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Elements and Performance Criteria

1. Prepare to dismantle alternator
   • Job requirements are determined from workplace instructions
   • Dismantling information is sourced and interpreted
   • Dismantling options are analysed and those most appropriate to the circumstances are selected
   • Hazards associated with the work are identified and risks are managed
   • Dismantling tools and equipment are selected and checked for serviceability
2. Dismantle and evaluate alternator and components
   • Alternator is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements, and without causing unnecessary damage to alternator
   • Alternator components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
   • Components are measured and compared with manufacturer specifications and serviceability is determined
   • Component repair method is determined
   • Unserviceable parts are identified and replacement parts sourced
3. Carry out overhaul
   • Overhaul information is sourced and interpreted
   • Overhaul options are analysed and those most appropriate to the circumstances are selected
   • Overhaul tools and equipment are selected and checked for serviceability
   • Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems
4. Assemble alternator and components
   • Alternator is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
   • Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
   • Assembly of alternator is completed within workplace timeframes and without causing damage to other components or systems
   • Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
5. Complete work processes
   • Final inspection is made to ensure work is to workplace expectations and alternator is presented ready for use or storage
   • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
   • Tools and equipment are checked and stored, and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
   • Workplace documentation is processed according to workplace procedures
6. Prepare to dismantle alternator
   • Job requirements are determined from workplace instructions
   • Dismantling information is sourced and interpreted
   • Dismantling options are analysed and those most appropriate to the circumstances are selected
   • Hazards associated with the work are identified and risks are managed
   • Dismantling tools and equipment are selected and checked for serviceability
7. Dismantle and evaluate alternator and components
   • Alternator is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements, and without causing unnecessary damage to alternator
   • Alternator components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
   • Components are measured and compared with manufacturer specifications and serviceability is determined
   • Component repair method is determined
   • Unserviceable parts are identified and replacement parts sourced
8. Carry out overhaul
   • Overhaul information is sourced and interpreted
   • Overhaul options are analysed and those most appropriate to the circumstances are selected
   • Overhaul tools and equipment are selected and checked for serviceability
   • Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems
9. Assemble alternator and components
   • Alternator is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
   • Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
   • Assembly of alternator is completed within workplace timeframes and without causing damage to other components or systems
   • Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
10. Complete work processes
    • Final inspection is made to ensure work is to workplace expectations and alternator is presented ready for use or storage
    • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
    • Tools and equipment are checked and stored, and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
    • Workplace documentation is processed according to workplace procedures

Range Statement

This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.

Safety and environmental requirements must include:

work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for: using specialised tools and equipment using appropriate personal protective equipment (PPE) identifying hazards and controlling risks associated with wearing jewellery while working around high current wiring systems environmental requirements, including procedures: found in safety data sheets (SDS) relating to toxic and corrosive substances for disposing of replaced alternator components.

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Performance Evidence

Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:

overhaul charging system alternators of two different vehicles, vessels or machinery, which include an alternator with a:

star connected stator

delta connected stator.

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Knowledge Evidence

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to overhauling charging system alternators, including procedures for:

using specialised tools and equipment

using appropriate personal protective equipment (PPE)

identifying hazards and controlling risks associated with wearing jewellery while working around high current wiring systems

environmental requirements, including procedures:

found in safety data sheets (SDS) relating to toxic and corrosive substances

for disposing of replaced alternator components

types, characteristics and operating principles of charging system alternators, including alternators with both star and delta connected stators

charging system alternator overhaul procedures, including:

methods for cleaning and preparing charging system alternators for overhaul

charging system alternator dismantling procedures

charging system alternator repair and adjustment procedures, including:

brushes to slip ring alignment

bearings shimmed and seated in alternator housing

rotors rebalanced

rectifier installation to alternator housing

component assembly procedures, including procedures for measuring and calculating tolerances, and adjusting components

post-overhaul bench testing procedures, including:

use of load simulator load tester for complete system analysis

analysis of system operation while using gauges, current clamps, electrical test equipment, scan tools, oscilloscopes and other industry-relevant test equipment

post-overhaul testing procedures of alternator in vehicle, vessel or machinery, including:

accessing and interpreting diagnostic trouble codes (DTCs)

DTC clearing procedures

checking for electrical connector mating

checking for correct charging voltage at battery.

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