SHORANDAM INDUSTRIAL PARK OJT TASK SHEET

Task Description: Alternator replacement JHA Hazards Injuries to eye, hand Burns Accidental engine start Control measure Wear safety glasses, glove Allow engine to cool/use gloves Battery cable removed, E stop pusshed

PPE: Gloves, Safety Glasses, Safety shoe List of equipment required      Wrench 17, 19 mm Torque wrench Belt tensioner Repair manual pages 13-2 to 13-8 New alternator

Detail task description: 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 Push E stop button Disconnect battery cable Remove the belt guard Disconnect the wiring and ground strap from the alternator, write down connection points Loosen the adjusting link jam nut and the upper/lower alternator mounting bolts Loosen the adjusting nut to remove tension on the alternative belt Remove the alternator belt Remove the bolt that fastens the adjusting link to the alternator bracket Remove the lower alternator mounting bolt and nut Remove the alternator and adjusting link Remove the nut and the pulley from the alternator Clean and check the pulley for reuse, if any damage then replace the pulley Lubricate the shaft of the new alternator with clean 15W-40 engine oil Install the pulley and nut on the alternator shaft Torque the alternator shaft nut to 100Nm (75 ft-lb) Install the alternator and the adjusting link Lightly tighten the alternator mounting bolts and adjusting link bolt until the belt is adjusted Install the alternator belt, replace if required Turn the adjusting nut clockwise to tighten the belt Tighten the belt until the belt tensioner indicates 670 N (150 lbf) Page 1

Alternator replacement

23 1.24 1.27 Remove the bolt that fastens the adjusting link to the alternator bracket.SHORANDAM INDUSTRIAL PARK OJT TASK SHEET Torque the jam nut on the adjusting bolt to 196Nm (125 ft-lb) Torque the alternator adjusting link mounting bolt to 75 Nm (55ft-lb) Torque the alternator top mounting bolt to 75 Nm (55ft-lb) Torque the alternator bottom mounting bolt to 120 Nm (89ft-lb) Connect the wiring to the alternator as per note from step 1. 1. Alternator Drawing  adjusting nut to remove tension on the alternative belt Disconnect the wiring and ground strap from Then remove the alternator belt the alternator 1.21 1.22 1.4 Connect the battery cable Release the E-Stop Loosen the  adjusting link jam nut Attachments  alternator mounting bolts.26 1.25 1. the lower alternator mounting bolt and then remove the alternator and adjusting link Remove the nut and the pulley from the alternator Alternator replacement Page 2 .

Technicians Name: _______________________________________ Employee # _____________ Instructors Name: ________________________________________ Instructors Signature: _____________________________________ Date:__________________ Alternator replacement Page 3 . This OJT task sheet will then be filed in the Technicians training folder.SHORANDAM INDUSTRIAL PARK OJT TASK SHEET Connect the wiring to the alternator Once the Power Station Technician has followed this OJT task and exhibits a complete understanding of how to perform this task the instructor will sign on the signature line below and mark this task being completed on the technicians OFT tracking sheet.

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