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

FIGURE 3

2. Remove the alternator belt (FIGURE 4).
3. Unscrew the alternator pulley mounting nut
(FIGURE 4). Keep nut for reuse if nut provided
with the alternator is not a flange nut.
4. Remove the alternator pulley (2 pulleys)
(FIGURE 4).

FIGURE 4

5. Disconnect power cable (circuit 102/102A)
from the 24VI junction block or relay R1 as
applicable in the rear junction box/main
power compartment (FIGURE 8 & FIGURE 10).
6. Identify and disconnect alternator cables.
Properly clean cable ring terminals as applicable using a brass wire cup brush, a ScotchBrite pad or an emery cloth.
Take note that the existing 2/0 gauge power
cable (identified 102 or 102A depending on the
type of vehicle) connected to the upper alternator and routed up to the main power compartment will not be reused.

BRASS WIRE CUP BRUSH

7. Remove the existing alternators. To do so,
unscrew identified mounting bolts on FIGURE 5
and keep for reuse.

FIGURE 5

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8. 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 6). Also,
mount arched support loosely onto alternators
using bolts B (FIGURE 6).
For reference:
C= bolt M12 #5001853
C= nut M12 #5001761
B= bolt M10 #5001801
B= nut M10 #5001930
FIGURE 6

9. Replace the existing 2/0 gauge power cable
(circuit 102 or 102A) (FIGURE 7) with new 3/0
power cable (FIGURE 2). This cable is routed
from the upper alternator B1+ stud terminal
up to the 24VI junction block in the rear junction box/main power compartment (FIGURE 8,
FIGURE 9, FIGURE 10 & FIGURE 11).
a) While removing power cable 102/102A,
separate the Automatic Fire Suppression
System (AFSS) LTD wire attached to the
power cable if applicable depending on
your vehicle option and actual LTD installation. The LTD will be reinstalled on new
power cable 102/102A similarly using
appropriate nylon ties later on.

FIGURE 7

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/main
power compartment.
Installation of power cable 3/0 will required the use of 3 HellermannTyton
double-tie mounts #509490 and corresponding hardware:
3x cap screw #500169,

FIGURE 8: X3 SERIES - POWER CABLE 102A CONNECTED
TO BUSSMAN JUNCTION BLOCK - TORQUE 10 lbf-ft. APPLY
COLOR GUARD RUBBER COATING

3x nylon insert nut #502716,
3x wide nylon tie #509491,
3x nylon tie #504637.
Use

FIGURE 12, FIGURE 13, FIGURE 14, FIGURE 15 & FIGURE 16 as reference to com-

plete the installation.

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HellermannTyton
double-tie
mounting screw torque: 8 lbf-ft.

FIGURE 9: X3 SERIES

mounts

FIGURE 10: H3 SERIES

FIGURE 11: ALTERNATOR POWER CABLE

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FIGURE 12: POWER CABLE ATTACHED TO #1, #2, #3 DOUBLE-TIE MOUNT AND PROPER NYLON TIES INSTALLATION

HellermannTyton double-tie mounts mounting screw torque: 8 lbf-ft.

FIGURE 13: POWER CABLE ATTACHED TO #1 DOUBLE-TIE MOUNT AND PROPER NYLON TIES INSTALLATION

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FIGURE 14: POWER CABLE ATTACHED TO #2 DOUBLE-TIE MOUNT AND PROPER NYLON TIES INSTALLATION

FIGURE 15: POWER CABLE ATTACHED TO #2 DOUBLE-TIE MOUNT AND PROPER NYLON TIES INSTALLATION

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FIGURE 16: POWER CABLE ATTACHED TO #2, #3 DOUBLE-TIE MOUNT AND PROPER NYLON TIES INSTALLATION

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FIGURE 17: X3 SERIES - USING DOUBLE SWIVEL ANCHOR AND 2 WIDE NYLON TIES, SECURE THE POWER CABLE TO
THE AIR COMPRESSOR INLET HOSE
ON H3 SERIES, USE THIS DEVICE TO SECURE THE POWER CABLE TO NEARBY COMPONANTS AS REQUIRED.

DUAL SWIVEL SADDLE SPACER

10. If applicable, reinstall the LTD along the power cable using double-loop nylon ties #507664 as
previously installed. For proper installation and location, refer to FIGURE 18 to FIGURE 22 and read LTD
INSTALLATION GUIDELINES in this document.

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FIGURE 18

FIGURE 19

FIGURE 20

FIGURE 21

FIGURE 22

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LTD INSTALLATION GUIDELINES
IMPORTANT: WHEN INSTALLING THE “LTD”, THE FOLLOWING GUIDELINES MUST BE FOLLOWED.

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

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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

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11. In order to assure proper installation, it is important to tighten the alternator mounting bolts
in the following proper sequence. Use Loctite
243 blue on threads (FIGURE 23).
1st Bolt/Nut B, 43 lbf-ft (2x).
2nd Bolt/Nut C, 74 lbf-ft (2x).

FIGURE 23

12. One (1) flat washer #500449 is required
between the pulley and the flange nut (FIGURE
24).
IMPORTANT NOTE: If the two flat washers are not
included in the kit, please order two flat washers
#500449. Without these washers, flange nut
tightening may be insufficient, the pulley could then
slip.

FIGURE 24

13. Mount pulley onto alternators (FIGURE 25). Use
Loctite 243 blue on threads. Tighten pulley
mounting nut to 75 lbf-ft.

FIGURE 25

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14. Install the alternator belt (FIGURE 26)

FIGURE 26

15. Cable connection overview. Upper
and lower alternator (FIGURE 27).

FIGURE 27

UPPER ALTERNATOR - (use new hardware for cable connection)
16. Power cable and jumper (positive) cable.
a) Install jumper cable (a.k.a. positive cable) onto B1+ stud terminal on upper alternator (FIGURE 28).
b) Place one new flat washer #5001341 against the cable ring terminal (FIGURE 28).
c) Screw and tighten the adapter stud #060297 (torque: 10 lbf-ft) (FIGURE 28) prior installing power
cable.
d) Fit the power cable terminal onto adaptor stud, place one new flat washer #5001341 against the
power cable terminal and screw a new nut #5001787 (nut torque: 10 lbf-ft) (FIGURE 28).

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FIGURE 28

15. Fit the ground cable onto the alternator ground stud, place one new flat washer #502573 against
the ground cable terminal and screw a new nut #5001182 (nut torque: 6 lbf-ft) (FIGURE 28).
16. Plug alternator harness onto alternator connector and secure using nylon cable ties (FIGURE 29).

FIGURE 29

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LOWER ALTERNATOR - (use new hardware for cable connection)
17. Jumper (positive) cable.
a) Fit jumper cable (positive cable) onto B1+ stud terminal on lower alternator (FIGURE 30).
b) Place one new flat washer #5001341 against the cable ring terminal and screw new nut
#5001787 (nut torque: 10 lbf-ft) (FIGURE 30).
c) Fit the ground cable onto the alternator ground stud, place one new flat washer #502573 against
the ground cable ring terminal and screw a new nut #5001182 (nut torque: 6 lbf-ft) (FIGURE 30).

FIGURE 30

18. Plug lower alternator harness onto lower alternator
connector and secure using
two
nylon
cable
ties
#504637 (FIGURE 31).

FIGURE 31

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19. Apply anti-corrosion compound on alternator terminals and cable ring terminals or
use color guard rubber coating #684013 if
available.
20. Reinstall the A/C compressor idler pulley
bracket assembly (FIGURE 32). Apply Loctite
243 on threads. Reinstall the A/C compressor belts.
21. Finally, check that all cables are properly
installed, start engine and check for proper
functioning. Check for proper functioning of
charging system.

FIGURE 32

PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)