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TO-221 / Instruction Manual
120-V Power Generator Package - Part No. 283782
(3) Place the generator in proper mounting position (as shown in Figure 2) , and make certain that
holes in generator base and holes in the mounting bracket are lined up properly for inserting
mounting screws.
(4) Place a 1/4-inch flat washer on each of six 1/4-20 X 1-1/4 hex head cap screws. Then insert the
screws down through the holes in the generator base and the holes in the mounting bracket.
Assemble the six 1/4-inch lock washers and six 1/4-20 hex nuts to these screws and tighten all
six nuts securely.
(5) In preparation for connecting input cables to the output of the ground power unit, put the loose
ends of the power input cables in Z-flex protective tubing (provided in the kit) . Then route these
cables through the rectangular hole in the mounting bracket, and slide the rubber grommet over
the cables so that it is between the generator and the mounting bracket.
c. Connect Generator Input Cables to Output of Ground Power Unit
Input power for the generator will come from the "hot" side of the load contactor, which is located
just behind the battery on the right side of the ground power unit. Connections for the generator are
to be made at the load contactor and at the output terminal panel. The No. 6 AWG generator
power input cables each have one 3/8-inch terminal lug, and these cables are marked for polarity
per paragraph 2, b, (1). Connect the input cables as follows:
(1) Remove the 3/8-16 hex-head cap screw, lock washer, and flat washer that connect the two short
cables (from the heat sink) to the angle bus at the rear of the load contactor.
(2) Place the 3/8-inch terminal lug of the POSITIVE (+ ) generator input cable ON TOP OF the two
cable lugs loosened in the step above. Then re-install and re-tighten the 3/8-16 hex-head cap
screw, lock washer, and flat washer.
(3) Remove the hex-nut, lock washer, and flat washer that connect the large negative power output
cable to the negative output connection on the output terminal panel, but do not remove the
terminal lug of the negative power output cable from the terminal.
(4) Place the 3/8-inch terminal lug of the NEGATIVE ( - ) generator input cable ON TOP OF the
terminal lug where the negative power output cable connects to the negative terminal of the
ground power unit. Figure 4 shows how this should be done.
(5) Re-install and re-tighten the hex-nut, lock washer, and flat washer.
d. Mount the Generator Cover
(1) Place the generator cover in proper mounting position over the generator, such that it is mounted
as shown in Figure 2, and such that the rubber grommet on the power input cables fits in the slot
in the rear of the cover. Make certain that holes in the base of the generator cover and holes in
the mounting bracket are lined up properly for inserting mounting screws.
(2) Insert the six 1/4-20 X 1/2 self-tap screws down through the holes in the base of the generator
cover and into the holes in the mounting bracket. Tighten all six screws securely.
e. Install the Generator Cover Access Door
To install this small access door (9, Fig. 1) on the generator cover (7, Fig. 1), use the three 1/4-20 X
5/8-inch hex head screws, the three remaining 1/4-inch flat washers, and the three remaining
1/4-inch lock washers, and the three remaining 1/4-inch hex nuts. Make this installation such that
the nuts and washers are INSIDE the generator cover, and make certain that the nuts are tightened
down securely.
May 15/92
Page 5
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