LTD must be routed clear of screws, sharp
edges, etc.
NOT ALLOWED
CORRECT
Rubbing or possible rubbing against abrasive
surfaces
LTD must be secured with double loop cable
ties. Distance between cable ties must not
exceed 4 inches (100mm) max
NOT ALLOWED
LTD touching cut cable tie
Writer: FL

IS-19908E
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NOT ALLOWED
LTD extending slantingly from the cable tie
CORRECT
LTD is not a flexible harness. Avoid tight
bends and kinks which could short circuit the
LTD. Loops must hace a minimum radii of 4
inches (100 mm)
NOT ALLOWED
CORRECT
Cable tie tighten in excess on the LTD.
Tighten cable tie on LTD by hand only.
Tighten just enough to prevent LTD from
slipping from once side to the other inside
the cable tie loop
Proper tightening of the cable tie on the LTD
Writer: FL

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LABOR REFERENCE TABLE
Table for reference only.
Actual times will vary depending on vehicle condition.
Operation
Approximate
labor (hours)
Step 1
BOSCH ALTERNATORS REMOVAL, RIGHT HAND SIDE
1h
Step 2
INSTALLING THE RIGHT HAND ALTERNATOR. (includes wiring)
2h
Step 3
FUNCTIONAL TESTING
0.5h
Total
3.5 hours
PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)
Writer: FL