809875A 1 Mercury MANIFOLD KIT

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) - 1/2 Inch Drive T50 Torx Bit 1
- 1/2 Inch Drive x 8 mm Hex Drive 1
(1) Either tool may be necessary in order to install the alternator pulley.
If necessary, follow Step 1.a through Step 1.j in order to install the alternator bracket to the cylinder block of the hydraulic excavator.
Ensure that all of the components of the alternator bracket are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 1 g02422757
Position bracket (23) onto the cylinder block. Ensure that the bracket is correctly oriented.
Install bolts (22) and tighten the bolts to a torque of 44 N m (32 lb ft).
Illustration 2 g02422756
Illustration 3 g02425358
Position bracket (18) onto the cylinder block. Install bolts (19) to the bracket and hand tighten the bolts. Note: Support the bracket as the bolts are installed.
Ensure that the spacers (17) are correctly installed to bracket (18).
Install bolts (16) to bracket (18). Hand tighten the bolts.
Tighten bolts (19) to a torque of 44 N m (32 lb ft). Note: Ensure that Position (X) on bracket (18) does not move in either direction as the bolts are tightened.
Tighten bolts (16) to a torque of 44 N m (32 lb ft).
If necessary, install belt tensioner (20) from alternator (18). Refer to Disassembly and Assembly, "Belt Tensioner - Remove and Install" for the correct procedure.
If necessary, remove idler pulley (21) from alternator (18). Refer to Disassembly and Assembly, "Idler Pulley (Grooved) - Remove and Install" for the correct procedure. Installation Procedure
Illustration 4 g02422740
Illustration 5 g02422739
If necessary, follow Step 1.a through Step 1.f in order to install alternator bracket (12) onto the cylinder block.
Ensure that bracket (12) is clean and free from wear and damage. If necessary, replace the bracket.
Ensure that dowels (15) are free from wear and damage. If necessary, replace the dowels.
Position bracket (12) onto the cylinder block. Ensure that the dowels (15) are correctly located into the cylinder block.
Install bolts (13) hand tight.
Tighten bolts (13) to a torque of 44 N m (32 lb ft).
If necessary, install the belt tensioner (14) onto alternator bracket (12). Refer to Disassembly and Assembly, "Belt Tensioner - Install" for the correct procedure.
Illustration 6 g02422738
HEDC Heavy Duty Alternator
If necessary, follow Step 2.a through Step 2.d in order to install pulley (8) to alternator (2). Note: Either of Tooling (A) may be required in order to carry out the installation of the alternator pulley.
Install fan (11) from alternator (2). Ensure that the fan is correct oriented. Note: Note on some alternator the fan is an internal part of the alternator.
Ensure that the pulley (8) is correctly oriented.
Install pulley (8) and nut (9) to alternator (2).
Position a cranked ring spanner onto nut (9) and use a suitable tool in order to prevent the cranked ring spanner from turning. Use Tooling (A) in order to turn the shaft of the alternator in a counterclockwise direction. Tighten the nut to the correct torque. Refer to Specifications, "Alternator" for the correct torque.
Illustration 7 g02422737
HEDC Heavy Duty Alternator
Illustration 8 g02426956
HEDC Heavy Duty Alternator
Position alternator (2) onto the alternator mounting bracket. Install bolts (1). Tighten the bolts hand tight.
Tighten the bolts in Position (X) to a torque of 50 N m (37 lb ft).
Tighten the bolts in Position (Y) to a torque of 50 N m (37 lb ft).
Connect wiring harness assembly (4) to alternator (2). Install nut (5) and nut (6). Tighten the nuts to the correct torque. Refer to Specifications, "Alternator" for the correct torque.
Connect grounding strap (3) to alternator (2). Install bolt (7). Tighten the bolt to the correct torque. Refer to Specifications, "Alternator" for the correct torque.
Install the alternator belt. Refer to Disassembly and Assembly , "Alternator Belt - Remove and Install" for the correct procedure.
Turn the battery disconnect switch to the ON position.