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  C04027 5/08Power TrainC4-3 POWER TRAIN ALTERNATOR REMOVAL The following instructions cover the removal of themain alternator from the engine after the power module has been removed from the truck. The alternator weighs approximately 3720 kg (8200 lbs). Ensure the lifting device to be used has adequate capacity. Lift the alternator only at the lifting eyes on the alternator. 1. Attach a hoist with two lifting chains to bothlifting eyes (8, Figure 4-2) on top of alternator (1).2. Block up the rear of the engine.3. Loosen cradle adjustment setscrews (3, Figure4-1).4. Loosen engine-to-cradle capscrews (5, Figure4-2).FIGURE 4-1. CRADLE STRUCTURE1.Cradle Structure2.Jam Nut3.Adjustment Setscrew4.Subframe5.GapFIGURE 4-2. ENGINE AND ALTERNATOR1.Alternator 2.Mounting Hardware3.Cradle Structure4.Flywheel Housing5.Capscrews6.Engine7.Subframe8.Alternator Lifting Eyes  C4-4Power Train5/08 C040275. Remove the access cover at the front, right sideof engine flywheel housing (4). Reach throughthe access openings and remove 12 capscrews(6, Figure 4-3) that join engine drive ring (7) toalternator rotor (8). Rotate the crankshaft toalign each capscrew with the access hole. NOTE: Ensure that all 12 capscrews have beenremoved. 6. Remove 16 capscrews (3) that secure flywheelhousing adapter (2) to alternator housing (1). NOTE: The clearance between the head of capscrew (3) and flywheel housing (4) will not permit completeremoval of the capscrews at all locations. Ensure that all of the capscrew threads are completely disengaged from alternator housing (1). 7. Take up any slack in the hoist. Removemounting hardware (2, Figure 4-2) that securesthe alternator to the cradle structures.8. Keep the alternator as level as possible andmove away from engine.9. Note the location and quantity of the shims.Keep the shims for possible reuse duringinstallation. NOTE: For further disassembly instructions for thealternator, refer to the GE Service Manual. FIGURE 4-3. ALTERNATOR TO ENGINE MOUNTING1.Alternator Housing2.Flywheel Housing  Adapter 3.Capscrews4.Flywheel Housing5.Capscrew6.Capscrews7.Engine Drive Ring8.Alternator Rotor   C04027 5/08Power TrainC4-5 ALTERNATOR INSTALLATION The following instructions must be followed toensure proper alignment and engine crankshaft endplay. Failure to follow these instructions canresult in serious damage to the engine and/or alternator. ãNever pry on the engine crankshaft damper.ãLoosen or remove fan belts before measuringcrankshaft endplay to ensure that the crankshaftmoves easily and completely.ãWhen taking measurements, always take four equally spaced readings and average them.ãAlways measure from mating surface to matingsurface.ãA reference to crankshaft rotation - clockwise(CW) or counterclockwise (CCW) - is thedirection of rotation when looking at the front(damper end) of engine. ãCrankshaft end play: 0.13 - 0.38 mm (0.005 - 0.015 in.)Measuring Procedure 1. Thoroughly clean the alternator housingmounting surface, rotor drive adapter mountingsurface and flywheel housing adapter mountingsurfaces.2. Mount a magnetic base on the front of theengine and a dial indicator on the front of thecrankshaft. Measure total crankshaft endplay.Verify end play is within 0.13 - 0.38 mm (0.005 -0.015 in.). Total Crankshaft Endplay_________________ 3. Refer to Figure 4-4. Move the engine crankshaftto the rear of its end travel.a.Carefully measure Dimension “C” at four locations, 90° apart:1st measurement:___________________ 2nd measurement:__________________ 3rd measurement:___________________ 4th measurement:___________________ Dimension “Cavg”:______________ b.Add 1/2 (one-half) of Total CrankshaftEndplay from step 2 to Dimension “Cavg”.c.Record (Step 3a + Step 3b) as Measurement “C”:___________________  SERVICE DATA - Eccentricity & Runout LimitsDescriptionT.I.R Maximum Eccentricity of Flywheel Housing Bore0.66 mm(0.026 in.)Maximum Face Runout of Flywheel Housing0.25 mm(0.010 in.)Maximum Eccentricity of Flywheel (Coupling Assembly)0.18 mm(0.007 in.)Maximum Axial Runout of Flywheel Face (Coupling Assembly)0.25 mm(0.010 in.)FIGURE 4-4. SHIM LOCATION1.Alternator Housing2.Alternator Rotor 3.Flywheel Housing  Adapter 4.Engine Flywheel Housing5.Engine Drive Ring“A” - Dimension “A”“B” - Drive Shims“C” - Dimension “C”“D” - Housing Shims  C4-6Power Train5/08 C040274. Refer to Figure 4-5 to determine alternator endplay:a.Using flat steel bar (3) bolted rigidly toalternator rotor (2), install 5/8 - 11NCcapscrew (4) finger tight at each end intoalternator housing (1).b.Move alternator rotor (2) axially toward therear (slip ring end) by alternately tighteningcapscrews (4) one-half turn at a time. Do notexceed 16 Nãm (12.0 ft lbs) on eachcapscrew.  This establishes the maximumpermissIble rear travel for the alternator rotor.c.Alternately loosen capscrews (4) one turn ata time until all torque is released. Carefullyremove steel bar (3).Refer to Figure 4-4.d.Carefully measure Dimension “A” at four locations, 90° apart, and average themeasurements. Do not move the alternator rotor. 1st measurement:___________________ 2nd measurement:___________________ 3rd measurement:___________________ 4th measurement:___________________ Dimension “Aavg”:____________ e.Add 0.25 mm (0.010 in.) to Dimension“Aavg”.f.Record (Step 4d + Step 4e) as Measurement “A”:___________________ 5. To determine the correct shims to use,compare Measurement “C” (Step 3c) withMeasurement “A” (Step 4f). a.If C is greater than A, subtract: (C - A) = B B = ______________Shim pack thickness to be installed at location B, Figure 4-4.b.If A is greater than C, subtract: (A - C) = D D = ________________Shim pack thickness to be installed at location D, Figure 4-4. Rotor-to-Drive Ring Location “B”Shim Part NumberShim Thickness TM34670.10 mm(0.004 in.)TM34690.18 mm(0.007 in.) Alternator-to-Flywheel Housing Adapter Location “D”Shim Part NumberShim Thickness TM34660.10 mm(0.004 in.)TM34680.18 mm(0.007 in.)FIGURE 4-5. ALTERNATOR END-PLAY1.Alternator Housing2.Alternator Rotor 3.Steel Bar 4.Capscrew
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