﻿GET_GEVOMechL2_09_01_01_72 - ANIMATION Screen
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Alternator Installation: Engine Alternator Coupling:

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1. Install the engine barring over motor and open the compression release valves.

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2. If not already removed, remove the alternator guards from both sides of the engine to make the engine-alternator coupling accessible.

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3. Prepare the alternator conical mount base plate as follows:

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a. Clean the conical mount base plate with a 120 grit flap wheel.

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b. Apply Lubriplate<sup>®</sup> 630AA to the base plate surface.

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c. Apply Molykote<sup>®</sup> 77 paste to the base plate bolt hole threads and to the bolt threads.

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4. 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.

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5. With the rotor support loosely installed or, more preferably, rotor support and alignment guide pins installed in two of the coupling bolt holes and the conical mount buffer studs fully unscrewed, attach the rigging to the alternator and adjust for a level lift.

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6. Lift and move the alternator toward the engine, adjusting the lift as needed, to align the engine top pad alignment dowel pins with the corresponding alternator top pad holes and, pause the lift as needed, to bar the engine to align the rotor yoke alignment pins with the engine flex plate bolt holes.

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7. When coupling guide pins are being used:

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a. With the pins aligned to the flex plate holes, continue advancing the alternator toward the engine to align the engine dowels with the corresponding alternator top flange holes.

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b. Once the pins and dowels are aligned to their holes, apply the four top flange bolts to the top flanges and then, using a ¾-inch air impact gun, tighten the four top flange bolts evenly, while alternating sides, so as to draw the pins and dowels completely through their holes until no gap exists between the rotor and the flex plate.

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8. If guide pins are not being used:

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a. When the engine dowels are aligned with the top pad holes, move the alternator close enough to apply the four top flange bolts and then, using a ¾-inch air impact gun, tighten the four top flange bolts evenly, while alternating sides, until the tips of the engine mounting pad alignment dowels have entered and are within 1/8th inch of the outside edge of the alternator top flange holes.

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b. Bar the engine as needed until three adjacent coupling bolts can be loosely started by hand through the vent screen openings on opposite sides of the alternator.

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9. Install the previously assembled 0.075-inch (1.905-mm) shim packs in the top left and right mounting flanges.

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10. Using a ¾-inch air impact wrench, continue to tighten the four alternator top flange mounting bolts (the inner top flange bolts first followed by the outer top flange bolts), while alternating sides, to draw the alternator tight against the engine.

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11. Tighten the previously installed coupling bolts with a 90° air ratchet.

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12. Torque the four alternator top flange mounting bolts (the inner top flange bolts first followed by the outer top flange bolts) to 650 ± 25 lb.-ft. (881 ± 34 Nm) and repeat this torque pattern to confirm the proper torque.

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13. After adjusting the conical mount central buffer lock nuts to lower the plates enough to install the 5/8-inch conical mount base plate bolts to the platform mounting pads, loosely apply the base plate bolts with a 15/16-inch wrench.

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14. Apply Molykote<sup>®</sup> 77 paste to the torsion bar base hole and the bolt threads.

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15. Install the torsion bars through the alternator bottom flange hole leaving the nuts loosely applied.

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16. With the conical mount central buffer nuts fully backed off and ample thread showing on the loosely applied conical mount base plate bolts, slightly lift the rear of the engine from the centerline lifting eye just high enough to remove the support blocks.

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17. With the support blocks removed, lower the engine-alternator assembly to fully rest on the conical mounts.

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18. After a minimum of 90 minutes, inspect the conical mounts to ensure full engagement with the alternator flange.

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19. If 90 minutes have passed since setting the alternator, before proceeding with alignment, adjust the conical mount clearances with the 4-mm GEVO Conical Mount Stud Clearance Check Set Gauge (TESCO T85500).

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20. After adjusting the conical mount clearance, torque the conical stud locknut to 185 lb.-ft. (251 Nm).

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21.	Using a torque wrench and a 2-1/16-inch socket, torque the torsion bar base bolts to the platform to 100 lb.-ft. (136 Nm).

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22. Using a 2-1/16-inch socket and either a HYTORC Stealth 2 or other hydraulic head with pressure set for 1,600 lb.-ft. (2,169 Nm), torque the torsion bar nuts.

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23. Using a 2-1/16-inch socket and either a HYTORC Stealth 2 or other hydraulic head with pressure set for 1,500 lb.-ft. (2,034 Nm), tighten the 1-3/8-inch torsion bar base bolts.

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24. If previously removed, re-apply wedges to the torsion bar base block and tack weld in place.

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25. Replace the two rotor support and alignment guide pins with flex plate-to-alternator rotor bolts.

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26.	Install the remaining 22 flex plate-to-alternator rotor bolts in a 10-point pattern and tighten the bolts with an air ratchet.

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27. Torque all 30 flex plate-to-alternator rotor bolts in a 10-point pattern to 367 ± 37 lb.-ft. (498 ± 50 Nm).

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28. Unbolt the rotor support, allowing it to drop to the platform beneath the alternator, then remove the rotor support from beneath the alternator.

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29.	Install the alternator guards to both sides of the engine.

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30. Re-connect the electrical connections, including the main and auxiliary output and input wiring.

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31. Torque the aux stator cable terminals to 23 +2/-1 lb.-ft. (31 +3/-1 Nm) and torque all other hardware to the correct torque value.

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32. Reinstall the blower cab.

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33. Reinstall the hidden bolt removed earlier and torque to appropriate torque values.

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34. Reinstall the corner duct to the B-side of the locomotive.

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35. Reinstall all applicable bolts and cooling air connections to the blower cab.