5036630 JOHNSON GASKET, CYL HEAD PORT

Introduction
Do not perform any procedure that is outlined in this Special Instruction until the entire instruction has been read and understood.This Special Instruction provides the procedure for installing a new alternator group on certain 793D Off-Highway Truck Engines.Special Instruction, REHS6106, "Procedure to Upgrade the Electrical Wiring Group on Certain 793D Off-Highway Trucks" and Special Instruction, REHS7483, "Installation of the 364-9117 Engine Wiring Gp on 793D Off-Highway Truck Engines" must be completed on S/N:FDB00001-01605 before updating the alternator group.Note: This alternator upgrade is compatible with any vintage of the 364-9117 Engine Wiring Gp . The latest vintage which contains the 457-9172 Engine Harness As is not required.Required Parts
Table 1
392-3623 Belt Guard Gp    
Part    Qty    
1A-2029 Bolt     5    
198-4766 Hard Washer     5    
434-0773 Guard As     1    
Table 2
417-6940 Charging Alternator Gp    
Part    Qty    
1A-5183 Bolt     2    
5M-2894 Hard Washer     4    
8F-8544 Bolt     2    
374-8497 Belt     1    
378-0997 Bracket     1    
436-6511 Pulley     1    
437-0125 Charging Alternator Gp     1    
Table 3
439-2152 Alternator Mounting Gp    
Part    Qty    
0S-1587 Bolt     4    
0T-0573 Bolt     1    
5M-2894 Hard Washer     1    
5P-8245 Hard Washer     4    
391-3864 Support As     1    
436-6512 Belt Tensioner     1    
Table 4
Alternator Wiring    
Part    Qty    
0L-1351 Bolt     1    
0S-0509 Bolt     1    
0S-1588 Bolt     2    
0S-1594 Bolt     3    
4P-7581 Clip     1    
4P-8097 Bracket     2    
5M-2894 Hard Washer     8    
5P-4116 Hard Washer     1    
6V-0826 Grommet     13    
7K-1181 Cable Strap     3    
7V-6571 Grommet     3    
8F-8544 Bolt     2    
8T-1889 Clip     10    
8T-1890 Clip     10    
8T-4121 Hard Washer     15    
8T-4136 Bolt     4    
8T-4137 Bolt     1    
8T-4191 Bolt     1    
8T-4195 Bolt     1    
8T-8911 Bolt     1    
9L-1566 Support     1    
9S-8752 Full Nut     2    
091-0081 Spacer     1    
091-9035 Spacer     1    
109-3001 Taperlock Stud     3    
110-8769 Wire As     1    
133-6934 Spacer     1    
136-4877 Wire Splice     1    
223-3490 Clip     6    
259-7140 Taperlock Stud     4    
298-6591 Bracket As     1    
344-5675 Nut     5    
351-2579 Bracket As     1    
359-1828 Bracket As     1    
461-5754 Cable As     1    
462-6449 Cable As     1    Removal
Refer to Disassembly and Assembly, SENR1126, "Alternator - Remove and Install" for more information.
Illustration 1 g03664578
Illustration 2 g03664580
Remove the belt guards.
Remove the belt.
Remove the alternator.
Remove the existing positive cable and all associated hardware.Note: Some of the existing hardware may be reused.
Remove the existing negative cable and all associated hardware.Note: Some of the existing hardware may be reused.
Illustration 3 g03664581
Remove the alternator mounting group.Installation of the Alternator Pulley