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Alternator Installation: Alternator-Engine Alignment

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1. Rotate the gauge’s outer ring to zero the gauge to the needle, then press the probe tip in and out to ensure the needle returns to zero without binding.

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2. Observe the needle movement direction as the probe is pressed and released.

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3. After mounting the probe with a pre-load and zeroing the gauge, record the face-on indicator readings to the right of zero as negative values and face-on readings to the left of zero as positive values.

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4. Drape the cloth across an oil pan to catch the indicator should it fall.

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5. Bar over the engine to set the cam-gear timing window-pointer to 110, setting the crankshaft to position A.

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6. Through the R6 crankcase inspection cover opening, mount the dial indicator in the webbing prick punch holes.

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7. With the gauge mounted, gently rock the gauge until the indicator needle no longer moves.

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8. Rotate the dial face outer ring to zero the gauge.

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9. Bar over the engine to the cam gear positions B, C, D and E stopping each time to record the gauge reading with the proper signage.

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10. Calculate the TIR.

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11. Calculate the top right (engine right/locomotive left) and the top left (engine left/locomotive right) shim pack adjustment, by using the formulas.

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12. If the formulas require that shims be added, prepare to do so by using a 0 - 1-inch outside diameter micrometer, not a blade caliper, to measure and identify individual shims that add up to the thickness calculated by the formula.

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13. Without disturbing the bottom flange torsion bar nuts, use an air impact wrench to evenly loosen the four top flange mounting bolts.

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14. Use a jack bolt at either one of the top ear flanges to slightly pry the alternator away from the engine far enough to remove the shim pack.

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15. Remove the shim packs with a spare thick shim or a piece of bent wire.

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16. Remove or add shims from or to the pack to adjust the thickness in accordance with the shim adjustment formulas.

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17. Install the adjusted shim packs.

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18. Remove the jack bolt.

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19. Using a ¾-inch air impact wrench, tighten the four alternator top flange mounting bolts evenly (the inner top flange bolts first followed by the outer top flange bolts), while alternating sides.

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20. Torque the four alternator top flange mounting bolts (the inner top flange bolts first followed by the outer top flange bolts) to 650 ± 25 lb.-ft. (881 ± 34 Nm) and repeat this torque pattern to confirm the proper torque. 

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21. Until TIR is less than 0.0005 inches (0.0127 mm), repeat the above-mentioned steps of rocking the gauge at position A (until the needle stops moving before zeroing the gauge), re-measuring web deflection, recalculating TIR, and adjusting the shim pack thickness.

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Alternator Installation: Compressing the Web

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1. Use the air impact wrench to loosen all four alternator top flange mounting bolts.

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2. Install and tighten a jack bolt on either the right or left mounting flange to slightly pry the alternator apart from the engine.

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3. Install 0.015-inch (0.381-mm) shims to both the top right and top left flanges. 

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4. Remove the jack bolt.

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5. Using a ¾-inch air impact wrench, tighten the four alternator top flange mounting bolts evenly (the inner top flange bolts first followed by the outer top flange bolts), while alternating sides.

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6. Torque the four alternator top flange mounting bolts (the inner top flange bolts first followed by the outer top flange bolts) to 650 ± 25 lb.-ft. (881 ± 34 Nm) and repeat this torque pattern to confirm the proper torque.

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7. Verify that the crank-position dial indicator gauge readings are within the ranges.

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8. If needed, equally add or remove the shims at the top right and left flanges to achieve a reading of -0.003 ± 0.0005 inches (-0.076 ± 0.0127 mm) in position C.

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9. After alignment is complete, torque the 5/8 -11 x 2-inch alternator conical plate mounting bolts and hardened washers to 166 - 185 lb.-ft. (225 - 250 Nm).