Special Bulletin
REVISION E

SP15-304E
Date

Expiration

Release

Page

01.2015

01.2017

7

1(19)

THIS REVISION SUPERSEDES THE PREVIOUS VERSION
For vehicles from F-7000, use power cable 3/0 p/n 069282

ALTERNATOR REPLACEMENT WITH BOSCH HD10PLBH 150A
Prevost vehicles
DESCRIPTION
On the vehicles affected by this bulletin, the Bosch HD10 alternators need to be replaced with new Bosch
HD10PLBH 150 Amps alternators.

MODEL YEAR(S) AND VEHICLES INVOLVED

Model

VIN

From 2PCG33495CC735053 up to 2PCG33495CC735232 incl.
And

NYCT X3-45 Commuter coaches
Model Year : 2012, 2014, 2015

4RKG33495F9737000
4RKG33499F9737002
4RKG33490F9737003
4RKG33492F9737004
4RKG33494F9737005
4RKG33496F9737006
4RKG33498F9737007
4RKG3349XF9737008
4RKG33491F9737009
4RKG33498F9737010

4RKG3349XF9737011
4RKG33491F9737012
4RKG33493F9737013
4RKG33495F9737014
4RKG33497F9737015
4RKG33499F9737016
4RKG33490F9737017
4RKG33492F9737018
4RKG33494F9737019
4RKG33494F9737022

The above list of VIN was valid at the time of publishing this document. Please refer to SAP for most recent information about
outstanding vehicles

Special Bulletin

SP15-304E
Date

Expiration

Release

Page

01.2015

01.2017

7

2(19)

MATERIAL
Order the following parts:
Part No.
069222

Description
POWER CABLE 3/0 (CIRCUIT 102A)
vehicles from C-5053 up to C-5232 (90 first busses)

Qty
1

069282

POWER CABLE 3/0 (CIRCUIT 102A)
vehicles starting from F-7000 (2nd contract)

1

502573

WASHER, FLAT M6 STAINLESS STEEL

2

504637

CABLE TIE

15

507664

CABLE TIE, DOUBLE LOOP

12

509491

CABLE TIE, WIDE

10

564590

ADAPTER

1

564593

ALTERNATOR, BOSCH HD10PLBH 28V 150A

2

5001182

NUT, M6 STAINLESS STEEL

2

5001341

WASHER, FLAT M8 STAINLESS STEEL

3

5001787

NUT, M8 STAINLESS STEEL

2

500169

SCREW, CAP ¼-20 x 1 ½ GR5

3

502716

NUT, NYRT ¼-20

3

509490

DOUBLE-TIE MOUNT, HELLERMANN TYTON, GREY

3

504751

ANCHOR, DOUBLE SWIVEL HELLERMANN TYTON

1

Other parts or products that may be required:
Part No.

Description

684013

COLOR GUARD RUBBER COATING, 14.5 OZ CAN

5001853

BOLTS, ALTERNATOR MOUNTING M12 x 130mm lg

QTY: 2

5001728

NUTS, ALTERNATOR MOUNTING M12

QTY: 2

680038

LOCTITE 243, BLUE

685353

TORQUE SEAL, YELLOW

680335

ANTI-SEIZE COMPOUND

Special Bulletin

SP15-304E
Date

Expiration

Release

Page

01.2015

01.2017

7

3(19)

REQUIRED TOOLS
RATCHET AND SOCKET SET - METRIC

TORQUE WRENCH

BRASS WIRE CUP BRUSH

SPECIAL TOOLS REQUIRED TO TIGHTEN THE ALTERNATOR PULLEY MOUNTING NUT

METRIC 10mm 12-POINTS SPLINE DRIVE LONG (CARLYLE SLTS3810M AVAILABLE FROM NAPA )

OFFSET 7/8 WRENCH (CYLINDER HEAD WRENCH), SNAP-ON PART
NUMBER M4201

7/8 SOCKET (PART NUMBER WA2828A)

OFFSET 7/8 WRENCH FITTED WITH 7/8 SOCKET AND 10mm 12-POINTS
SPLINE DRIVE

Special Bulletin

USING THE CYLINDER HEAD WRENCH
RATCHET AND A FLEX SOCKET WRENCH

SP15-304E

WITH

Date

Expiration

Release

Page

01.2015

01.2017

7

4(19)

A

PROCEDURE

DANGER
Park vehicle safely, apply parking brake, stop engine. In the battery box, set the battery cut-off switch
to the OFF position prior to working on the vehicle.

1. Remove the A/C compressor belts and then
remove A/C compressor idler pulley bracket
assembly (3 bolts to be removed, FIGURE 1).

FIGURE 1

Special Bulletin

SP15-304E
Date

Expiration

Release

Page

01.2015

01.2017

7

5(19)

2. Remove the alternator belt (FIGURE 2).
3. Unscrew the alternator pulley mounting nut
(FIGURE 2).
4. Remove the alternator pulley (2 pulleys)
(FIGURE 2).

FIGURE 2

5. Remove the existing alternators. To do so,
unscrew identified mounting bolts on FIGURE 3
and retain for reuse if in good condition.
6. Identify alternator cables and then disconnect
cables. Properly clean cable ring terminals as
applicable using a brass wire cup brush, a
Scotch-Brite pad or an emery cloth. Take note
that the existing power cable identified 102A
connected to the upper alternator will not be
reused.

BRASS WIRE CUP BRUSH

FIGURE 3

Special Bulletin

SP15-304E
Date

Expiration

Release

Page

01.2015

01.2017

7

6(19)

7. Install new alternators. Fix lower and upper
alternators loosely to alternator supports using
bolts C. Apply anti-seize compound inside the
alternator mounting ears and inside the
sleeves found on the support attached to the
engine (see location C on FIGURE 4). Also,
mount arched support loosely onto alternators
using bolts B (FIGURE 4). If applicable, install
stone guard.
NOTE: Reuse existing bolts unless they are
not in good condition (damaged, pitted,
eroded).
For reference:
C= nut M12 #5001728
C= bolt M12 #5001853
B= nut M10 #5001727
B= bolt M10 #5001801 (upper one)
B= bolt M10 #5001843 (lower one)

FIGURE 4

8. Replace the existing power cable (circuit 102A)
(FIGURE 5) with new power cable (#069222 or
#069282 as applicable). This cable is routed
from the upper alternator B1+ stud terminal up
to the 24VI junction block in the rear junction
box (FIGURE 6, FIGURE 7, FIGURE 8).
NOTE: The red junction block rubber cap is
identified “BUSSMAN”.
a) While removing 102A, separate the AFSS
LTD wire from power cable. It will be
reinstalled on new power cable 102A
similarly using appropriate nylon ties later
on.

FIGURE 5

b) It is recommended to install the new power
cable simultaneously with the removal of
former power cable already there in order
to use up to a certain point, the same
attachment points and to place appropriate
nylon ties at the same locations. Start in
the rear junction box.
Installation of power cable 3/0 will required
the use of 3 HellermannTyton double-tie
mounts #509490 and corresponding
hardware: 3x cap screw #500169, 3x nylon
insert nut #502716, 3x wide nylon tie
#509491 and 3x nylon tie #504637. Use
FIGURE 9, FIGURE 10, FIGURE 11, FIGURE 12,
FIGURE 13 as reference to complete the
installation.
HellermannTyton
double-tie
mounting screw torque: 8 lbf-ft.

mounts

FIGURE 6: POWER CABLE 102A CONNECTED TO
BUSSMAN JUNCTION BLOCK - TORQUE 10 lbf-ft.