﻿GET_GEVOMechL2_09_01_01_71 - ANIMATION Screen
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Alternator Installation: Preparing the Alternator:

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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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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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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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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.

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6. Remove the bottom shims.

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7. If the alternator is reused, perform the following steps a through e; however, if the alternator is new, only perform steps d and e.

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a. Clean and polish both sides of shims and the alternator mounting face surface using an aluminum oxide flap sanding wheel no coarser than 120 grit.

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b. Use emery cloth or a file to remove any raised metal or burrs on the bottom flanges.

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c. Apply a rust inhibitor to the polished flanges and shims.

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d. Measure and confirm each bottom flange shim is approximately 0.090 inches (2.286 mm) thick, and the thicknesses of both shims are equal to within 0.001 inches (0.0254 mm).

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e. Re-apply the shims to the alternator and then torque the 1/2-13 x 0.75-inch grade 5 bolts to 55-62 lb.-ft. (75-84 Nm).

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8. Use compressed air to clean all of the prepared surfaces and bolt holes.

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9. Apply WD40 or other rust inhibitor to the polished areas and wipe down with a clean dry cloth.

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10. Apply Lubriplate<sup>®</sup> 630AA to the following surfaces:

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Alternator top flange bolt holes, jack bolt hole threads, and dowel alignment holes, including the back side washer mounting surfaces.

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Torsion bar washer load surfaces.

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Flex plate-to-alternator rotor bolt hole threads and rabbet fit.

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11. Install two rotor support and coupling alignment guide pins (GPM060) in the fourth bolt holes to the left and right of the 12 o’clock position in the flex plate-to-alternator rotor.

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12. Prepare the conicals for transfer to the replacement alternator by cleaning and inspecting them.

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13. Install the conicals on the replacement alternator ensuring that the buffer stud is screwed completely counterclockwise.

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14. Prepare the air duct adapter for transfer to the replacement alternator by removing any old sealant, dirt, grime, or rust.

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15. Install the adapter using grade 5 1/2 inch-13 x 1.75-inch bolts.

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16. Torque the mounting bolts to 59 +3/-4 lb.-ft. (80 +4/-5 Nm).

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Alternator Installation: Hardware Preparation:

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1. Prepare the flex plate-to-alternator rotor bolts for installation as follows:

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a. If re-using the bolts, clean them thoroughly.

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b. Inspect the bolt threads and chase as needed.

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c. Apply Lubriplate<sup>®</sup> 630AA to the bolt threads, washer faces, and contact face of bolt heads.

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2. Apply Lubriplate<sup>®</sup> 630AA to the torsion bar threads, nut threads, and washer faces.

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3. Build two shim packs with a thickness of 0.075 inches (1.905 mm).

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4. When building the shim packs, ensure the following:

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Do not use wrinkled shims.

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Build the shim pack with the thickest shim against the engine and the thinnest shims sandwiched between thicker shims.

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For greater accuracy, measure individual shim thicknesses with a 0 - 1-inch (0 - 25-mm) micrometer, not a blade-type caliper.

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Never reuse shims removed from an in-service alternator. 