POWER TRAIN

ALTERNATOR REMOVAL
The following instructions cover the removal of the
main 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 both
lifting eyes (8, Figure 4-2) on top of alternator
(1).
2. Block up the rear of the engine.
3. Loosen cradle adjustment setscrews (3, Figure
4-1). FIGURE 4-1. CRADLE STRUCTURE
4. Loosen engine-to-cradle capscrews (5, Figure 1. Cradle Structure 4. Subframe
4-2). 2. Jam Nut 5. Gap
3. Adjustment Setscrew

FIGURE 4-2. ENGINE AND ALTERNATOR

1. Alternator 4. Flywheel Housing 7. Subframe
2. Mounting Hardware 5. Capscrews 8. Alternator Lifting Eyes
3. Cradle Structure 6. Engine

C04027 5/08 Power Train C4-3

 5. Remove the access cover at the front, right side
of engine flywheel housing (4). Reach through
the access openings and remove 12 capscrews
(6, Figure 4-3) that join engine drive ring (7) to
alternator rotor (8). Rotate the crankshaft to
align each capscrew with the access hole.
NOTE: Ensure that all 12 capscrews have been
removed.
6. Remove 16 capscrews (3) that secure flywheel
housing adapter (2) to alternator housing (1).
NOTE: The clearance between the head of capscrew
(3) and flywheel housing (4) will not permit complete
removal 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. Remove
mounting hardware (2, Figure 4-2) that secures
the alternator to the cradle structures.
8. Keep the alternator as level as possible and
move away from engine.
9. Note the location and quantity of the shims.
Keep the shims for possible reuse during
installation.
NOTE: For further disassembly instructions for the
alternator, refer to the GE Service Manual. FIGURE 4-3. ALTERNATOR TO ENGINE
MOUNTING
1. Alternator Housing 5. Capscrew
2. Flywheel Housing 6. Capscrews
Adapter 7. Engine Drive Ring
3. Capscrews 8. Alternator Rotor
4. Flywheel Housing

C4-4 Power Train 5/08 C04027

ALTERNATOR INSTALLATION
The following instructions must be followed to
ensure proper alignment and engine crankshaft
endplay. Failure to follow these instructions can
result in serious damage to the engine and/or
alternator.
• Never pry on the engine crankshaft damper.
• Loosen or remove fan belts before measuring
crankshaft endplay to ensure that the crankshaft
moves easily and completely.
• When taking measurements, always take four
equally spaced readings and average them.
• Always measure from mating surface to mating
surface.
• A reference to crankshaft rotation - clockwise
(CW) or counterclockwise (CCW) - is the
direction of rotation when looking at the front
(damper end) of engine.
• Crankshaft end play: 0.13 - 0.38 mm
(0.005 - 0.015 in.)
Measuring Procedure
1. Thoroughly clean the alternator housing
mounting surface, rotor drive adapter mounting
surface and flywheel housing adapter mounting
surfaces.
2. Mount a magnetic base on the front of the
engine and a dial indicator on the front of the
crankshaft. 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 crankshaft
to 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 Crankshaft
Endplay from step 2 to Dimension “Cavg”.
c. Record (Step 3a + Step 3b) as
Measurement “C”:___________________

SERVICE DATA - Eccentricity & Runout Limits

Description T.I.R
Maximum Eccentricity of Flywheel 0.66 mm
Housing Bore (0.026 in.)
Maximum Face Runout of Flywheel 0.25 mm
Housing (0.010 in.)
Maximum Eccentricity of Flywheel 0.18 mm
(Coupling Assembly) (0.007 in.)
Maximum Axial Runout of Flywheel 0.25 mm
Face (Coupling Assembly) (0.010 in.)

FIGURE 4-4. SHIM LOCATION

1. Alternator Housing “A” - Dimension “A”
2. Alternator Rotor “B” - Drive Shims
3. Flywheel Housing “C” - Dimension “C”
Adapter “D” - Housing Shims
4. Engine Flywheel
Housing
5. Engine Drive Ring

C04027 5/08 Power Train C4-5

 4. Refer to Figure 4-5 to determine alternator
endplay:
a. Using flat steel bar (3) bolted rigidly to
alternator rotor (2), install 5/8" - 11NC
capscrew (4) finger tight at each end into
alternator housing (1).
b. Move alternator rotor (2) axially toward the
rear (slip ring end) by alternately tightening
capscrews (4) one-half turn at a time. Do not
exceed 16 N•m (12.0 ft lbs) on each
capscrew. This establishes the maximum
permissIble rear travel for the alternator
rotor.
c. Alternately loosen capscrews (4) one turn at
a time until all torque is released. Carefully
remove steel bar (3).
Refer to Figure 4-4.
d. Carefully measure Dimension “A” at four
locations, 90° apart, and average the
measurements. Do not move the alternator
rotor.
1st measurement:___________________
2nd measurement:___________________
3rd measurement:___________________
4th measurement:___________________
Dimension “Aavg”:____________ FIGURE 4-5. ALTERNATOR END-PLAY
e. Add 0.25 mm (0.010 in.) to Dimension
“Aavg”. 1. Alternator Housing 3. Steel Bar
2. Alternator Rotor 4. Capscrew
f. Record (Step 4d + Step 4e) as
Measurement “A”:___________________
5. To determine the correct shims to use,
compare Measurement “C” (Step 3c) with
Measurement “A” (Step 4f). b. If A is greater than C, subtract: (A - C) = D
a. If C is greater than A, subtract: (C - A) = B D = ________________Shim pack thickness
B = ______________Shim pack thickness to be installed at location D, Figure 4-4.
to be installed at location B, Figure 4-4.

Alternator-to-Flywheel Housing Adapter

Rotor-to-Drive Ring Location “D”
Location “B” Shim Part Number Shim Thickness
Shim Part Number Shim Thickness 0.10 mm
TM3466
0.10 mm (0.004 in.)
TM3467
(0.004 in.) 0.18 mm
TM3468
0.18 mm (0.007 in.)
TM3469
(0.007 in.)

C4-6 Power Train 5/08 C04027

Joining the Alternator and Engine

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.
1. Use two lifting eyes (8, Figure 4-2) provided on
the alternator. The top front lifting eye should be
equipped with some method of adjusting the
alternator to keep it horizontal.
2. Carefully move the alternator into place and
engage engine drive ring (6, Figure 4-6) into
alternator rotor drive (7) using shims “B”, if
required. Refer to step 5a. in Measuring
Procedure.
3. Install flywheel housing adapter capscrews (2)
into alternator housing (1). Tighten to 237 N•m
(175 ft lbs).
4. Install capscrews (5) through engine drive ring
(6) into alternator rotor adapter (7). Rotate the
crankshaft to access and align holes. Tighten
capscrews (5) to 237 N•m (175 ft lbs). FIGURE 4-6. ALTERNATOR TO ENGINE
5. Install alternator-to-cradle mounting hardware MOUNTING
(2, Figure 4-2). Tighten to 712 N•m (525 ft lbs).
1. Alternator Housing 5. Capscrew
6. Tighten engine-to-cradle capscrews (5) to 465 2. Point Capscrew 6. Engine Drive Ring
N•m (345 ft lbs). 3. Flywheel Housing 7. Alternator Rotor
Adapter “B” - Drive Shims
4. Engine Flywheel “D” - Housing Shims
Housing

The total engine crankshaft endplay (step 7) must

Never pry on the engine crankshaft damper.
Severe engine damage can result.
7. Mount a magnetic base on the front of the
engine and a dial indicator on the front of the
crankshaft. Measure total crankshaft endplay.
Total Crankshaft Endplay:________________
8. Compare the value above to the measurement
taken before the alternator was installed on the
engine.
equal the original measurement or 0.51 mm
(0.020 in.), whichever is smaller.
If the endplay after the alternator and engine are
assembled is less than 0.51 mm (0.020 in.), and
less than the original engine crankshaft endplay,
reshimming is required.
9. Rotate the crankshaft one full revolution and
listen for any unusual noise caused by moving
components contacting stationary parts.
10. Install the engine side cover, if removed. Install
the lockwire on all alternator mounting
capscrews.
11. Install the access cover on the flywheel housing.

C04027 5/08 Power Train C4-7

ENGINE
Removal
NOTE: Refer to previous sections for removal
procedures for the power module, alternator, and
radiator assembly.
The engine weighs approximately 9,300 kg
(20,515 lbs). Ensure that the lifting device to be
used has adequate capacity.
1. Disconnect any remaining wiring or hoses
between engine (6, Figure 4-2) and subframe
(7).
2. Remove the capscrews at the front engine
mounts.
3. To ensure that the engine stays level while
lifting, attach a spreader bar with lifting straps to
the engine lifting eyes. Remove engine-to-
cradle structure mounting capscrews (5).
4. Lift the engine from the subframe and move to
clean work area for further disassembly.
C4-8
Service
Complete instructions for the disassembly, assembly
and maintenance of the engine and its components
can be found in the engine manufacturer's service
manual.
Installation
1. Align the engine with subframe (7, Figure 4-2)
and install the capscrews at the front engine
mounts.
2. Align and install capscrews (2) through the rear
engine mounts and into cradle structure (3), but
do not tighten at this time.
3. Install the alternator on the engine. Refer to
Alternator Installation in this section.
4. Adjust setscrew (3, Figure 4-1) to equalize gap
(5) between cradle structure (1) and subframe
(4) at the left side and right side. Lock the
setscrew with jam nut (2).
Power Train 5/08 C04027