Bus Alternator Replacement Guide

Safety (PPE)

Always wear the correct PPE:

• Steel toe cap boots
• Overall
• Hard hat
• Latex gloves
• Safety glasses

Tools Needed

• Spanners: 13mm, 17mm, 19mm
• Socket set: 16mm, 17mm, 19mm
• Wrench set: 3/8 and 1/4
• Multimeter
• 6mm short bolt or pin

Step 1: Battery Check

Remove the battery (2x 19mm nuts) and check voltage before starting the vehicle.

A healthy battery: 12.6–12.8V (engine off), 13.7–14.7V (engine running).

Step 2: Alternator Voltage Check

Turn off the bus and switch off the main power to protect the electronics.

Step 3: Remove Belt

Use 16mm spanner/socket to release the tensioner and insert a 6mm pin to hold it.

Step 4: Disconnect Cables

Remove positive and signal cables (13mm spanner) behind the alternator.

Step 5: Remove Alternator

Remove 5 bolts/nuts (17mm & 19mm). The alternator is heavy.

Step 6: Install New Alternator

Fit the new alternator by reversing removal steps.

Reinstall the belt (don’t forget to remove the tensioner pin).

Switch on main power and check voltage again.