Tuesday, April 8, 2008


I made the generator starting with the Changfa diesel engine, dynamo and a Chevy 10SI alternator. A friend welded the frame up because I didn't know how to arc weld yet when I started this project nearly a year and a half ago and didn't want to burn up all my acetylene using the torch to weld the job. The brown step pulley and driveshaft adapter which is bolted to the engine flywheel is a special casting. I made the pattern for the casting and then took it to a foundry where they poured the casting for me. I then machined the casting all over cut a keyway in the shaft and centered it on the flywheel. I used a lovejoy L110 42mm coupling and buna-N spider to connect the two shafts after a very careful alignment job the maximum angular misalignment allowable is 1degree. With a little trepidation I tested the generator in March 2007 and found that it worked great. After our return from the USA in May I mounted the Chevy 10SI alternator only to have it fail after relatively little usage, it just couldn't handle the heavy work of battery bank charging. Two days I ago I replaced the Chevy alternator with a Lecy-Neville 145amp alternator that I took off another battery charger that had a engine with a cracked head. This time I welded a heavy duty alternator mount onto the generator frame. (I learned the basics of arc welding in June.) Welding the mount onto the generator frame was a bit of a challenge due to the vibration, diesel exhaust in my face etc.. but I managed to pull it off without getting any of my body parts tangled in the flywheel. So we now have reliable power just over 6Kw 100% duty cycle 220V 110V and 12V. When I replaced the alternator I had to split the coupling to put the new alternator belt on and found that the spider showed no sign of wear, I must have done a decent job on the shaft alignment.

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