WORK PROCEDURE
for distributors and service points

WP1154
ADDRESSEES

: ABC Customer Care and Parts Source

VEHICLE MODEL

: CX45 and TX45 with Cummins X12 engine

MANUAL CHAPTER

: 14.10 Electricity – Alternators

BULLETIN TYPE

: Informative

DATE

: January 13th, 2020

SUBJECT

: To replace alternators

APPLICATION
The work procedure is applicable to vehicles with Cummins X12 engine.

Figure 1: Location of alternators in
engine compartment
1. Engine mounted alternator
2. Refrigerant compressor
mounted alternator

JOB REQUIREMENTS:
This job has to be carried out by an experienced automotive electrician.
PREPARATIONS
•
•
•
•
•
•

Park the coach on a level-surfaced service pit.
Apply the parking brake and shut down the engine.
Switch off all systems and turn off the battery master switch.
Turn off the mechanical battery switch.
Put a “DO NOT OPERATE” tag on the instrument panel.
Read the entire procedure before beginning to work.

WARNING!
Observe safe shop practices at all times.

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TO REPLACE ENGINE MOUNTED ALTERNATOR

Step
1
2
3

Action
Ensure that the mechanical battery switch is turned off.
Open the engine compartment access door in the vehicle rear.
Insert a ratchet wrench with a ½ inch square drive into the hole of the automatic belt
tensioner (refer to figure 2). Relieve the belt tension by turning the ratchet wrench in
the opposite direction to the spring tension of the automatic belt tensioner. Remove
the belt. Carefully let the automatic belt tensioner return to its stop.

Figure 2

4

Remove the oil filler pipe bracket from the alternator bracket and the oil filler pipe
itself.

Figure 3

5

While supporting the alternator, remove the fasteners indicated in figure 4.

Figure 4

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6

Disconnect the flex tube at the rear of the alternator.

Figure 5

7
8
9

Turn the alternator to gain access to the rear of the alternator.
Remove the protective cover at the rear of the alternator. For convenience during reinstallation, note the position of the cables through the holes in the protective cover.
Disconnect “B+” (red), “B-“ (brown) and “D+” alternator cables and remove the
alternator.

Figure 6

10

Reconnect the electric cables to the new alternator. Route the cables so that they will
pass afterwards through the holes of the protective cover.
• Re-tighten the terminal nut of the “B+” (red) and “B-“ (brown) cables to a torque of
6.6 to 9.6 ft.lbf (9 to 13 Nm).
• Re-tighten the terminal nut of the “D+” cable to a torque of 1.8 to 2.35 ft.lbf (2.4 to
3.2 Nm).

Figure 7: “B+” and “B- “
cables reconnected

11
12

Re-install the protective cover at the rear of the alternator. Verify that the rubber
grommets for the cables are in place. Secure the nuts.
Secure the flex tube to the protective cover at the rear of the alternator.

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13
14

Secure the alternator with the fasteners removed in step 5 removed to its bracket.

CAUTION!
Never twist or roll the belt over the edge of the pulley. Even if this
action does not cause immediate visible damage, it does shorten belt
life.
Re-install the alternator belt as follows:
a.
b.
c.
d.
e.

Loop the new belt over drive pulley (1).
Tighten automatic belt tensioner (2).
Loop the belt over alternator pulley (3).
Carefully release the automatic belt tensioner against the belt.
Check that the belt rides in the grooves of all the pulleys.

Figure 8

15

Close the engine compartment access door in the vehicle rear.

End of procedure.

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TO REPLACE REFRIGERANT COMPRESSOR MOUNTED ALTERNATOR
Step
1
2
3

Action
Ensure that the mechanical battery switch is turned off.
Open the rearmost access door at the right and the engine compartment access door
in the vehicle rear.
Behind the engine compartment access door in the vehicle rear:
a. Insert a ratchet wrench with a ½ inch square drive into the hole of the automatic
belt tensioner.
b. Relieve the belt tension by turning the ratchet wrench in the opposite direction to
the spring tension of the automatic belt tensioner.
c. Remove the belt.
d. Carefully let the automatic belt tensioner return to its stop.

Figure 9: Automatic belt
tensioner

4

Behind the rearmost access door at the right:
a. At the rear of the alternator, remove the air hose connected to the protective
cover.
b. Disconnect the cable clamp from its bracket by unscrewing nuts (1 and 2).
c. Remove the cable clamp bracket from the protective cover by unscrewing nuts (3
and 4).
d. Remove the protective cover.
e. Re-install nuts (1 and 2) to prevent cable clamp falling to pieces.

Figure 10

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5

Disconnect the “B+” (red), “B-“ (brown) and “D+” alternator cables.

Figure 11

6

While supporting the alternator, remove the fasteners (1 and 2) indicated in figure 12
and remove the alternator.

Figure 12

7
8

Secure the new alternator with the fasteners removed in step 6.
Reconnect the electric cables to the alternator. Route the cables so that they will
pass afterwards through the holes of the protective cover.
• Re-tighten the terminal nut of the “B+” (red) and “B-“ (brown) cables to a torque of
6.6 to 9.6 ft.lbf (9 to 13 Nm).
• Re-tighten the terminal nut of the “D+” cable to a torque of 1.8 to 2.35 ft.lbf (2.4 to
3.2 Nm).

Figure 13: “B+” and “B- “
cables reconnected

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9

At the rear of the alternator:
a. Re-install the protective cover.
b. Re-install the cable clamp bracket.
c. Secure the protective cover and the cable clamp bracket to the alternator with the
nuts removed in step 4.
d. Secure the cable clamp to its bracket.
e. Re-install the air hose to the protective cover.

10

CAUTION!
Never twist or roll the belt over the edge of the pulley. Even if this
action does not cause immediate visible damage, it does shorten belt
life.
Re-install the alternator belt as follows:

11

a. Loop the new belt over the refrigerant compressor pulley.
b. Tighten the automatic belt tensioner.
c. Loop the belt over the alternator pulley.
d. Carefully release the automatic belt tensioner against the belt.
e. Check that the belt rides in the grooves of all the pulleys.
Close the engine compartment access door in the vehicle rear and the rearmost
access door at the right.

End of procedure.

DISCLAIMER:
The procedures contained herein are not exclusive. Van Hool cannot possibly know, evaluate, or
advise the transportation industry of all conceivable ways in which a procedure may be undertaken
or of the possible consequences of each such procedure. Other procedures may be as good, or
better, depending upon the particular circumstances involved. Each carrier who uses the
procedures herein must first satisfy himself thoroughly that neither the safety of his employees or
agents, nor the safety or usefulness of any products, will be jeopardized by any procedure
selected.

VAN HOOL CUSTOMER PORTAL:
Consult the customer portal regularly for the latest service documentation. In addition to the
maintenance manual, you will also find the operating manual and the spare parts catalogue of your
vehicle on the customer portal. The customer portal is accessible through www.vanhool.be, and
only with a code (password) from Van Hool. If you do not have a password yet, request it by using
the link on the Van Hool website.

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