r--------------, I I

GENERACI owners manual

~-------------~ PULLEY DRIVEN

PORTABLE ALTERNATOR MODEL NO's 6509-0, 6511-1 and 6653-0

OPERATING INSTRUCTIONS REPAIR PARTS ACCESSORIES

CAUTION: REAO INSTRUCTIONS AND RULES FOR SAFE OPERATION CAREFUllY TO PREVENT ACCIDENTS.

Printed in U.S.A.

GENERAC P.O. Box 8, Waukesha, Wisconsin 53186

Part No. 42477 SB-66530·103 SB-65090·103 S8·65111·103

ONE YEAR LIMITED WARRANTY

the original Purchaser dale 01 original pure

IS covered solei V bV It ilS, demonstralorS, or llntalunits,demonstn not undor warranty t

----!tBLE

II be free from defect lowever does not mell ,ulaclurer olsuch eng lnssucha$construct,( pplicalions such as cor In. Anv warranty whl

manship for a period e,when lurnishedor

I Lee\ro Van are war­xcluding Lee\fo Van >!ied restswlelv with

period. Generae will or replace any part \ltion bV Generac. is , under normal use ar Ihieh the consumer el Tlust be examIned bV

"'~,,~.''',. ,,~<,,~., .... ,horized warranty serv.~ .""n •• , ~ __ "" ..... n ~nerae·s IIstmg 01 " ..... ~ ..• wu "_, "w" • __ llities, All Tran'porta­tion costS under this warranty, ,neluding return to the factory, >f neee""rv, are to be borne by the pureh",er (and prepaId bV him). This warrantY does not include normal maintenance and ",Nice <lna aues not apply to'" alternator. Or eng'ne. or any of the parts thereof, which have ueen subject to improper or unauthortzea Installation. misuse. negligence, accident, overloading, OV9rspeed"'g or improper maintenance, repair or storage so as, in Gencr8c'S Judgme,n, to alfflCt adverselv its performance anti reliabiliw.

Thera is no other express warranty. Generac Iwreby disclaims any a"d all implied w<lrranties, ~nc'uding but not limited to. those of merchantability a"d I<tness for a particular purpose, to tho el<tent permitted hV law. The duration of II"V Implied warranties which cannot be disl'laimed is lim'ted to the time period (ane-year) as specl/ied in tM express warranty_ Liability for consa quantial, incidental or special damages undl!r any and all Wilrranti,. os oKcluded to the extent permitted by law, Some state. do not allow limitations on how long an implied WlJrranty lasts.. or the exclusion or "mitation of incidantal or con~uential damages. 5<1

';; ;::'r~~~C::;a:ynot.. 'anty gives you specifi may al5<l have other

tiva for all products m four nearest Generac I. Warranty service cal ervice,evidencaof ori,

amber 31, 1976 and $1

service facility as sho by a Genorac authoriz, lSt be presented,

GENERAC CORI

RULES FOR SAFE OPERATION

rrantiesof Generac.

9 of authorized War_ dlity. At the tilM af

lYaukesha. WI. 53186

A Never handle electrical equipment while standing in water, while barefoot, or while hands or feet are wet. Dangerous electrical shock can result.

A Exposed pulleys and V-belts are dangerous. Provide safety guards around them. Never work on the alternator while it is running.

A Loose dangerous. KE tension on V ANCE.)

Ii volta perrr Operi

)r produces dan I safety precal eople - especiall,

A Gasoline engines used to drive your pulley driven alternator consume oxygen and give off DEADLY carbon monoxide gas. Carbon monoxide can cause unconsciousness and even death. Never operate the engine in any unventilated area.

A caus freq'

Worn, bare or damaged electrical cords can )ck. I nspect ex taln them in goo

BE

belts are extren It. Maintain pre ,tion 3, MAINT

A Never<..,. __ ~ _ .. _ .. lator in any enck. __ _ space where cooling air flow might be obstructed_ Severe heat damage to the alternator will occur, as well as possible fire and property damage.

A Excessively high drive speeds are dangerous. Operate only at the minimum drive speed required to provide a n )Its on the altern voltmeter.

:CIDEITS OPERATO BEFORE ACTING

AND

BY READING YOUR OWNER'S MANUAL

Model No. Wattage Voltage

Amperes

Phase(s) Frequency Voltage Regulation

Drive Speed

Rotation

Drive Shaft

Minimum Horsepower ReQuired

Made 10 flt 3/16 Sq. Key

ALTERNATOR SIZE

1100 W. THRU 3000 W.

3500 W. THRU 6000 W.

6509·0 3000 120

25

6

SPECIFICATIONS

6511·1 6653·0 5000 4000

120/240 120/240

41.7 at 120 Volts 33.3 at 120 Volts 20.8 at 240 Volts 16.7 at 240 Volts

Single Phase 60 Hz. at 3600 RPM

120 Volts A·C (± 2%) at 60 Hz.

3600 RPM Clockwise or counterclockwise

7/8 Inch Diameter

12 10

MAJOR DIMENSIONS

e------

PULLEY DRIVEN PE ALTERNATOR INSTALLATION

Drawing No. 45935

~~1lI l r1~ ~~ ~~ ~" N

g •• 1 N • ~E 1 <1::; ~1 1

~

8l2,,~.

~ ~

!l~~ -<:{ li!liia ~

=:d

2

'"

SCHEMATIC .3 -<,

~Jr.,'r ~J-.... F~" ~ ~ 44 }~O 4~30 .• 4:A2 I 1 14 T

llAGRAM

120 VOLT UNITS

--22-

22 --------, WIRE NUT~ I: ~2~ 44~ VOLTMETER

2pJ 2°1 44 ~)/

20 ~ ~. 2-

,B

{ I IIII ~:6--4 ~. REGULATORJ

I

B4 , --«---

~~ 6

r······'·_·"· ',177

o .... ::?

~GlNE

&r;;;;" •• vN 1 ENGINES, PULLEYS, V·BELTS AND MOUNTING HARDWARE

Make sure the engine you select to drive your alternator meets the following requirements:

1. The engine must be rated at 10 horsepower, or greater, for Alternator Model 6653·0. For Model 6509-, lIetA "",t least a A hnr!>oPl)ower el"'nln"" ""''1d for Mnrl",,1 ~~11-1, use"'" 1? j.4P engine

engine horsepower ~t~;gs are usually given for a specifiC rpm, such as "10 horsepower at 3000 mrn." The p-nDine ~Ileed needArf tn drive tI lator at m must I lent t( ~ the req Irsepowe

-- --2. The engine must have a horizontal drive shaft, capable of mounting and driving a pulley wheel.

3. The engine must be equipped with speed controls that permit selection of a specific speed. The engine rn,,,,t "t.hen be ah1p"tft "1aintain th<>t .,~.

engine I

engine, 'e provis' in good t

THE ENGINE PULLEY

rigid,sec:

n, prope

The Dulley that mounts to the enaine drive shaft meet th ing requ

engine should I inches

2. The pulley groove (or grooves) should have a nominal inside width of 5/8 inch. ~ ,. .. - pulley g---'- -,gle shou l "'! I..~ ~a, degrees

ey groo' ! and if idth she the 9ro Jle and 'idth of

Clilellidtor pull&y. 5. The pulley bore must match the engine drive shaft on which it is to be mounted.

ulley ha,' d for mt Ie can 0

... "', .... ,e used.

j (or mar • lIations. en only

res is ree, leavy 10

mting-1 j and ml

5t be no

moothly

~nt durir

.• ,...--3BO~ raove Angle

/

I~

I~ Groove Wi"

This requmumnlt cannoL ,,'_y1 be mEn, IQfI'I'..:ially in lIa,,"LVI installatlvn::. wndre only a

single groove pulley is provided on the tractor·

tion.

THE ALTERNATOR PULLEY An alternator pulley that meets the following requirements should be purchased:

1. Pulley diameter is 4% inches, with a nominal groove width of 5/8 inch, and a groove angle of 38 degrees.

2. Engine pulley groove angle and width must match the alternator pulley groove angle and width.

3. Pulley bore diameter is 7/8 inch.

NOTE

A pulley that meets all of the above require­ments may be obtained by ordering pulley part No. 47447.

V-BELTS

A standard "S" type belt will fit the engine and alternator pulleys recommended in this section. A cross-section of a B Type belt is shown at right.

ACAUTION V-belts and pulleys MUST match. Use only a "B" type bait with the pulleys recommended in this manual. Mismatched belts and pulleys will cause slippage, loss of power and early belt failure.

V-belt length will vary with each installation. To find the required belt length for your installation, proceed as follows:

1. Measure the distance between the engine pulley center and the alternator pulley center. Multiply the distance times 2.

2. Add the engine pulley diameter (4-3/4 inch) and the alternator pulley diameter (4% inch).

3. Multiply the sum found in (2) by 1.57.

4. Add the result found in (3) to the result found in (1) to find the V-belt length required.

For Example:

The distance between pulley centers is 30 inches. Engine pulley diameter is 4~ inches. Alternator pulley diameter is 4% inches.

(.) 30x2 =60 (b) 4% plus 4% = 9 (e) 9times1.57 =14.13 (d) 14.13 plus 60 = 74.13

A 75 inch V-belt would be required.

Engine Distance Between Pully Centers 1 ;~--fE:=f-~

Pullev Diameter Pulley Diameter

L=1.57 (D+d) +(Cx2) Where L=V·Belt Lenght

D=Engine Pulley Diameter d= Alternator Pulley Diameter c= Distance Between Pulley

Centers

THE MOUNTING BM

~r

~c'~ "'-~

Slotted Angle Iron For Take-Up Of v-Belt Tension

'Flat Platform

The alternator can also be installed onto any flat mounting platform, such as a heavy board, a cement slab, a work bench, or the bed of a truck or trailer. When this is the case, adjustment of V-belt tension may be provided by mounting the unit to four lengths of angle iron as shown above. Slotted holes in two of the lengthc nf :annl<> ;rnn n<>rrni't h<>I't

tension to be adjusted,

Cut two more 10 inc four 11/32 inch hole! saw to cut elongated h

6

Construct two of the lengths of angle iron as shown above. Cut the angle iron into two 10 inch lengths. Then drill four 11/32 inch holes as shown.

A

Mounting Holes 11/32 in. Drill

NOTE - To Make Slotted Holes Drill FOlJr 11/32 inch Holes as Shown, Then cut Slot With Saber s"w.

"

5/16-24 Bott ____ 14 Req'd To Mount

Alternator)

1- ~ ---L.. 5/16" Flatwasher 'rTf i 14 Roo'd)

1----"(1:' ' ~jL,~Alternator

I Mounting Leg

5/16 lodc:washer (8 Req'dl

5/16" Bolts of suitable lenght retain angle iron to mounting platform ( 6 Req:d )

Bolts, hex nuts and washers as shown above are required. The two lengths of angle iron must be bolted securely to the flat mounting platform. Use masonry bolts to attach them to a cement slab. Make sure all bolts are long enough.

7

INTRODUCTION

SECTION 2 INSTALLATION

1 the sit and its ( ngine ar installed flat mou ~tform -. (or boa._, __ Jrkbench. . .. mt slab, _ or traiIE. an engin .•.. _IS, V-beL ..

mounting base will have to be provided. Be sure to follow the recommendations in Section 1 of this Manual carefully.

section [)rm.

Owner' II cover! :tallation

A DANGER

alternat( a flat m

Gasoline engines consumD oxygen and give on DEADL y carDon monozlae gas. Adequate ventilation MUST be provided. Never install or operate the engine where exhaust gasses can accumulate. These gasses, when breathed in sufficient quantity. can cause unconsciousness or even ,iAath

A DANGER

Never ir operate "nator or no engin enciosUi npartme that mi!:t .. ~ " ..... ~:uct the .............. .::ooling Co ... ~ ..... I the altf.. •. _ ...... nd engir ... n ...... .Jickly 0\, ... -

heat if cooling air flow is inadequate. An overheated alternator or engine can cause fire, per­sonal injury, or damage to property and equipment.

SREQU

The following tools are required for installation of the pulley driven alternator:

1 A. % inch f':nmhin:;ltion wfjlOnrh t? Req'd) . % inch Electric .n 11/32 ill Bit {fl or meta ng platfl 1/32 inc ry drill ( Inting to slab on I'

5. Metal pry bar (for adjusting V-belt tension) 6. Light Hammer 7. Screwdriver or Allen Wrench (to fit set screw on pulleys) - "letal rulE "ght edge

ools reql , mounti ngine

MOUNTING HAROWARE REOUIREO

Obtain the required materials and mount the driving engine according to the engine manufacturer"s instructi')ns and recommendations. Use the following CHECK LIST to make sure you have the items re­quired tor mounting the alternator:

See ., Item Description Quantity Page

1 ENGINE - I 4 2 *ENGINE PULLEY - 4*" Diameter 1 4 3 *ALTERNATOR PULLEY - 4%" Diameter 1 5 4 V-BELTS -Type "B" 2 5 5 ADJUSTABLE MOUNTING BASE 1 6 6 DRIVE KEY - 3/16" square 1 10

7 ALTERNATOR MOUNTING BOLTS - 5/16-241" Long 4 7

8 FLATWASHERS - 5/16" 4 7

9 LOCKWASHERS - 5/16" 18 7 10 HEX NUTS - 5/16-18 14 7

11 ANGLE IRON BOLTS-5/16-18x3/4" Long 4 7

12 "ANGLE IRON TO PLATFORM BOLTS - 5/16-24 6 7

* Engine and alternator pulley groove must have 5/8" width and 38° taper. Two (or more) grooves are recommended.

**These bolts mount the adjustable base to the flat mounting platform. Bolt length will depend on thickness of flat mounting platform.

MOUNTING THE ALTERNATOR AND ENGINE

~.~. , '" :I::~:~

1. As.o;emble the four lengths of angle iron and retain with 5/16-24 x 3/4 inch long bolts, hex nuts and lockwashers. Position bolts in approximate centers of slotted holes, then tighten securely.

2. Retain the' assembled adjustable base to the alternator, using four 5/16-24 x 1 inch long bolts, flatwashers, lockwashers and hex nuts. Tighten securely.

9

3. Set the engine and c platform. Determine c the following guidelim

a, Make sure the engll any combustible IT

gasses are HOT. b. Engine and alternat!

other as possible. E: slippage, wear and ei

c. Make sure that mou base are not dire( wiring, etc.

4. Install a 3/16 inch ~ tor shaft key slot. Taf keyway.

Shaft

ALTERNATOR CAN S CLOCKWISE OR cour

Recommended (See THE ALTERNATOR PULLEY, Page 9)

'---------5. Align the alternator pulley k key on alternator shaft. Install th securely. If pulley has a set sere' tighten securely. If pulley does nc follow the manufacturer's instl on shaft.

Align Pulleys Like This

I~ NOT Lik, Th;'~ ~

MOUNTBELTSSTnAIGHT

6. Follow the manufacturer's instructions to install 7. Hold the edge of a metal rule (or other straight pulley onto engine shaft. edge) against the front of the engine pulley. Then

position the alternator until the edge of the rule is flush against both the alternator and engine pulley.

10

f engine ar EXACT a the engine

,ys is obtai ling. Slide' .. _. __ ,unting ho _,. Drill mour'~;~~turer .

•.. - _"_:'nato~ °S~:~i'fi;;;; by en;~~em~ua~ting holes, for engl~~c: and drill 6 alterna ~~~~e:~ 11/32" drill.

• <>, ,~ .. ,"uun~ing h~'~f~c~~r;;;~ ~""" engine ~ per the engine mi~s mounting ;~gine to plat~~;ain alternator ~rs and hex nuts. instruct:~~s;iX 5116·24 bOI:~rW::~ent sl.h.! M.ke ~I~~s ::: .. onry fasterne" . 3 thread

Its are lo~ wn. ,ith bolts tl

I Eo,,", . ' Distance Between Pully Centers I

Alternator I Pulley

Mark, ~~~r ~~~~~ing Holes and nr,1I Drill With

nator

Base

Any Flat

Mo"o," ~'

~'1fm MOX ",ut ,~\ :

5/16-24601

Make sure ~~ea~~en tight

~I At Least ,.... .. 3 Threads

n ~

Use masonry bOltSI in Cement Slab

'"'11:: -=::t I Pullev Diar.._ Pulle', _

L = 1.57 (~ +(Cx2)

L=1.57 1D_ • elt Lenght. r

Where ~-=-~:gine Pulley Dlamete - rnator Pulley

mee Betweer

3 threads 5 ====

,"" -

- between e"~,",,, .:"'~ the \.I' ...... ".... calculate reqUir v 1Y,,;;asure centers. Then ~It~rnator pulley tUned on Page 5

V-belt length as ou

! [ ~,.~"". JOlts in slot~""~ ....... ·"";or as near the 11 Lo __ ... " ~ Slide the altern~ V.belts. DO

ba;e on alterna~:, Then insta~U~~EYS.

3y from en~ nSlon un!!1 le adjustabbe,,,. AO/Ust v.be~~!':,.n pulleys up le",ion on VapPlied half·way 1~4 to 3/8 inch. thumb press~~~ belt downward adjustable base will deflect II four bolts In Then tighlten e~urol\l 0:1,,+1-...... ho es s

engine as P~-BELTS OVER NOT FORCE

'~l:ai8 '" ~--...::=

11

SECTION 3 OPERATING INSTRUCTIONS

DO AND DON'T CHART

1. DO c

2. DO I

condi

3. OGre OPERATION.

----j alternator for ~

:::al power cord bare electrical

vith all RULES F

4. DO maintain proper tension and alignment of V belts and pulleys.

5. DO inspect V-belts frequently for wear, cracking, or other damage. A worn or damaged V-belt can come nff rilJrinn nm>r~tion.

6. DO n nator reeon

ine used to driVE ion. Service the manufacturer.

BEFORE STARTING THE ALTERNATOR

1. Check the engine and alternator rulleys for looseness on their drive shafts. Tighten the pulleys, if necessary. before starting the unit.

2. Check the V-belt (s) for excessive looseness. If the belt (5) appear loose, take up slack as out­lined If t"" __ ~. __ A UA'NTENANCE.

3. Make ~ is properly se .anufacturer.

NATOR

CAUTION

Never start the engine with electrical equip­ment plugged in and turned ON. The alterna· tor can produce the proper frequency and voltage only at 3600 rpm. Some electrical equipment can be damaged if operated at a high or low frequency and voltage.

1. Start 1 manuf

2, Siowl, altern" indical no fur

3. With

Ie as recommend

speed while obsl Vhen the voltme land, increase en!

Intrals set to IT constant voltage reading in the voltmeter green band, plug in the desired electrical equipment.

12

DON'T work 0 they are runn;n V-belts, etc. are

DON'T exceed alternator. Ad( equipment to b

. or engine whilE such as pulleys

capacity of thf Ige rating of al e unit.

3. DON'T run the engine where exhaust gasses cnn nccumulnte. These gasses contain DEADLY car­bon monoxide.

4. DON'T rlug in electrical equipment until the control ranel voltmeter reads a steady 115 125 volts (in the green band on the voltmeter.)

a;, DON'T install a npw V_hplt fln a badly wort"' pulley groove. F damaged pulleys They can cause j loss of power.

DON'T permit ople especiall" children to a 'rnator. The un;' produces paten IOltages.

NOTE

After the desired electrical equipment is plugged in and turned ON, engine speed may decrease. This will result in a reduced voltage reading on the, .. _.- ... _. -lck the voltage reading after E rned ON and increase engine tain a voltage inl of the voltmetel

INDICATED WHE NEEDLE IS IN TH

;sary to main­'een band area

A DANGER

Operation of the alternator at excessively high speeds is extremely dangerous. At speeds approaching 10,O()() rpm, the rotating parts of the unit can contact stationary parts. If this happens. rotating parts can become flying projectiles. The voltmeter is your inojication of alternator speed . operate the unit only with the needle in the green band.

STOPPING THE ALTERNATOR

r. Unplug all electrical equipment. Let the alterna­tor run for several minutes with no equipment plugged in. This will allow the unit (and the driving engine) to cool.

2. Shut down the engine as recommended by the manufacturer.

USING YOUR ALTERNATOR

1. Comply with all RULES FOR SAFE OPERA· TION.

2. Don't overload your alternator. Read ALTER­NATOR WATTAGE CAPACITY and MOTOR STARTING REQUIREMENTS Add up wattage ratings of all electrical equipment to be powered by the unit at one time. THIS TOTAL SHOULD NOT EXCEED THE RATED WATTAGE CAPACITY OF THE ALTERNA· TOR.

3. Don't exceed amperage/wattage ratings of in­dividual electrical outlets or electrical power cords. Study the sections on ELECTRICAL OUTLETS and ELECTRICAL POWER CORDS carefully.

4. If the alternator and its driving engine run normally when no electrical devices are plugged in, but slow noticeably or "bog down" when electrical equipment is plugged in proceed as follows:

a. Alternator may be overloaded. Unplug, or turn OFF. all LIGHTS. APPLIANCES and MOTORS plugged into the unit. Add up wattages of all equipment again. Total should not exceed wat­tage capacity of the unit.

b. One of the tools, appliances or motors powered by the unit may be defective. Unplug all equip­ment, then start plugging devices back in one at a time. As individual equipment is plugged in and turned ON, alternator and engine should surge and then return to normal speed as indicated on voltmeter. If plugging in a certain item causes the driving engine to "bog down" that item is defective. Try plugging in another device of comparable wattage rating. If unit surges and returns to normal speed with second device plugged, in the original device is definitely defective.

c. The driving engine may be defective. Check for a dirty air cleaner or spark plug, carburetor improperly adjusted, excessive engine carbon buildup or any other factor that might rob engine power.

d. As a last resort, have the alternator checked.

ALTERNATOR WATTAGE CAPACITY

The alternator is rated at 4000 watts. WA TIS is a measure of electrical power. In most cases, ap­proximate wattage can be found by multiplying VOLTS times AMPS. For example, if an alternator is rated at 33.3 amps at 120 volts:

WATTS' VOLTS x AMPS WATTS· 120 x 33.3 WATTS· 3996

That particular unit is rated at approximately 4000 watts.

The wattage rating of your alternator should never should never be exceeded. Add up the wattages of all LIGHTS. APPLIANCES and MOTORS to be powered by the unit at one time. This total should not be greater than the wattage rating of your alternator.

13

Obtain wattages direct plates, whenever possiblf a nameplate, approxima by multiplying namepla amperage.

ACAI

The VOLTS timesA~ wattage is generall" wattage requirement! crease as internal tool operating temperatures increase. Under hard use, tool operating temperatures will go up rapidly, causing the wattage demands of that tool to go up. Under extremely hard use, wattage requirements of a tool may be as much as 300 - 400 per cent above the nameplate rating. For this reason, the EXTREME use to which a tool may be put must be considered.

MOTOR STARTING REQUIREMENTS

Many electric motors require more watts of power for starting than for running. To find the wattages required for starting and running these motors, find the type of motor and its horsepower rating on the motor nameplate. Th-- _....a: __ ... - .. 1..- unT.no

STARTING REQUIRE lows to locate approx watts.

If several motors art time, it may be best time, beginning with most starting watts.

___ --'MOTOR U

ELECTRICAL OUTLETS

The 120 volt, parallel blade, outlets on your alter­nator control panel are each rated at 15 amps. Using the volts times amps method (Watts = Volts

14

x Amps), the wattage capacity 1800 watts.

The 240 Volt, 4-Prong outlet is giving [t a wattage capacity of 4800 watts. The full wattage capacity of the alternator can be taken from this outlet.

A CAUTION

Do not exceed the amperage/w of individual electrical outlets. in damage to the outlets.

'LECTRICAL POWER CORDS

:Iectrical power cords must h nough to handle the amperage/ Ie subjected to. Wiring sizes dep nd the length of the cord. T :ORD REQUIREMENTS CHA ists some of the recommended lased on equipment amperage a he cords.

EXTENSION CORD REaL

AMPERE LENGTH OF caRli IN "lI:tl

RATING 50 Ft. 100 Ft. 150 Ft.

I----2 18GA. 18 GA. 18GA. 3 HI GA- l8GA- 18GA. 4 16 GA. "GA 16GA. 5 16GA. 16GA. 16GA. . 16GA. 16 GA . 14GA. . 16GA. 14GA. 12GA.

10 16GA. 14GA. 12 GA. 12 14GA. 14GA. 12GA. 14 14 GA. 12GA. lOGA.

" 12 GA. 12GA- 10GA.

V-BELT MAINTENANCE

SECTION 4 MAINTENANCE

1. Maintain proper tension on V-belts. Thumb pressure, exerted halfway between the engine and alternator pulley, should deflect the belt downward 1/4 to 3/8 inch. ~

ELIMINATESLACIc:

T LIKE THIS

(§1 l@) KEEP BELTS CLEAN

~ Y NOT THIS OR THIS

2. Keep V-belts clean, free of oil and protected from sunlight. Clean belts with a dry cloth. If grease or oil get on a belt. remove with carbon tetrachloride. Never use belt dressing on a V-belt.

3. V-belt should ride in the pulley gr~ve so that their top surface is just above the highest point on the pulley. If belt rides too high, it loses contact area and will slip. If belt rides too low in pulley groove, belt 'Viedging" action will be reduced. This

Maintain Proper Fit Of V-Belt In Pully Groove

will cause slipping or burring.

ENGINE MAINTENANCE

A property maintained engine Is required to ensure proper operation of the alternator. Comply with the following rules:

1. Otange engine oil regularly, at intervals recommended by the engine manufacturer. Use only oils recom­mended by the engine manufacturer.

2. Service the engine air cleaner at intervals recommended by the manufacturer, more often if operating under dirty or dusty conditions. A clogged air cleaner causes loss of engine power and "bogging down~' under load.

3. Use only the fuet recommended by the engine manufacturer. 4. Use the spark plug{s) recommended by the engine manufacturer. Replace, clean and regap spark plug as recommended by the manufacturer.

5. Have the engine cylinder head de-carbonized at operating intervals recommended by the engine manu­facturer. 6. If engine is to remain idle for more than 30 days, prepare it for storage as recommended by the engine manufacturer.

15

13

l~i

Item Part No. 1 4508B

31971 22816 22122 44961·H 44961·L 22694 43994 24413 45803 45092

10 24049 11 23877-D 12 A·24Q44· 13 25105 I. 45660 15 22145 16 22142 17 44357 18 43874 19 24489 20 22129 21 44338 22 45040 23 4439S-A

44395-B 2. 22097 25 22127

16 26 44943 27 46079

TS

PLOOED VIEW OF ALTERNAl 42480

Ion G, Adapter IG ING (Internal) ING (External) I, (3000 Watt units without battery ch I, (4000 and 5000 Watt units without I ACLE, White ACLE, Red Taptite· No. 10·32x%" Long (3000 Watt units only) (4000 and 5000 Watt units) G ~, Brush

...... no;;u & LOCKWASHER· No. 6-32x%" Long FAN, Cooling (Aluminum) WASHER, Flat - 5/16 SCREW, Machine· S/16-lax'}.;" Long COVER, Cooling Fan BACK, Panel Shroud SCREW, Taptite· No. 1O-32x3/8" Long WASHER, lock· 5/16 BAR, Stator Bolt SUPPORT, Rear Alternator BOLT, Stator· 8%" Long (3000 Watt Units) BOLT, Stator - 11 7/8" Long (4000 and 5000 Watt Units) WASHER, Lock - %" NUT, Hex - %-20 CARRIER, Re~r Bearing RETAINER, Receptacle

EXPLODED VIEW OF PANEL 4247

Item

2 3 4 5 6 7 8 9 10 11 12

Part N

45084 45084 45084 45084 45084 43482 26579 22471 45049 22693 36918 23203 36901 22155 23243 27272

2 2 2 2 2

* As Required

\ 4

iption

:L, Silkscreened (3000 Watt) : L, Silkscreened (3000 Watt with :L, Silkscreened (4000 Watt) :L, Silkscreened (5000 Watt) : L, Silk screened (5000 Watt with _ET, 240V. 20A. 4 Prong Twistlc -IER, No.8 Shakeproof No. 8-32 Hex.

rMETER _ET, 120V. 15A. Parallel Blade

MACHINE SCREW, No. 8-32x.50 Lg. Phillips Pan Head HOLDER, Fuse (GSA Units Only) MACHINE SCREW, No. 6-32x.37 Lg. Phillips Pan Head WASHE R, No.6 Lock FUSE, FNM 15 (eSA Units Only) RETAINER OUTLET,

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FRONT PANEL ASSEMBlY

4/

~

18

Item

1 2 3 4

43875 42541 46852

~~ EXPLOD SHROUD

Drawing r

Description . 10-32x3/B Taptltes

No, Panel SHROUL~TOR, Voltag~ ~O~~~-32X.25L9. Taptlte

INSTI<

I Installation of Stan TRICAl AND BUlL TREMEL Y DANGEt

RECOMMENDED

A typical Stand-By F Switch, (3) two Buil!

The CONNECTION I with a 1201240 Yolt, connections for the connection boxes h

liD-BY POWER SY~

be done by 8 QUALIFIED electrician. I N'ITH. Improper Installation methods ld personal property_

EM

3ystem uses a (1) Connection Box ar lerconnecting wiring

ternators equipped with a 120 vo!t,: ,ators may 'not have any outlets, but he latter case, a connection box is n'

pi ion

It, 30 Amp, 3-wire cord set. J Volt, 20 Amp, 4-wlre cord set

A TRANSFER SWIT! "feedback" between utility company nator. Be sure to In lSed on the following: 1. If utility company input to the building is rated at LESS THAN 100 Amps, install a Switch having a utility line connec· tion rated at 100 Amps. 2. If utility company Input to the bulldlng Is rated at MORE THAN 100 Amps but LESS THAN 200 Amps, Install a Switch having a utility line connection rated at 200 Amps. 3. Make sure the Transfer Switch alternator connection is rated at a higher amperage than the alternator to be used. The following Transfer Switches are available:

Utility Line Connection Alternator Connectlon

L-M"'5;.;,;d,..;''--+ ____ Am'''p;.;~,c;:''~~:'''~n"g'-----+----A,m~~r~~~~ng 5963 200 Amps 200 Amps 5964 200 Amps 200 Amps 6379 100 Amps 60 Amps 6384 200 Amps 100 Amps

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The use of two BUILDING DISTRIBUTION CENTERS is recommended. The Auxiliary Building Distribution Center is powered by both utility company and alternator power, and supplies ESSENTIAL building circults. Total wattage re­quired to power these essential circuits should not be greater than alternator wattage capacity. The Main Building Distnbution Center is powered only by utility company lines.

Wh, capi the,

~ Interce codes.

Iding Distribution I

Ige ratings of aU ee capacity. If necess

vi ring conduits, wi

d, care must be ta led on at one time. nllal loads off until

,mustbefullyinc

-, alternator wattage

,ot be greater than ired Is within alter-

I applicable electri

To selected essential Utility Range building circuits

outlet-50 amp ~ o ~.+~ .~ In, ~~::,~:~;~" I~ - ,to, Roo"

'" - SOamp

50 amp

Meter

Range PIL

From Alternator---+- OPTIONAL STAND-BY CONNECTION SYSTEM (Suggested interconnection only-Be sure to check for compliance with local electrical codes)

OPTlnN4' 'NT"Rr,ONNECTION I"Y"T"M An OP INNECTION SYST e, using materials suppl) ing Main Distributi with selected eSSE cuit br 1ected 10 circuit b Emergency Distri break{ e Main Distributio ~cted to a 50 amp l Outlet lternator A-C Qutp p Range Plug and Emerg Panel. The RangE Iged into the Utilil cQmp;; the Generalor Rar ~rating on alternal ~~ _____ jbaC_k'_' b_,_twee_" _" _____ '_alternator.

hardware or electri onnected from its \0 volt, 50 amp cir( ~t. A Generator Ral sential circuits in Ir operation on uti Jer. This arrangem

I " NOTE When operating on Stand-By power, care must be taken to ensure that Emergency Distribution Panel loads do not ex· ceed alternator wattage capacity. Add up wattage ratings of all equipment to be turned ON at one time. This total should not be greater than the alternator's rated capacity.

MAIN DISTRiBUTION PANEL - Selected essential circuits must be disconnected from their circuit breakers in the Main Distribution Panel and reconnected to equivalent circuit breakers in the Emergency Distribution Panel. A 240 volt,!:"' -,-- ,,' akercanbeinstal"~'- . __ .--•• L-50ampUtilityRa,-·'" .. _.

EMEF UTION PANEL - lential circuits dil Panel circuit breakers in stribution Panel. 1 high ( to handie the eire rgency Dislrlbutic and 11 y Of stand-by pow UTILI' T - The 240 vall, in) ane ibution Panel with by a 5! ker· this is done .... Panel.

ge Outlet providel rom utility compar amp circuit break~

the Main Distribu ;ers must be rated ld by the Range C

when cord Is plug, ,t should be pratec the Main Distribul

STAND-BY RANGE OUTLET - This outlet may be either 120 or 240 volts, or both. Like the Utility Range Outlet, It should be rated at 50 Amps. Output wiring from the alternator connects to this outlet. RANGE CORD - The Range Cord is connected to the Emergency Distribution Panel. Use a cord rated at 50 amps. In· stall a range plug onto the cord that will fit both the Utility and Alternator Range Outlets.

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