r--------------,

I
I

GENERACI
owners
manual

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

OPERATING INSTRUCTIONS
REPAIR PARTS
GENERAC
P.O. Box 8, Waukesha, Wisconsin 53186
ACCESSORIES

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

Part No. 42477

SB-66530·103
SB-65090·103
Printed in U.S.A. S8·65111·103
 ONE YEAR LIMITED WARRANTY
----!tBLE
the original Purchaser II be free from defect manship for a period
dale 01 original pure lowever does not mell e,when lurnishedor
IS covered solei V bV It ,ulaclurer olsuch eng
ilS, demonstralorS, or lnssucha$construct,( I Lee\ro Van are war-
llntalunits,demonstn pplicalions such as cor xcluding Lee\fo Van
not undor warranty t In. Anv warranty whl >!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'porta-
tion 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 amber 31, 1976 and $1 rrantiesof Generac.
four nearest Generac service facility as sho 9 of authorized War_
I. Warranty service cal by a Genorac authoriz, dlity. At the tilM af
ervice,evidencaof ori, lSt be presented,
GENERAC CORI lYaukesha. WI. 53186

RULES FOR SAFE OPERATION

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.

Ii )r produces dan
A Loose
dangerous. KE
belts are extren
It. Maintain pre
volta I safety precal tension on V ,tion 3, MAINT
perrr eople - especiall, ANCE.)
Operi

A Gasoline engines used to drive your pulley

A Never<..,. ~
__ _.. _.. lator in any enck. __ _
space where cooling air flow might be obstructed_
driven alternator consume oxygen and give off Severe heat damage to the alternator will occur, as
DEADLY carbon monoxide gas. Carbon monoxide well as possible fire and property damage.
can cause unconsciousness and even death. Never
operate the engine in any unventilated area.

A Worn, bare or damaged electrical cords can

A Excessively high drive speeds are dangerous.
Operate only at the minimum drive speed required
caus )ck. Inspect ex to provide a n )Its on the altern
freq' taln them in goo voltmeter.

:CIDEITS
BE OPERATO
BEFORE ACTING
AND
BY READING YOUR OWNER'S MANUAL
 SPECIFICATIONS

Model No. 6509·0 6511·1 6653·0

Wattage 3000 5000 4000
Voltage 120 120/240 120/240
Amperes 41.7 at 120 Volts 33.3 at 120 Volts
25 20.8 at 240 Volts 16.7 at 240 Volts
Phase(s) Single Phase
Frequency 60 Hz. at 3600 RPM
Voltage 120 Volts A·C (± 2%) at 60 Hz.
Regulation
Drive Speed 3600 RPM
Rotation Clockwise or counterclockwise
Drive Shaft 7/8 Inch Diameter
Minimum
Horsepower 6 12 10
ReQuired

MAJOR DIMENSIONS

e------

Made 10 flt 3/16

Sq. Key

PULLEY DRIVEN PE
ALTERNATOR SIZE
ALTERNATOR INSTALLATION
1100 W. THRU 3000 W. Drawing No. 45935
3500 W. THRU 6000 W.
 ~~1lIl r1~
~~ ~~
~" N

~Eg••1
1
N

<1::; ~11
•

8l2,,~.

2
~ ~
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<:{ li!liia ~

=:d
 SCHEMATIC

.
.3
-<,

~Jr.,'r ~J- F ~ "

B4 ,
--«---
~~
6
o
....
::?
~~ }~O 4~30
44

.•4:A2 I 1 14 T
--22-

llAGRAM

WIRE NUT~ I:
22 - - - - - - - - ,

~2~ 44~ VOLTMETER

2pJ 2°1 44 ~)/

{
20 I IIII ~:6-
~
~. 2-
,B
-4 ~. REGULATORJ
I
120 VOLT UNITS
r······'·_·"· ',177
'"
 &r;;;;" •• vN 1
ENGINES, PULLEYS, V·BELTS
AND MOUNTING HARDWARE

~GlNE

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

e tI
t(
ngine horsepower

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

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 'e provis' rigid,sec: mting-1 5t be no ~nt durir tion.
engine, in good t n, prope j and ml moothly
THE ENGINE PULLEY

The Dulley that mounts to the enaine drive shaft .• ,...--3BO~

meet th ing requ raove
Angle
engine should I inches /

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

I~
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.
Groove
ulley ha,' j(or mar • res is ree, Wi"
d for mt lIations. leavy 10
Ie can 0 en only
..."', .... ,e used.

This requmumnlt cannoL ,,'_y1 be mEn, IQfI'I'..:ially in lIa,,"LVI installatlvn::. wndre only a
single groove pulley is provided on the tractor·
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 require-
ments 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).

1
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.

Engine Distance Between Pully Centers

;~-
-fE:=f-~
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 Pullev Diameter Pulley Diameter
(e) 9times1.57 =14.13 L=1.57 (D+d) +(Cx2)
(d) 14.13 plus 60 = 74.13 Where L=V·Belt Lenght
D=Engine Pulley Diameter
A 75 inch V-belt would be required. d= Alternator Pulley Diameter
c= Distance Between Pulley
Centers
THE MOUNTING BM

~r

~c'~
"'-~ 'Flat Platform

Slotted Angle Iron

For Take-Up Of v-Belt
Tension

The alternator can also be installed onto any flat Construct two of the lengths of angle iron as shown
mounting platform, such as a heavy board, a cement above. Cut the angle iron into two 10 inch lengths.
slab, a work bench, or the bed of a truck or trailer. Then drill four 11/32 inch holes as shown.
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
Mounting
Holes
11/32 in. Drill
A
NOTE - To Make Slotted Holes
Drill FOlJr 11/32 inch Holes as
Shown, Then cut Slot With Saber
s"w.

6
 5/16-24 Bott
_ _ _ _ 14 Req'd To Mount
Alternator)
1-
" ---L..
~
'rTf i
5/16" Flatwasher
14 Roo'd)
1----"(1:' '
~jL,~Alternator
I Mounting Leg

5/16" Bolts of suitable lenght

retain angle iron to mounting
platform ( 6 Req:d )

5/16 lodc:washer
(8 Req'dl

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
 SECTION 2
INSTALLATION
INTRODUCTION

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 Owner' II cover! :tallation alternat( a flat m

[)rm.

A DANGER

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, per-
sonal 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 re-
quired tor mounting the alternator:

Item Description Quantity

See
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 ALTERNATOR CAN S
base are not dire( CLOCKWISE OR cour
wiring, etc.

Recommended (See
THE ALTERNATOR
PULLEY, Page 9)
'---------
4. Install a 3/16 inch ~ 5. Align the alternator pulley k
tor shaft key slot. Taf key on alternator shaft. Install th
keyway. 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~
Shaft

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
 Mark,
and nr,1I
~~~r ~~~~~ing
Drill
Holes
f engine ar With
EXACT a the engine
,ys is obtai ling. Slide' .. _. __
,unting ho_,. Drill mour'~;~~turer .
_"_:'nato~ °S~:~i'fi;;;;
for engl~~c: and drill 6 alterna
•.. - by en;~~em~ua~ting holes,
~~~~e:~ 11/32" drill.

nator

,~.. ,"uun~ing h~'~f~c~~r;;;~

~""" engine ~ per the engine mi~s mounting
;~gine to plat~~;ain alternator ~rs and hex nuts.

~I
• <>,

instruct:~~s;iX 5116·24 bOI:~rW::~ent sl.h.!

Base

~I~~s :::..onry fasterne" . 3 thread

M.ke Any Flat At Least
,...... 3 Threads
~'
Its are lo~
,ith bolts tl
wn.
Mo"o,"

~'1fm ,~\ n
MOX ",ut :
~
IEo,,", . '
Distance Between Pully Centers I

I 5/16-24601 Use masonry bOltSI

'"'11:: -=::t
Alternator in Cement Slab
Pulley
====
Make sure ~~ea~~en tight
3 threads 5

~,.~"".
I Pullev Diar.._ Pulle', _

L = 1.57 (~ +(Cx2)
L=1.5 7 1D_ • elt Lenght. r
Where ~-=-~:gine Pulley Dlamete
- rnator Pulley

- between
mee Betweer
,"" -

e"~,",,, .:"'~
![ ~ altern~
JOlts in slot~""~ ....... ·"";or as near the
~It~rnator the centers.
\.I' ...... "....Then calculate reqUir
alterna~:, insta~U~~EYS.
v 1Y,,;;asure 11 Lo __ ... " Slide the V.belts. DO
pulley tUned on Page 5 ba;e on Then
V-belt length as ou
engine as
NOT FORCE P~-BELTS OVER

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

3y from en~ nSlon un!!1

v.be~~!':,.n
1~4
le adjustabbe,,,. AO/Ust pulleys

press~~~
up le",ion on VapPlied half·way to 3/8 inch.
thumb belt downward adjustable base
will deflect II four bolts In
Then tighlten e~urol\l
0:1,,+1-...... ho es s

11
 SECTION 3
OPERATING INSTRUCTIONS
DO AND DON'T CHART

1. DO c
-alternator
j
- -for- ~ DON'T work 0 . or engine whilE
they are runn;n such as pulleys
2. DO I :::al power cord V-belts, etc. are
condi bare electrical DON'T exceed capacity of thf
alternator. Ad( Ige rating of al
3. OGre vith all RULES F equipment to b e unit.
OPERATION. 3. DON'T run the engine where exhaust gasses cnn
nccumulnte. These gasses contain DEADLY car-
4. DO maintain proper tension and alignment of bon monoxide.
V belts and pulleys. 4. DON'T rlug in electrical equipment until the
5. DO inspect V-belts frequently for wear, cracking, control ranel voltmeter reads a steady 115 125
or other damage. A worn or damaged V-belt can volts (in the green band on the voltmeter.)
come nff rilJrinn nm>r~tion. a;, DON'T install a npw V_hplt fln a badly wort"'
6. DO n ine used to driVE pulley groove. F damaged pulleys
nator ion. Service the They can cause j loss of power.
reeon manufacturer. DON'T permit ople especiall"
children to a 'rnator. The un;'
produces paten IOltages.

BEFORE STARTING THE ALTERNATOR

1. Check the engine and alternator rulleys for

looseness on their drive shafts. Tighten the NOTE
pulleys, if necessary. before starting the unit. After the desired electrical equipment is
2. Check the V-belt (s) for excessive looseness. If plugged in and turned ON, engine speed may
the belt (5) appear loose, take up slack as out- decrease. This will result in a reduced voltage
lined If ~.
t"" __ A UA'NTENANCE.
__ reading on the, .. _.- ... _. -lck the voltage
3. Make ~ is properly se reading after E rned ON and
.anufacturer. increase engine ;sary to main-
tain a voltage inl 'een band area
NATOR of the voltmetel

CAUTION
Never start the engine with electrical equip-
ment 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 Ie as recommend
manuf
2, Siowl, speed while obsl
altern" Vhen the voltme
indical land, increase en!
no fur INDICATED WHE
3. With Intrals set to IT NEEDLE IS IN TH
constant voltage reading in the voltmeter green
band, plug in the desired electrical equipment.

12

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 alterna-
tor 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 ALTER-
NATOR 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 in-
dividual 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 wat-
tage capacity of the unit.
b. One of the tools, appliances or motors powered
by the unit may be defective. Unplug all equip-
ment, 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, ap-
proximate 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 x Amps), the wattage capacity
plates, whenever possiblf 1800 watts.
a nameplate, approxima
by multiplying namepla
amperage.

ACAI

The VOLTS timesA~

wattage is generall"
wattage requirement! The 240 Volt, 4-Prong outlet is
crease as internal tool operating temperatures
increase. Under hard use, tool operating giving [t a wattage capacity of 4800 watts. The
temperatures will go up rapidly, causing the full wattage capacity of the alternator can be taken
wattage demands of that tool to go up. Under from this outlet.
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
A CAUTION

Do not exceed the amperage/w

STARTING REQUIRE of individual electrical outlets.
lows to locate approx in damage to the outlets.
watts.
'LECTRICAL POWER CORDS

:Iectrical power cords must h

If several motors art nough to handle the amperage/
time, it may be best Ie subjected to. Wiring sizes dep
time, beginning with nd the length of the cord. T
most starting watts. :ORD REQUIREMENTS CHA
ists some of the recommended
_ _ _--'MOTOR U lased on equipment amperage a
he cords.
EXTENSION CORD REaL
LENGTH OF caRli IN "lI:tl
AMPERE
RATING
50 Ft. 100 Ft. 150 Ft.
I----
2 18GA. 18 GA. 18GA.

.
3 HI GA- l8GA- 18GA.
4
5
16 GA.
16GA.
"GA
16GA.
16GA.
16GA.
16GA. 16 GA. 14GA.
ELECTRICAL OUTLETS 16GA. 14GA. 12GA.
10 16GA. 14GA. 12 GA.
12 14GA. 14GA. 12GA.
The 120 volt, parallel blade, outlets on your alter- 14 14 GA. 12GA. lOGA.
nator control panel are each rated at 15 amps. 12 GA. 12GA- 10GA.
Using the volts times amps method (Watts = Volts "
14
 SECTION 4
MAINTENANCE

V-BELT MAINTENANCE

~
1. Maintain proper tension on V-belts. Thumb
pressure, exerted halfway between the engine and
alternator pulley, should deflect the belt downward
(§1 l@)
1/4 to 3/8 inch. ELIMINATESLACIc: KEEP BELTS CLEAN
2. Keep V-belts clean, free of oil and protected

T ~ Y
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 LIKE THIS NOT THIS OR THIS
their top surface is just above the highest point on Maintain Proper Fit Of V-Belt In Pully Groove
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
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 recom-
mended 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 manu-
facturer.
6. If engine is to remain idle for more than 30 days, prepare it for storage as recommended by the engine
manufacturer.

15
 TS

PLOOED VIEW OF ALTERNAl

42480

13

l~i

Item Part No. Ion

1 4508B G, Adapter
31971 IG
22816 ING (Internal)
22122 ING (External)
44961·H I, (3000 Watt units without battery ch
44961·L I, (4000 and 5000 Watt units without I
22694 ACLE, White
43994 ACLE, Red
24413 Taptite· No. 10·32x%" Long
45803 (3000 Watt units only)
45092 (4000 and 5000 Watt units)
10 24049 G
11 23877-D ~, Brush
12 A·24Q44·
13 25105 ...... no;;u & LOCKWASHER· No. 6-32x%" Long
I. 45660 FAN, Cooling (Aluminum)
15 22145 WASHER, Flat - 5/16
16 22142 SCREW, Machine· S/16-lax'}.;" Long
17 44357 COVER, Cooling Fan
18 43874 BACK, Panel Shroud
19 24489 SCREW, Taptite· No. 1O-32x3/8" Long
20 22129 WASHER, lock· 5/16
21 44338 BAR, Stator Bolt
22 45040 SUPPORT, Rear Alternator
23 4439S-A BOLT, Stator· 8%" Long (3000 Watt Units)
44395-B BOLT, Stator - 11 7/8" Long (4000 and 5000 Watt Units)
2. 22097 WASHER, Lock - %"
25 22127 NUT, Hex - %-20
16 26 44943 CARRIER, Re~r Bearing
27 46079 RETAINER, Receptacle
 \4

EXPLODED VIEW OF PANEL

4247

Item Part N iption

45084 :L, Silkscreened (3000 Watt)

45084 : L, Silkscreened (3000 Watt with
45084 :L, Silkscreened (4000 Watt)
45084 :L, Silkscreened (5000 Watt)
45084 : L, Silk screened (5000 Watt with
2 43482 _ET, 240V. 20A. 4 Prong Twistlc
3 26579 -IER, No.8 Shakeproof
4 22471 No. 8-32 Hex.
5 45049 rMETER
6 22693 _ET, 120V. 15A. Parallel Blade
7 36918 MACHINE SCREW, No. 8-32x.50 Lg. Phillips Pan Head
8 23203 2 HOLDER, Fuse (GSA Units Only)
9 36901 2 MACHINE SCREW, No. 6-32x.37 Lg. Phillips Pan Head
10 22155 2 WASHE R, No.6 Lock
11 23243 2 FUSE, FNM 15 (eSA Units Only)
12 27272 2 RETAINER OUTLET,

* As Required
17
FRONT
PANEL
ASSEMBlY

~~
EXPLOD
4/ SHROUD

~ Drawing r

Item Description .
1 10-32x3/B Taptltes
No, Panel
SHROUL~TOR, Voltag~
2 43875

~O~~~-32X.25L9. Taptlte
3 42541
4 46852

18
 INSTI< liD-BY POWER SY~

Installation of Stan be done by 8 QUALIFIED electrician. I

I TRICAl AND BUlL N'ITH. Improper Installation methods
TREMEL Y DANGEt ld personal property_

RECOMMENDED EM

A typical Stand-By F 3ystem uses a (1) Connection Box ar

Switch, (3) two Buil! lerconnecting wiring

The CONNECTION I ternators equipped with a 120 vo!t,:

with a 1201240 Yolt, ,ators may 'not have any outlets, but
connections for the he latter case, a connection box is n'
connection boxes h

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

Am'''p;.;~,c;:''~~:'''~n"g'-----+----A,m~~r~~~~ng
L-M"'5;.;,;d,..;''--+____
5963 200 Amps 200 Amps
5964 200 Amps 200 Amps
6379 100 Amps 60 Amps
6384 200 Amps 100 Amps
19
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 re-
quired 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, Iding Distribution I d, care must be ta alternator wattage
capi Ige ratings of aU ee led on at one time. ,ot be greater than
the, capacity. If necess nllal loads off until ired Is within alter-

~
Interce vi ring conduits, wi ,mustbefullyinc I applicable electri
codes.

To selected essential
Utility Range building circuits

Meter

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

I~ '"
,to, Roo"
- SOamp

50 amp
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 hardware or electri
suppl) ing Main Distributi with selected eSSE onnected from its
cuit br 1ected 10 circuit b Emergency Distri \0 volt, 50 amp cir(
break{ e Main Distributio ~cted to a 50 amp l ~t. A Generator Ral
Outlet lternator A-C Qutp p Range Plug and sential circuits in
Emerg Panel. The RangE Iged into the Utilil Ir operation on uti
cQmp;; the Generalor Rar ~rating on alternal Jer. This arrangem
~~ _ _ _ _ _jbaC_k'_'b_,_twee_"_"_ _ _ _ _'_alternator.

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 the Main Distribu
Panel circuit breakers in stribution Panel. 1 ;ers must be rated
high ( to handie the eire rgency Dislrlbutic ld by the Range C
and 11 y Of stand-by pow
UTILI' T - The 240 vall, ge Outlet providel when cord Is plug,
in) ane ibution Panel with rom utility compar ,t should be pratec
by a 5! ker· this is done .... amp circuit break~ the Main Distribul
Panel.
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.
20