SECTION 2 BODY

Group 2 Engine/Alternator

Removal and Installation of Alternator

(Cummins Engine)
Removal
1. Park the machine on a level surface with the service
position.
2. Raise the dump body. Insert the body prop pins to
prevent the dump body from lowering.
3. Remove the obstructive parts for removing
alternator such as high-voltage cable, blower duct
and alternator cooling blower.

T8DS-04-04-005

4. Remove bolts, washers (3) (4 used). Remove bracket 54 1 2 3 c

(2) of drive shaft (1) from bracket (c).

j : 17 mm
5. Remove bolts, washers (46) (5 used) and bolts,
washers (47) (6 used). Remove covers (48, 54) of
drive shaft (1). a

j : 17 mm, 19 mm
6. Remove bolts (5) (8 used) and washers (43) (8 used).
5, 43 48 47 5, 43 46 b
Remove drive shaft (1) from pump device (b) and
alternator (a). WQEB-02-03-001
a- Alternator c- Bracket
j : 19 mm b- Pump Device

WQEB-EN-01(20151120) W2-2-2-13
 SECTION 2 BODY
Group 2 Engine/Alternator

7. Remove bolts (6) (3 used). Remove cover (7) at the

rear right of engine.

j : 5/8 in 6
8. Remove clip (8). Push shaft (9).
7

WQEB-02-02-044

8 9

Detail a WQEB-02-02-045

9. Turn the flywheel by turning shaft (9). Remove 10

socket bolts (11) (12 used) from rotor flange (10) of
the alternator.
Shaft (9)

j : 14 mm
Socket bolt (11)

l : 14 mm

11

WQEB-02-02-047

WQEB-EN-01(20151120) W2-2-2-14
 SECTION 2 BODY
Group 2 Engine/Alternator

10. Turn rotor flange (13) so that the position of rotor A 16

position adjusting plates (15) (4 used) and rotor
16
position adjusting bolts (4, 16) (2 used for each)
should be set correctly. 15

13

4 4
WQEB-02-02-074

4, 16 4, 16

dCAUTION: If removing the alternator from the

engine without performing following work, the
17
18 17

rotor of the alternator may fall and cause serious

injury. 19
11. Loosen rotor position adjusting bolts (4, 16) (2
used for each) and lock nuts (17) (4 used). Remove
spacers (18) (4 used). Secure rotor flange (13) with
rotor position adjusting bolts (4, 16) (2 used for
each) and lock nuts (17) (4 used).
Confirm that all ends (4 places) of rotor position
adjusting bolts (4, 16) (2 used for each) come in
contact with rotor position adjusting plates (15) (4
15 13
used) completely.
Section A
WQFB-02-02-061

WQEB-EN-01(20151120) W2-2-2-15
 SECTION 2 BODY
Group 2 Engine/Alternator

20 21
dCAUTION:
lb)
Alternator (20) weight: 3300 kg (7280
22
12 Install shackles to lifting brackets (21) (2 used) of
alternator (20). Hoist and hold alternator (20).
13. Remove bolts (23) (8 used) and washers (24) (8
used) from brackets (22) (2 used) for mounting the
engine and the alternator.

j : 36 mm

23, 24
WQEB-02-02-046

14. Remove bolts (25) (16 used) and washers (26) (16 25, 26
used) from alternator (20).
Hoist and remove alternator (20).

j : 24 mm

20
WQEB-02-02-047

15. Remove bolts, washers (29) (16 used), flange (19), 30 19 29

and shim packs (30) (4 used) from engine (27).

j : 19 mm

27
WQEB-02-02-053

WQEB-EN-01(20151120) W2-2-2-16
 SECTION 2 BODY
Group 2 Engine/Alternator

16. Install flange (19) to alternator (20) with bolts (25) 19 25, 26
(16 used) and washers (26) (16 used).

j : 24 mm

m : 270 N·m (27 kgf·m, 200 lbf·ft)

17. Install transport brackets (33) (2 used) to flange (19)
of alternator (20) and rotor flange (13) with bolts
(34) (4 used), bolts (35) (2 used) and bolts (37) (2
used).

j : 19 mm

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

Bolt (35)
20
j : 24 mm WQEB-02-02-052

m : 100 to 120 N·m (10 to 12 kgf·m, 74 to 89

lbf·ft)
34 35 34 37
f NOTE: Store alternator (20) with transport brackets (33) 33
(2 used) attached.
13
19

WQEB-02-02-008

WQEB-EN-01(20151120) W2-2-2-17
 SECTION 2 BODY
Group 2 Engine/Alternator

Shim Adjustment Procedure

1. Install the measurement tool (ST 6717) to flange A
(38) at the engine side.
2. Measure following two dimensions (a, b) at four ST 6717
holes (A, B, C, D) of the measurement tool (ST 6717).
D
a. Dimension between the end of flywheel (39) and B
outer end of the measurement tool (ST 6717)
(including thickness of the measurement tool)

Measurement Result (mm)

point 1st 2nd 3rd Average
a’
A C
B WQEB-02-02-034
C
D
Average a’’ 38

b. Dimension between outer end of the measurement

tool (ST 6717) and extension of end of flange (38) at
engine side
39

ST 6717
Measurement point Result (mm)
A
B
C
b
D
Average b’ a

c
3. Sum values (a’’) and (b’). Calculate distance (c)
between end of flywheel (39) and extension of end WQEB-02-02-035
of flange (38).
a’’ + b’ = c

WQEB-EN-01(20151120) W2-2-2-18
 SECTION 2 BODY
Group 2 Engine/Alternator

4. Measure following dimension (d) at four points (A, A

B, C, D) at the alternator side.
19
d. Dimension between outer end of rotor flange (13)
and outer end of flange (19) at stator side
13

Measurement point Result (mm)

D
A
B B
C
D
Average d’

5. Subtract values (c) from (d’). Calculate thickness (e)

of shim packs (30) (4 used).
d’ – c = e
6. Create shim packs (30) (4 used) of the required c
thickness by using shims. The tolerance of the shim
WQEB-02-02-009
pack (30) thickness (against calculated thickness (e))
E
must be within 0.00 to +0.05 mm.

fNOTE: There are 3 types of shims available – thickness

of 0.5 mm (20 used), 0.3 mm (8 used), 0.1 mm (8 used). 19
Wipe the surface of each shim to remove dirt and
oil. Use a micrometer to measure the thickness.
Check that the total measurement value is within
the tolerance value described above. d

Lay the shims. Measure the shim pack (30) thickness

to check that it is within the tolerance value
described above.

13

Section E WQEB-02-02-037

WQEB-EN-01(20151120) W2-2-2-19
 SECTION 2 BODY
Group 2 Engine/Alternator

Installation 17
4, 16

IMPORTANT: Create shim packs (30) (4 used) before

installing the alternator. Refer to the heading
"Shim adjustment procedure" (W2-2-2-18) for
detail.
1. Confirm that the rotor is secured with rotor position
adjusting bolts (4, 16) (2 used for each) and lock 15
nuts (17) (4 used). 13
W8R7-02-02-025
Confirm that the all ends (4 places) of rotor position
adjusting bolts (4, 16) (2 used for each) come in
34 35 34
contact with rotor position adjusting plates (15) of 33 37
rotor flange (13) completely. 16 16
2. Remove bolts (34) (4 used), bolts (35) (2 used), bolts
(37) (2 used), and transport brackets (33) (2 used) 15
from flange (19) of alternator (20) and rotor flange 19
(13).
13
j : 19 mm
3. Remove bolts (25) (16 used), washers (26) (16 used),
and flange (19) from alternator (20).

j : 24 mm

4 4
WQEB-02-02-009

19 25, 26

20
WQEB-02-02-052

WQEB-EN-01(20151120) W2-2-2-20
 SECTION 2 BODY
Group 2 Engine/Alternator

4. Install flange (19) and shim packs (30) (4 used) to 30 19 29

engine (27) with bolts, washers (29) (16 used).

j : 19 mm

m : 87 N·m (8.7 kgf·m, 64 lbf·ft)

27
WQEB-02-02-053

21 20
d CAUTION: Alternator (20) weight: 3300 kg (7280
lb)
5. Install shackles to lifting brackets (21) (2 used) of
alternator (20). Hoist and hold alternator (20).

WQEB-02-02-046

20
19

6. Install alternator (20) to flange (19) with bolts (25)

(16 used) and washers (26) (16 used).

j : 24 mm

m : 270 N·m (27 kgf·m, 199 lbf·ft)

25, 26
WQEB-02-02-047

WQEB-EN-01(20151120) W2-2-2-21
 SECTION 2 BODY
Group 2 Engine/Alternator

7. Loosen rotor position adjusting bolts (4, 16) (2 used 4, 16 4, 16

for each) and lock nuts (17) (4 used) so that spacers
(18) (4 used) can be installed. After inserting spacers 18 17
17
(18) (4 used), secure rotor position adjusting bolts 20
(4, 16) (2 used for each) with lock nuts (17) (4 used).
Confirm that all ends (4 places) of rotor position
adjusting bolts (4, 16) (2 used for each) are
separated from rotor position adjusting plates (15)
through the observation window of alternator (20).

15

8. Turn the flywheel by turning shaft (9). Install socket WQFB-02-02-061

bolts (11) (12 used) to rotor flange (10).
Shaft (9)

j : 14 mm
Socket bolt (11)

l : 14 mm

m : 270 N·m (27 kgf·m, 200 lbf·ft)

WQEB-02-02-044

10

11

WQEB-02-02-047

WQEB-EN-01(20151120) W2-2-2-22
 SECTION 2 BODY
Group 2 Engine/Alternator

9. Install alternator (20) to alternator mounting

brackets (22) at the right and left sides with bolts 22
(23) (8 used) and washers (24) (8 used).
20
j : 36 mm

m : 950 N·m (95 kgf·m, 700 lbf·ft)

23, 24
WQEB-02-02-046

10. Install cover (7) at the rear right of engine with bolts
(6) (3 used).

j : 5/8 in 6

m : 60 N·m (6 kgf·m, 44 lbf·ft)

7
11. Pull out shaft (9). Install clip (8).

WQEB-02-02-044

8 9

Detail a WQEB-02-02-045

WQEB-EN-01(20151120) W2-2-2-23
 SECTION 2 BODY
Group 2 Engine/Alternator

12. Install drive shaft (1) to pump device (b) and

alternator (a) with bolts (5) (8 used) and washers
(43) (8 used).

j : 19 mm

m : 110 N∙m (11 kgf∙m, 81 lbf∙ft)

13. Install covers (48, 54) of drive shaft (1) with bolts, 54 1 2 3 c
washers (46) (5 used) and bolts, washers (47) (6
used).
Bolt, Washer (46)

j : 19 mm
a
m : 90 N∙m (9 kgf∙m, 66 lbf∙ft)
Bolt, Washer (47)

j : 17 mm 5, 43 48 47 5, 43 46 b

WQEB-02-03-001
m : 50 N∙m (5 kgf∙m, 37 lbf∙ft)
a- Alternator c- Bracket
14. Install bracket (2) of drive shaft (1) to bracket (c) b- Pump Device
with bolts, washers (3) (4 used).

j : 17 mm

m : 50 N∙m (5 kgf∙m, 37 lbf∙ft)

15. Install the parts such as high-voltage cable, blower
duct, and alternator cooling blower that are
removed when removing the alternator.
16. Remove the body prop pins and lower the dump
body to travel position.

WQEB-EN-01(20151120) W2-2-2-24