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

IS-19908E
Page 2 / 26

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

IS-19908E
Page 3 / 26

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

IS-19908E
Page 4 / 26

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

IS-19908E
Page 5 / 26

ELECTRICAL SCHEMATICS

FIGURE 1: ALTERNATOR CONNECTIONS

Writer: FL

IS-19908E
Page 6 / 26

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
Page 7 / 26

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
Page 8 / 26

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
Page 9 / 26

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

IS-19908E
Page 10 / 26

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

IS-19908E
Page 11 / 26

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