Foretravel Motorhome Forums => Foretravel Renovations => Topic started by: Bill and Marsha on July 31, 2020, 09:15:22 pm
Title: Generator Box Reconditioned
Post by: Bill and Marsha on July 31, 2020, 09:15:22 pm
My generator box insulation was failing horribly, the deterioration was to the point I told the DW no more trips until it is repaired, guess what just became priority #1. My plan was to completely remove the generator, thank goodness for a tractor with a forklift attachment, remove the old insulation and use a self adhesive thermal acoustical product of some sort. I chose Design Engineering 050130 Boom Mat Under-Hood Thermal Acoustic Lining, 32" x 54" x .75" It took 3 sheets. Amazon.com: Design Engineering 050130 Boom Mat Under-Hood Thermal Acoustic... (https://www.amazon.com/gp/product/B0055VTOBA/ref=ppx_yo_dt_b_asin_title_o03_s00?ie=UTF8&psc=1)
I called and spoke to the technical department about this use and what they recommended for taping the seems and edges , they suggested their cool tape or their Reflect-A-Cool Heat Reflective Adhesive Backed Sheets, 36" x 48" which I chose to go with so I would have more flexibility in sizing. Amazon.com: Design Engineering 010412 Reflect-A-Cool Heat Reflective... (https://www.amazon.com/gp/product/B000E267J2/ref=ppx_yo_dt_b_asin_title_o03_s01?ie=UTF8&psc=1)
While I had the 10KW Powertech Isuzu generator out I replaced the following parts: From Diesel Parts Direct, thermostat Part number 1Z8971606540, thermostat gasket part number 1Z8943259561 From Amazon, waterpump belt Gates 7335 Amazon.com: Gates- 7335 Belt: Automotive (https://www.amazon.com/gp/product/B000C2WIQU/ref=ppx_yo_dt_b_asin_title_o03_s02?ie=UTF8&psc=1) From Power Tech, 4ea motor mounts part number 09MNTRED, Radiator Cap part number 03CR271
In addition I had the generator slide and frame powder coated and changed the Isuzu coolant. Disclaimer: I chose the insulating product based solely on reviews of various web sources and since I just installed it I can't speak to the longevity or performance at this time. I will say it was very easy to work with and once the adhesive contacted the metal it was stuck.
Title: Re: Generator Box Reconditioned
Post by: folivier on July 31, 2020, 09:38:22 pm
Nice job! Mine was done by the PO. Do you notice a reduction in noise? I find mine is fairly loud and would like to find a way to cut the noise. Not a problem while driving but noisy when parked.
Title: Re: Generator Box Reconditioned
Post by: Bill and Marsha on July 31, 2020, 10:05:19 pm
Do you notice a reduction in noise? I find mine is fairly loud and would like to find a way to cut the noise. Not a problem while driving but noisy when parked.
I didn't think there was any reduction. The original stuff was pretty heavy duty, I was amazed of the weight of the old stuff. I ran the genny 5hrs today to make sure the coolant system was free of air and full, still pretty loud inside however the coach was raised and had safety stands sitting on the rails if that mattered.
Title: Re: Generator Box Reconditioned
Post by: jor on July 31, 2020, 10:38:54 pm
That thing looks sweet, Bill. Great job on the detail stuff. jor
Title: Re: Generator Box Reconditioned
Post by: Jan & Richard on August 01, 2020, 12:36:43 am
Bill,
Beautiful (and thorough) job. I have the same coach, only 32 coaches younger on the assembly line. I recently tore out the old failing insulation and replaced it with new. I did not remove the generator and clean the compartment up as nicely as you did or replace the motor mounts.
I noticed two things from your pictures. First, I see you have a blank plate on the front of the electronics box. I assume all the guts were moved over to the first bay on the driver side. Are the two big (45 or 50 amp) circuit breakers over there as well? Secondly, I notice that, like me, you did not replace the overhead light. Did you remove the 12 volt power wire and if so, how far back up under the coach did you go?
Richard
Title: Re: Generator Box Reconditioned
Post by: dsd on August 01, 2020, 01:03:29 am
When I was removing the carpet yesterday Foretravel had also installed thin soundproofing under the carpet for the drivers area. It was decomposing and I removed. My generator has the box but the soundproofing in it was also decomposing. I pulled it out last month. Bill you need to take a break finding more stuff for me to do. Nice job on your by the way. Scott
Title: Re: Generator Box Reconditioned
Post by: Bill and Marsha on August 01, 2020, 08:08:44 am
Beautiful (and thorough) job. I have the same coach, only 32 coaches younger on the assembly line. I recently tore out the old failing insulation and replaced it with new. I did not remove the generator and clean the compartment up as nicely as you did or replace the motor mounts.
I noticed two things from your pictures. First, I see you have a blank plate on the front of the electronics box. I assume all the guts were moved over to the first bay on the driver side. Are the two big (45 or 50 amp) circuit breakers over there as well? Secondly, I notice that, like me, you did not replace the overhead light. Did you remove the 12 volt power wire and if so, how far back up under the coach did you go?
Richard
Thanks Richard! Yes the electrical box had been modified by a PO, it contains the large breaker, voltage regulator and what appeared to be a reset button, I'm not sure what it does. The blank plate is actually mounted on a box with a air vent in the side. The 12 volt wire is still there, I plan to install a LED strip light in the near future.
Title: Re: Generator Box Reconditioned
Post by: Sven and Kristi on August 01, 2020, 09:56:43 am
Good job. Tractors come in handy (I used mine to remove radiator), but I as able to disassemble the cabinet when I replaced the insulation a few years ago.
Title: Re: Generator Box Reconditioned
Post by: Journey, Roam, Explore on August 01, 2020, 10:31:20 am
Great job. On the to do list this winter in Texas. Had my Generator fault yesterday, due to high temp I believe. Can't believe they didn't put in any gauges on these expensive items. Would be nice to monitor them from the coach. I have a big roll of Sound down Marine insulation in my bay waiting to go into the genny and engine compartment soon. How much did it cost you to have the slide powder coated?I also need some welding done to the drivers side part that locks it in place.
Title: Re: Generator Box Reconditioned
Post by: Pierce & Gaylie Stewart on August 01, 2020, 10:44:03 am
Come on, you just took a photo of a new unit as it was being built. Can't fool all of us!
Really nice job. Bet it took a while. +++++
Pierce
Title: Re: Generator Box Reconditioned
Post by: John44 on August 01, 2020, 11:28:48 am
Don't forget,if you have the generator out,nows the time to change the end bearing,not that hard a job.
Title: Re: Generator Box Reconditioned
Post by: John Morales on August 01, 2020, 11:54:07 am
Bill & Marsha, Nice Job! A lot of work, but worth it. We did our generator a few years ago when we replaced the pancake (generator head). We also powder coated the tray in black. Now for the engine area. The goal is to make it fire proof as much as possible. John & Carmen
Title: Re: Generator Box Reconditioned
Post by: Bill and Marsha on August 01, 2020, 12:14:07 pm
Bill & Marsha, Nice Job! A lot of work, but worth it. We did our generator a few years ago when we replaced the pancake (generator head). We also powder coated the tray in black. Now for the engine area. The goal is to make it fire proof as much as possible. John & Carmen
Looks good John, I almost went with black as well! My engine bay needs redone as well, haven't decide on the product to use, fire proof is good also want to reduce heat to the bedroom.
Title: Re: Generator Box Reconditioned
Post by: Bill and Marsha on August 01, 2020, 12:18:46 pm
Don't forget,if you have the generator out,nows the time to change the end bearing,not that hard a job.
Well I didn't forget however I didn't do it either, guess I didn't do enough research on all the items to square away when having the genny out.
Title: Re: Generator Box Reconditioned
Post by: TulsaTrent on August 01, 2020, 12:41:09 pm
Bill,
After seeing your pristine motor mounts, I have mount envy!
I have a quiet box and replaced all the insulation without removing the generator. Any chance of replacing the motor mounts without removing the generator? I think I might be able to get to the front ones; would that help?
Thanks,
Trent
Title: Re: Generator Box Reconditioned
Post by: John Morales on August 01, 2020, 01:21:39 pm
I paid $150 also for sandblasting and powder coating. John M.
Title: Re: Generator Box Reconditioned
Post by: Jan & Richard on August 01, 2020, 01:51:16 pm
One further question Bill. Did you have to replace any of the bearings in the roll-out tray?
Title: Re: Generator Box Reconditioned
Post by: Bill and Marsha on August 01, 2020, 02:16:02 pm
One further question Bill. Did you have to replace any of the bearings in the roll-out tray?
I did not, cleaned them up really well and lubricated the best I could, they were really in pretty good shape once cleaned, they aren't used that much.
Title: Re: Generator Box Reconditioned
Post by: Bill and Marsha on August 01, 2020, 02:28:42 pm
After seeing your pristine motor mounts, I have mount envy!
I have a quiet box and replaced all the insulation without removing the generator. Any chance of replacing the motor mounts without removing the generator? I think I might be able to get to the front ones; would that help?
Thanks,
Trent, I'm not sure about your set up, my mounts have a 2 1/2" bolt through the center that sticks up through the generator feet an inch or two, the genny would need to be lifted to clear the bolt. Does your genny have excess vibration or have visible defects, if not I'm not sure I would go through the trouble and expense to replace.
Title: Re: Generator Box Reconditioned
Post by: TulsaTrent on August 01, 2020, 08:31:41 pm
Does your genny have excess vibration or have visible defects,
Bill,
I replaced the insulation because of the total failure of the OEM insulation. I removed the quiet box panels and installed 1" of the Sounddown sound barrier with two layers of foam sandwiching a hard vinyl barrier.
My DW is still complaining about the noise from the generator, so I am going to try to add 2" of the Sounddown on the outside of the quiet box (where it will fit). This will make it about as quiet as I can make it, although new engine mounts would probably help with the vibration sound.
Trent
Title: Re: Generator Box Reconditioned
Post by: Caflashbob on August 01, 2020, 09:21:03 pm
Our non in box gen is fairly noticeable outside. Minor hum inside.
Title: Re: Generator Box Reconditioned
Post by: Lt403 on August 01, 2020, 10:36:50 pm
Great job Bill & Marha! Looks brand new.
Title: Re: Generator Box Reconditioned
Post by: John44 on August 02, 2020, 06:00:45 am
Cleaned and soaked the tray bearings in oil,good as new.
Title: Re: Generator Box Reconditioned
Post by: OSIN on August 03, 2020, 11:35:39 pm
100% Sweet - Nice COVID Project!
Title: Re: Generator Box Reconditioned
Post by: Realmccoy on August 05, 2020, 04:16:51 pm
Nice job Bill! I wish I had powder coated mine, it would've save me some time. Very nice and clean job.
Title: Re: Generator Box Reconditioned
Post by: Bill and Marsha on August 28, 2020, 09:35:43 pm
UPDATE: The sound seems to be about the same, no better for sure. There was significant increase in vibration inside the coach, I talked with Jeff at Power Tech, he stated there were not any torque specs for the mounting bolts just snug, he didn't have any suggestions on what else to check. I messed around with different torque values of the mounting bolts, adjusted the little rubber bumpers but couldn't eliminate the vibration. I decided to put the original mounts back on, after cleaning them up I could find no visible damage so replacing them was probably a waste of money to begin with. Old mounts in, no noticeable vibration, back to good!! I guess the durometer of the new mounts was to stiff for my liking, maybe they would have broken in over time however I wanted my Foretravel smoothness back immediately. Power Tech did authorize the return of the mounts, currently awaiting the refund.
Title: Re: Generator Box Reconditioned
Post by: oldguy on August 28, 2020, 10:22:30 pm
Nice job. I did mine a few months ago.
Title: Re: Generator Box Reconditioned
Post by: John Morales on August 30, 2020, 09:29:59 pm
UPDATE: The sound seems to be about the same, no better for sure. There was significant increase in vibration inside the coach, I talked with Jeff at Power Tech, he stated there were not any torque specs for the mounting bolts just snug, he didn't have any suggestions on what else to check. I messed around with different torque values of the mounting bolts, adjusted the little rubber bumpers but couldn't eliminate the vibration. I decided to put the original mounts back on, after cleaning them up I could find no visible damage so replacing them was probably a waste of money to begin with. Old mounts in, no noticeable vibration, back to good!! I guess the durometer of the new mounts was to stiff for my liking, maybe they would have broken in over time however I wanted my Foretravel smoothness back immediately. Power Tech did authorize the return of the mounts, currently awaiting the refund.
I kept the old mounts in mine also. They looked fine so we reused them. No vibration. John M.