NHTSA ID Number: 10231881
Manufacturer Communication Number: APS5370E
TSB/Document Date: 2023-02-24
Summary
The Delco-Remy alternator is obsolete. Air cooled ductless (Almott) alternator, power cable and hardware kit to replace the Delco-Remy oil-cooled alternator.
15-16
L82J9F3001746
L82J9F3001746
1
Woodstock - Ontario
LA08
17-08
17-08
L82J3H3750514
L82J3H3750514
1
Woodstock - Ontario
LB04
18-04
18-14
L82J3H9776363
L82J5H9776364
2
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NQF772001 VERSION 3
SERVICE PRODUCT
IMPROVEMENT
APS5370E
FOLLOW YOUR INTERNAL SAFETY PROCEDURES.
PROCEDURE
Figure 1 - Original Oil Cooled Delco Generator (Some Parts Removed for Clarity)
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APS5370E
Figure 2 - New Air Cooled Almott Generator (Some Parts Removed for Clarity)
Before starting any work on the vehicle, make sure the vehicle is completely and securely stationary.
Follow your internal safety procedures.
1.1.
Park the vehicle on an even surface with the transmission on neutral.
1.2.
Apply the parking brake and set the master control switch to the stop position.
1.3.
Set the battery disconnect switch in the battery compartment to the off position.
1.4.
Disconnect the starting circuit on the control box at the rear of the vehicle and place the battery disconnect
switches in the off position.
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SERVICE PRODUCT
IMPROVEMENT
APS5370E
REMOVE GENERATOR OIL COOLING SYSTEM PARTS
CAUTION
For information on hoisting and towing of the vehicle, see section 18: hoisting and towing in the Nova Bus
maintenance manual. Use appropriate hoisting equipment for your protection and to prevent damage to
the vehicle.
1.5.
Raise the vehicle.
1.6.
Remove the dust pans.
1.7.
Disconnect the hoses coming from the generator at the engine and be careful to collect the oil.
1.8.
Remove and discard the hoses once the oil has completely drained.
Figure 3 - Drain the Oil and Discard the Hoses
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IMPROVEMENT
APS5370E
1.9.
Remove and discard the port fittings on the engine that were used for the oil hoses.
1.10.
Install a plug 3678923 into the port for the supply line. Install cap plug 4962608 and 3936876 gasket on the
oil hose.
Install cap plug
4962608 and
3936876 gasket
Remove and install
plug 3678923
Figure 4 - Remove Oil Ports Fittings
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IMPROVEMENT
1.11.
APS5370E
Remove the hose and the hardware for the breather hose.
Remove Hose
and Hardware
Figure 5 - Remove Hose and Hardware
1.12.
Install a plug 0444620.
Plug
Figure 6 - Installation of Plug
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APS5370E
REMOVE GENERATOR CABLES
1.13.
Remove and discard bracket N66892.
1.14.
Remove and discard cables N76193-01 and N80190-04.
1.15.
Remove and discard bracket N83016. Retain mounting hardware and dipstick hardware.
1.16.
Discard all hardware.
Discard bracket
N66892
Discard cable
N80190-04
Discard cable
N76193-01
Discard bracket
N83016
Keep bracket
N10322
Figure 7 - Remove Cables and Brackets
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NQF772001 VERSION 3
SERVICE PRODUCT
IMPROVEMENT
1.17.
APS5370E
Remove the fan supply cable on alternator N76667-01. Discard bracket and hardware securing radiator fan
cable to the alternator. Retain fuse holder and fuse holder bracket.
Discard bracket
and hardware
Discard cable
N76667-01
Retain bracket
and fuse holder
Retain cable
Figure 8 - Fan Cable Removal
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SERVICE PRODUCT
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APS5370E
Before unbolting the generator from its bracket, make sure it is held in place by a safety clip.
1.18.
Lift up the retractor arm and pulley to remove the drive belt from the generator. Keep the belt for later
reinstallation.
1.19.
Remove and retain the pulley from the old alternator, discard hardware.
1.20.
Remove the bolts attaching the generator to the engine mounting bracket.
1.21.
Remove and discard the mounting bolts, except for the shorter bolt on the street side, retain for installation
of new alternator.
1.22.
Install the new generator. Due to its size, it might be easier to install the new generator from the inside of
the bus. Use the inside engine acess door from the seats located in the interior rear of the vehicle. Torque
screws N81450 with washers 0120384 to 69 ±4 lb-ft (94 ±6 N•m). The front streetside bolt can be re-used
due to space constraints.
1.23.
Install pulley from old alternator and torque to 270 ± 26Nm. Reinstall belt. See section 09: ALTERNATOR AND
VOLTAGE REGULATOR.
Torque: 69 ±4 lb-ft
(94 ±6 N•m) (4x)
Figure 9 - Torque Generator
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SERVICE PRODUCT
IMPROVEMENT
APS5370E
INSTALLATION OF CABLES AND BRACKETS
NOTE
Use a product like NOCO NCP-2 N67314 to inhibit the corrosion on electrical connections. Whenever torque
seal is applied, it must be done after the torque is applied and after the application of the anticorrosion product.
1.24.
Install bracket N98150 on the back of the alternator.
1.25.
Install all (3) cables on the back of the alternator and leave the connection loose.
1.26.
Install split blocks to support cables and secure them to support cables.
1.27.
Install L bracket for cable going to the radiator fans.
1.28.
Torque all joints on the back of the alternator. Install red lug protector.
N16755 Screw
N17904 Lock Washer
N20779 Washer
Torque 6.5 ± 0.5 lb-ft
(9 ±1 N•m)
N94734-01 Cable
N86311-06 Clamp
N93470-02 Cover
N43233 Nut
Torque to 8.85 ± 0.5 lb-ft
(12±1N•m)
N55828-06 Boot
N107247-01 Cable
N94733-01 Cable
N86311-07 Clamp
N93466-03 Cover
N86342 Nut
Torque to 4.43 ± 0.5lb-ft
(6±1N•m)
Torque: 32 ±2 lb-ft (44 ±3 N•m)
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APS5370E
Cable N107247-01
N84090-05 P-clamp
N44881-02 Screw
N44887 Nut
N34500-01 Bracket
N44887 Nut
Figure 10 - Installation of Cables and Brackets
1.29.
Cut ring terminals off of regulator wires, crimp on the proper terminals and connector.
WIRE MARKER
AWG
COLOR
64-1546
14
RD
12124582
15324981
12010996
WIRE MARKER
AWG
COLOR
64-2096
16
WH
12124580
15324981
12015791
Figure 11 - Crimp Terminals and Connectors
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NQF772001 VERSION 3
SERVICE PRODUCT
IMPROVEMENT
1.30.
APS5370E
Secure routing with (2) P-clamps at back of alternator.
N44881-02 Bolt
N44887 Nut
N84090-01 Clamp
(if required)
N84090-01 Clamp
G5007994 Tie-wraps
N44881-02 Bolt
N44887 Nut
N84090-01 Clamp
Figure 12 - Secure the Harness
1.31.
Secure power cable for radiator fans on the fuse holder. Torque lug on fuse holder to 8 ±0.5 lb-ft (11 ±1 N•m).
1.32.
Before installing the new bracket N92950, make sure that the bolt head for the breeze clamp on the thermostat
hose beside will be accessible (reposition it if required).
1.33.
Install new bracket N92950 and Reuse hardware from old bracket.
1.34.
Secure cables with provided P-Clamps and M6 lock nuts.
1.35.
Install dipstick on the bracket. Use new bolt N44881-02 and nut N44887 if required.
Rotate if required
N44881-02 Bolt
N44887 Nut
N84090-05 Clamp
Install bracket N92950
Figure 13 - Installation of Bracket
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APS5370E
1.36.
Connect cables to junction blocks and torque.
1.37.
Install new cables N94734-01 and N94773-01. Use the white tapes for proper positioning lined up with the
supports.
1.38.
Install P-Clamps and stand-offs on the engine cradle to support cable routing.
1.39.
Secure P-Clamps in the lower bracket already installed on the engine.
N56836 Swivel
G5007994 Tie Wrap
N17543 Bolt
N44887 Nut
N84090-05 Clamp
N17543 Bolt
N44887 Nut
N48107 Bushing
N84090-05 Clamp
Torque: 22 ±2lb-ft (31 ±3N•m)
Figure 14 - Installation of Cables and P-clamps
1.40.
Install new dual clamp ties N37749 on power cables.
N37749 Dual Tie
Figure 15 - Installation of Dual Clamp tie
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NQF772001 VERSION 3
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IMPROVEMENT
1.41.
APS5370E
Secure harness with tie wraps along power cables.
N37749 Dual Tie
Figure 16 - Installation of Dual Clamp tie
1.42.
If required and not already present, install the angled fitting N75180 to re-orient the Cummins coolant vent
line to avoid contact with the power cables.
1.43.
Undo the fitting and drain excess coolant from the vent line into a bucket. Temporarily cap the engine head
with cap nut N30734 if required until angled fitting is installed.
Install fitting
Figure 17 - Installation of Fitting
PAGE 22 OF 23
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APS5370E
NOTE
Clean terminals and use a product like NCP-2 N67314 to inhibit the corrosion on electrical connections.
Whenever torque seal is applied, it must be done after the torque is applied and after the application of the
anticorrosion product.
1.44.
The vehicle can be put back into service.
PAGE 23 OF 23
NQF772001 VERSION 3
- 6X better wear protection on critical engine parts than...
- 1.3X better sludge protection than industry standards*
- 3X Stronger against viscosity breakdown than leading full...
- Protection for 10,000 miles between oil changes
- Meets or exceeds the following specifications: API SP/SN...
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TSB/Document ID: APS5370E
Replacement Service Bulletin Number:
MFR Communication Date: 2023-02-10
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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