5002091 M10x120 bolts.
Apply blue Loctite 680038
Tighten to 48 lb-ft
Apply torque seal.

FIGURE 20

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Writer: fl

IS-19906
Page 17 / 45

RIGHT HAND ALTERNATOR INSTALLATION (continued)
24. Install stud 5000360 with Red Loctite 271 on
new modified compressor brace 450580.
Install it so it exceeds by 25mm.

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er FIGURE 21

n
25. Install modified* compressor brace
mi support
i
l
450580.
re
P

Install reserved hardware by hand.
Tighten C to 43 lb-ft
Tighten D to 22 lb-ft
Tighten E to 40 lb-ft
Apply torque seal.
*450580 is modified with clearance for the
Alternator fan and a different indexation angle
for the tensioner.

FIGURE 22

Writer: fl

IS-19906
Page 18 / 45

26. Install the alternator belt tensioner with
hardware E reserved earlier.
Tighten to 48 lb-ft.
Apply torque seal

FIGURE 23

27. Install alternator belt 506065. To do so,
rotate the automatic belt tensioner using a ½
square drive breaker bar

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FIGURE 24

Writer: fl

IS-19906
Page 19 / 45

28. Install A/C clutch coil.
Use blue Loctite 243
Tighten to 22lb-ft
Apply torque seal

FIGURE 25

29. 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.

30. Carefully mount the rotor on the shaft end by
hand.

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Never use a hammer for pressing the yrotor
r
a
on.
n

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Align the key on the compressor
e shaft with
Prbore. To avoid
the keyway on the pulley
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 26

Writer: fl

IS-19906
Page 20 / 45

31. Fasten the rotor to the shaft end using the
M12 screw and by holding-up with a wrench
on the rotor.
32. 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 27

33. Re-install compressor
Tighten to 82 lb-ft

mounting

bolts.

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Apply torque seal

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FIGURE 28

Writer: fl

IS-19906
Page 21 / 45

34. 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)

35. Apply blue Loctite 243 on bolt B threads and
then hand-tighten bolt 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 bolt
B to 43 lbf-ft. (58 N-m).
Apply torque seal

FIGURE 29

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Writer: fl

IS-19906
Page 22 / 45

RIGHT HAND ALTERNATOR CONNECTIONS
36. Connect control harness 0610036.
Refer to ELECTRICAL SCHEMATICS
Use 5001180 10-24 Nylon lock nut and
5001137 washer.
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)
Apply color guard 684013 on connections.

9

FIGURE 30

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37. Route control harness up over the engine
to C_ALT connector. (Figure 2)
Refer

to

ELECTRICAL

SCHEMATICS;

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FIGURE 31

Writer: fl

IS-19906
Page 23 / 45

38. Install ground cable 0610034 and power
cable 0610030 on alternator.
Ground:
Add 500411 SS Washer.
Tighten to 50-60 lb-in (5.6-6.8 N-m)
Positive:
Use 500685 Nylon lock nut and 5001341
SS Washer.
Tighten to 80-125 lb-in (9.0-14.0 N-m)
Apply color guard 684013 on connections.
39. Connect ground cable to the engine.
Tighten to 240 lb-in.
FIGURE 32

Apply color guard 684013 on connections.
40. Secure control harness and power cable
together with double loop cable ties as shown
in images below.

9

41. 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”.

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FIGURE 33

Writer: fl

IS-19906
Page 24 / 45

42. Route power cable from the main power
compartment towards the engine.
Dismantle the former cable progressively,
using the same routing, cable supports and
mounting points as the previous power cable
for the new power cable.

FIGURE 34

43. Connect to F101 24V junction block on the
fore wall, under R1 relay.
Tighten to 96 lb-in
Apply torque seal.

9

Refer to ELECTRICAL SCHEMATICS.

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FIGURE 35

Writer: fl

IS-19906
Page 25 / 45

BOSCH ALTERNATOR REMOVAL, LEFT HAND SIDE

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 prior disconnecting the alternator cables.

WARNING
Parts of this procedure require access to the underside of the vehicle. Prevost recommends using
mobile column lifts.

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WARNING
Fully deflate the vehicle’s suspension.

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The engine will be supported during engine
arymount removal. Minute deflating of the air springs may
unwillingly transfer some of the vehicle’sin
weight to the engine while it is supported

im

el
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1. Rotate the automatic belt tensioner A
clockwise using a ½ square drive breaker bar
and then remove the alternator drive belt B.
Discard belt.

FIGURE 36

Writer: fl

IS-19906
Page 26 / 45

2. Cut the nylon ties securing the cables to the
alternator and then disconnect the alternator
cables A, B & C.
Move cables on the other side of the engine.
A: (+) POWER CABLE
B: GROUND CABLE
C: ALTERNATOR HARNESS

FIGURE 37

3. Remove the alternator. To do so, unscrew the
two (2) mounting bolts identified on the figure.
Discard alternator.

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