﻿GET_GEVOMechL2_09_01_01_70 - ANIMATION Screen
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Alternator Removal:

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1. Disconnect the alternator wiring, including the main and auxiliary output and input wiring.

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2. Prepare the blower cab for removal.

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3. Remove the corner air duct from the B-side of the locomotive and save all hardware.

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4. Remove the hidden bolt located near the short hood end of the blower cab and remove the cab.

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5. While leaving the conical mount buffer stud and lock nuts tight, use a 15/16-inch wrench to remove the four alternator conical mount base plate bolts at the four corners of each conical mount, and save all hardware for reuse.

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6. Using a 2-1/16-inch socket and either a HYTORC Stealth 2 or other hydraulic head rated for higher than 1,600 lb.-ft. (2,169 Nm), loosen the alternator bottom flange nuts and remove the 1-3/8-inch torsion bar base bolts, and save all hardware for reuse.

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7. If the torsion bar base cannot be freed of wedge engagement by prying inboard, cut off the tack welds holding the torsion bar base fixed, mark each wedge with its location, remove the torsion bar from its base, and save all hardware for reuse.

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8. With the conical base plate bolts removed and the torsion bar disengaged from its wedged base, from the rear engine centerline lifting eye, lift the engine rear and alternator just enough to install the 4- to 6-inch blocks.

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9. After installing the blocks, lower the engine-alternator onto the blocks, remove the alternator bottom flange nuts and completely remove or slide the torsion bars back far enough that they no longer engage the alternator bottom flanges.

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10. Remove the alternator guards, also referred to as the alternator ventilation grates, from both sides of the engine to provide access to the engine-alternator coupling.

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11. Install the barring-over device and open the compression release valves.

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12. Bar over the engine as needed to access and remove the 30 bolts coupling the engine to the alternator rotor using either a 20-inch (508-mm) long or longer ¾-inch (19.05-mm) drive breaker bar and a 1-1/8-inch socket or a 24-inch (610-mm) long or longer 1-1/8-inch heavy-duty tubular box end wrench to initially loosen the bolts and a 90° air ratchet for rapid removal.

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13. To a properly rated crane, attach an adjustable three-leg rigging system or, more preferably, a turnbuckle-equipped rigging system that allows for a level lift of the alternator, then attach the rigging to the alternator and adjust the hooks or turnbuckle for a level lift.

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14. With crane tension applied to lift the rigging, remove the four alternator top flange mounting bolts using a ¾-inch air impact wrench and a 2-1/16-inch socket.

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15. Install 1-3/8-inch -12 jack bolts into both top flange threaded holes and tighten the jack bolts evenly to pry the alternator away from the engine and off the engine-to-alternator top flange alignment dowel pins.

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16. After jacking enough to clear the engine-to-alternator top flange alignment dowel pins, lift the alternator away from the engine.

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17. For later use in the same location, keep the hardware with the platform mounting pads from which they were removed.

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18. If the removed alternator will be processed for off-site repair, transfer the wooden rotor brace and cardboard spacers, the rotor-stator gap cardboard shims, and the EVO12 rotor support 84C602271ABP2 from the replacement alternator to the alternator being returned.

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Alternator Installation: Preparing the Engine:

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1. Ensure the engine is mounted on the platform with its rear end supported on blocks.

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2. Using an aluminum oxide flap wheel of not greater than 120 grit, polish and clean the engine coupling and mounting surfaces. 

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3. After polishing, with an ungloved hand, feel the four mounting pads and crankshaft flange face for nicks, raised metal, and burrs and remove any high spots with a file or light grinder. 

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4. Use compressed air to blow surfaces and bolt holes free of debris.

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5. Apply WD40 or equivalent rust inhibitor to polished areas and wipe down with a clean dry cloth, then apply Lubriplate<sup>®</sup> 630AA. 

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6. Using a paint marker, mark the flex plate-to-alternator rotor bolt torque pattern on the outside diameter of the flex plate flange.

