NHTSA ID Number: 10126258
Manufacturer Communication Number: IS-15003D
TSB/Document Date: 2017-12-22
Summary
This instruction sheet explains how to use the Bosch
HD10 24V-150A Alternator Conversion Kit
Instruction Sheet
IS-15003D
BOSCH HD10 24V-150A ALTERNATOR CONVERSION KIT –
TWIN BOSCH MOUNTED ON VOLVO D13 ENGINE
REVISION : D
THIS INSTRUCTION SHEET SUPERSEDES PREVIOUS VERSION.
Change of kit numbers. Kit 069425 becomes 061226. Kit 069426 becomes 061230.
Addition of two washers #500449 in kits #061226 and #061230.
IMPORTANT NOTE: It is mandatory to install two alternators of same rated amperage on the
vehicle. The twin Bosch installation cannot combine one 120A and one 150A simultaneously.
The conversion to twin 150A Bosch alternator requires a 3/0 gauge power cable (circuit
102/102A), included in this kit.
APPLICATION
H3 Series equipped with Volvo D13 engine
X3 Series starting from US10 compliant Volvo D13 engine
IS-15003D
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MATERIAL
H3 SERIES VEHICLES. Kit #061226 includes the following parts:
Part No.
New part
Description
Qty
060297
ADAPTER
1
069184
CABLE, POWER 3/0 GAUGE 2600mm lg
502573
WASHER, FLAT 6.4 x 12.5 x 1.6 STAINLESS STEEL
2
500169
SCREW, CAP ¼-20 x 1 ½ GR5
3
500447
WASHER, PLAT ZP .562X1.375X.109
2
502716
NUT, NYRT ¼-20
3
509490
DOUBLE-TIE MOUNT, HELLERMANN TYTON, GREY
3
(CIRCUIT 102A)
1
564593
ALTERNATOR, BOSCH HD10PLBH 24V-150A
2
504637
CABLE TIE
20
504751
DUAL SWIVEL SADDLE SPACER
1
507664
CABLE TIE, DOUBLE LOOP
10
509491
CABLE TIE, WIDE
10
5001182
NUT, M6 STAINLESS STEEL
2
5001341
WASHER, FLAT 8.4 x 17 x 1.6 STAINLESS STEEL
3
5001787
NUT, M8 STAINLESS STEEL
2
IS-15003
Instruction Sheet
1
FI-15003
Feuille d'instructions
1
X3 SERIES VEHICLES. Kit #061230 includes the following parts:
Part No.
New part
Description
Qty
060297
ADAPTER
1
069222
CABLE, POWER 3/0 GAUGE 2000mm lg
502573
WASHER, FLAT 6.4 x 12.5 x 1.6 STAINLESS STEEL
2
500169
SCREW, CAP ¼-20 x 1 ½ GR5
3
500447
WASHER, PLAT ZP .562X1.375X.109
2
502716
NUT, NYRT ¼-20
3
509490
DOUBLE-TIE MOUNT, HELLERMANN TYTON, GREY
3
564593
ALTERNATOR, BOSCH HD10PLBH 24V-150A
2
504637
CABLE TIE
20
504751
DUAL SWIVEL SADDLE SPACER
1
507664
CABLE TIE, DOUBLE LOOP
10
509491
CABLE TIE, WIDE
10
5001182
NUT, M6 STAINLESS STEEL
2
5001341
WASHER, FLAT 8.4 x 17 x 1.6 STAINLESS STEEL
3
5001787
NUT, M8 STAINLESS STEEL
2
IS-15003
Instruction Sheet
1
FI-15003
Feuille d'instructions
1
(CIRCUIT 102A)
1
IS-15003D
Page 3 / 20
Other parts that may be required:
Part No.
684013
Description
COLOR GUARD RUBBER COATING, 14.5 OZ CAN
5001853
SCREW, CAP ALTERNATOR MOUNTING M12-1.75 x 130 G10.9
QTY: 2
5001761
NUT, HEX ALTERNATOR MOUNTING M12-1.75
QTY: 2
5001801
SCREW, CAP ALTERNATOR MOUNTING M10-1.5x55 G10.9
QTY: 2
5001930
NUT, HEX ALTERNATOR MOUNTING M10-1.5 G10.9
QTY: 2
680038
LOCTITE 243, BLUE
680335
ANTI-SEIZE COMPOUND
NOTE
Material can be obtained through regular channels.
REQUIRED TOOLS
RATCHET AND SOCKET SET METRIC
BRASS WIRE CUP BRUSH
SPECIAL TOOLS THAT CAN BE USEFUL 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)
IS-15003D
Page 4 / 20
OFFSET 7/8 WRENCH FITTED WITH 7/8 SOCKET AND 10mm 12-POINTS
SPLINE DRIVE
USING THE CYLINDER HEAD WRENCH WITH A RATCHET AND A FLEX SOCKET WRENCH
IS-15003D
Page 5 / 20
PROCEDURE
DANGER
Park vehicle safely, apply parking brake, stop engine and set battery master switch(es) to the OFF
position prior to working on the vehicle.
FIGURE 1: PULLEY MOUNTING NUT – DO NOT USE THE STANDARD NUT AND SPRING
WASHER THAT MAY BE PROVIDED WITH THE ALTERNATOR. A FLANGE NUT MUST BE
USED
FIGURE 2: POWER CABLE 3/0 #069184 OR # 069222
IS-15003D
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TSB/Document ID: IS-15003D
Replacement Service Bulletin Number:
MFR Communication Date: 2017-04-05
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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