I'm about ready to reinstall the genset in my 96 model U295. It's a Powertech 10KW. I've gotten the sheet metal enclosure straightened out pretty well and will be reinstalling the foam sound deadening mtl. The front cap swing up "door" for the enclosure is/was also covered with this same mtl.
There is no front for the sheet metal enclosure box. Is this correct or am I missing this piece? Or does the exterior "door" form the front of the enclosure?
I've heard reference to relocating the genset control box from its present location on top of gen to an alternate location. Is this a recommended mod? I see evidence of welding on the belt cover housing so assume it does some shakin'.
The plastic film which originally covered the sound control mtl is 90% gone. Is there any locally available mtl that I could glue in to cover the foam? I'm specifically wondering about using a reflective mylar covered bubble mtl such as is used for windshield shade covers for autos. It will be need to be pretty thin to not interfere with genset. Alternately I could peel the foil facing from some duct board and use this, wasteful though. Had thought about using heavy alum foil but suspect it would corrode away in short order.
Thanks, Chuck
Chuck,
The swing up door forms the front of the gen enclosure-you're not missing anything. Yes, relocate the control box to the front wall of the first driver's side bay with the radiator blower. It saves damage from heat and vibration. The belt cover is a welded piece, and has been known to fail at the attachment legs.
We don't know of a cheap replacement for the sound deadening material. It's expensive, but works well and lasts. I'd leave it alone until you get to Nac. Of course, you'll have to pull the gen again, or have the professionals do it.
Earlier GenSets were not in "Quiet-Boxes", which are fully enclosed in a metal box. Yours is probably just open like our 8KW. Your swing up door is probably your only cover.
When the control box is mounted on genset, it receives all the vibrations. Relocating it to the genset blower/radiator compartment by extending the wires is what a tech came up with ten years ago to prevent component failures from vibration. Just a choice that some have done.
The plastic film is expensive sound reducing foam that has a layer of lead 1/3rd in from one side. Foretravel used a lot of it all over and it is one of the items that set Foretravel quality apart from other manufacturers.
When the outer skin of the foam comes off it usually means the foam inside is disintegrating and it all needs to be replaced. You'll know this is the case if it crumbles away easily and leaves a mess where the crumbs fall. Recovering it would certainly seem futile to me. While you have everything apart there I wouldn't hesitate the change out the foam. It certainly falls within your capabilities of what you are already doing.
Here's a recent discussion on replacing foam (assuming I did the link correctly):
Engine Compartment insulation (http://www.foreforums.com/index.php?topic=11956.msg61317#msg61317)
The insulation seems to be in good shape with the exception of the plastic skin. I prefer to rework/recycle what I can, that preference tempered by the fact that I'll have to order and wait for the new stuff makes me inclined to try to salvage it. Not knowing the exact mechanics of the sound dampening foam I'm a bit hesitant to cover it with thin aluminum but considering this. It would make a neat, cleanable surface. Would it still dampen properly? Anyone know?
Here's a neat tidbit I learned recently from a buddy who worked on pumps on nuclear submarines-"Boomers." To quieten the sound of air movement and machine noise, reverse the direction of air flow three times. I did this with simple baffles in my house air handler return. Went from obnoxiously loud to virtually silent. No application for Foretravel but neat trick.
Chuck