3
Mounting the generator on the engine
Find a place on the engine where the generator can be
mounted. The pulley of the generator should be aligned with
the pulley on the crankshaft.
For some car models there are standard brackets available
to mount the generator. However as there are many
different vehicle brands and models on the market of which
the engine configuration can change from year to year, one
has to design his own mountings. For fleet owners
WhisperPower can offer engineering help and adapt the
design to make it a standard.
Otherwise one hast to design brackets the are solidly
supported by the engine. For applications that require large
power at minimal RPM a belt tensioner will be necessary to
increase the contact between belt and pulleys.
4
Alignment of the pulleys
The generator pulley must be mounted parallel an aligned
to the crankshaft pulley as shown in fig. 9
ATTENTION!
It is of the highest importance that the generator
mounting is done properly. Misalignment or too
light mounting brackets, or vibrations will shorten the
lifetime of the belt and influence the available power.
To obtain a good alignment as possible it may be necessary
to put washers (shims) on the generator shaft behind the
pulley. As shown in figure 12.
1) Large support washer (part of the generator)
2) Throat nut (torque 80+ 5 Nm)
3) Pulley
4) Position ring
5) Fixing plate
6) Bearing
The washers for alignment should be placed on the large
support washer (1) to transfer the force to the shaft. The
pulley must press on the position ring and the indirectly on
the bearing. Without this transmission of the force to the
shaft the lifetime of the generator will be decreased
extremely.
5
Brackets
There are many vehicles on the market and every model
has several different engine arrangements. Moreover this
arrangements will change from year to year for each model.
For this reason it is very difficult to supply mounting brackets
for each vehicle model. In case of a new application
WhisperPower can check if brackets are already available.
If not WhisperPower dealers can arrange a cooperation with
a local workshops that can do the design and make the
brackets for a specific vehicle. In case of applications for
fleet owners with many cars of the same model
WhisperPower
engineering
department
can
offer
assistance to design and manufacture brackets.
In any case the brackets must assure a solid and stable
mounting of the generator. The alignment must be
guaranteed; also when the v-belt is on tension and the
power demand will pull heavily on the belt. Vibrations must
not occur.
Use Loctite to secure bolts and nuts.
One can arrange V-belt tension by designing the brackets
with a provision for adjustment.
In general one can make the brackets more simple and the
V-belt tension adjustment more effective by applying an
Figure 14
Figure 13: checking the alignment
