﻿GET_GEVOMechL2_09_01_01_35 - STEP-BY-STEP Screen
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Typical steps to prepare the alternator for installation are as follows:

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<b>Caution:</b> To remove or install rotor supports and cardboard shipping shims on EVO engine style alternators, only use the EVO Alternator Stator Lifter (TESCO T67471) designed and rated for lifting these rotors (30 bolt flex plate).

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Sling lifts from coupling bolts screwed into the rotor will bend the bolts.

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Hoist rings designed with coarse thread bolts must never be modified with fine thread flex plate-to-alternator rotor bolts.

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<b>Caution:</b> To avoid damaging the stator windings, never lift the rotor with a hook.

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<b>Note:</b> If guide pins are not available to aid in coupling bolt alignment, the rotor support may remain installed with the mounting bolts left hand tight so that the support may be easily removed once the coupling is complete.

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Alternatively, the cardboard shims may be installed in a double-folded manner.

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The shims and/or support must be removed once the rotor is coupled to the engine.

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1. Lift the rotor (30 bolt flex plate) using the EVO Alternator Stator Lifter (TESCO T67471) and remove the cardboard shipping shims from between the coils and stator.

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<b>Note:</b> Qualify the rotor bolt hole threads by fully hand threading into and out of each bolt hole.

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2. As necessary, apply cutting tap fluid to the flex plate-to-alternator rotor bolt hole threads and chase the threads using the ¾-16 tap.

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3. Using compressed air, blow the surfaces and bolt holes free of debris.

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<b>Note:</b> Dirty engine-alternator mating surfaces can hinder proper alignment.

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<b>Caution:</b> Avoid using a wire wheel grinder to clean surfaces.

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Using one can be unsafe as the strands of wire may break free during high speed rotation.

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Also, strands of wire entering the alternator winding have the potential for creating circuit defects.

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4. Using an aluminum oxide flap wheel of no greater than 120 grit, polish and clean the alternator coupling and mounting surfaces.

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<b>Caution:</b> When using a grinder to remove burrs or raised metal, limit the area being ground to the defect itself.

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Grinding large portions of the pad surface may change the precision reference plane to which all four pads have been machined.

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5. After polishing, with an ungloved hand, feel the four mounting pad surfaces and rotor yoke face for nicks, raised metal, and burrs and remove any high spots with a file, emery cloth, or light grinder.
