Gen set redux MAZ method

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Gen set redux MAZ method

April 12, 2017, 04:12:42 pm

I had been waiting on doing this until I got home again in a few weeks but we are going to make a quick turn for the Maritimes so...enter Old Town. We are in NAC for other work until next week. Why not get it finished.

I had read about the issues with gen set radiators in the 97 270s and decided to get this done using a modified MAZ method found on Beam-alarm.

Today we pulled the set to begin the separation process. It reminded me of bad dental hygiene. Steph and I are removing the old insulation and replacing while it's out. The tray and mechanism will be going out for sandblasting and powder coating. Replacing the fuel pump, radiator hose and motor mounts. Other than coolant I had already done all fluids and filters. Old Town is doing the frame work, repairing bolt retainers, welding and motor mounts. Let me know if you would add to this list...thanks!

Re: Gen set redux MAZ method

Reply #1 – April 12, 2017, 04:33:44 pm

Looks very familiar to me.

Mark

Re: Gen set redux MAZ method

Reply #2 – April 12, 2017, 05:07:55 pm

Mark that was a great post you made and the description/directions were very easy to follow. Having a full range of tools is making it much faster.

Re: Gen set redux MAZ method

Reply #3 – April 12, 2017, 07:39:51 pm

Quote from: George and Steph – April 12, 2017, 05:07:55 pm

Mark that was a great post you made and the description/directions were very easy to follow.

Original post and content is here for those interested Generator Insulation and general restoration

Re: Gen set redux MAZ method

Reply #4 – April 12, 2017, 08:27:00 pm

Here is the other post as well.
Generator Radiator Modification

Mark

Re: Gen set redux MAZ method

Reply #5 – April 12, 2017, 10:58:59 pm

Quote from: George and Steph – April 12, 2017, 04:12:42 pm

Let me know if you would add to this list...thanks!

May be a good time to replace the generator fuel lines if you haven't already done that?

Should be a great looking bay when you are done!

Chris

Re: Gen set redux MAZ method

Reply #6 – April 14, 2017, 06:58:21 pm

The old insulation came out today. Two part insulation with backing in the middle. Backing and top foam pulled right out. Second layer of foam is on with adhesive so a putty knife easily removed it but left a lot of adhesive behind. Picked up some goof off spray on but ended up painting it on. Removed nicely.

Not sure what is behind the panel on the right so left it for now. Have a joyous Easter.

Re: Gen set redux MAZ method

Reply #7 – April 14, 2017, 11:14:51 pm

Quote from: George and Steph – April 14, 2017, 06:58:21 pm

Not sure what is behind the panel on the right so left it for now. Have a joyous Easter.

George,
That panel you refer to is just a panel to protect the insulation from the exhaust pipe heat. The pipe pushes up against it when the genset is racked in. You can remove it and put new insulation in, then just reinstall it over the insulation.

Mark

Re: Gen set redux MAZ method

Reply #8 – April 15, 2017, 06:13:58 am

Mark that explains a lot. The exhaust had been in full contact with the insulation to the right and had burned/melted it. Three inches over from the panel. Good thing the old insulation was resistant.

Re: Gen set redux MAZ method

Reply #9 – April 17, 2017, 07:03:47 pm

We have finished the genset and it is ready to go back in the bay. The Soundown insulation will not go back in until Wednesday evening. Glad I found the Goof Off because it removed the adhesive that was a real pain in the.

I did not end up powder coating the tray as planned but after sandblasting it was shot with spray paint.

Waynes engineering resulted in a different approach with the strap and also a bit different with the base of the detached radiator. He came to Old Town from FOT and is a great addition to the service options available at Old Town. I am placing a few of the before and after pictures of the tray etc. The amount of rust between the insulation and side of the tray was surprising. Water is trapped between the foam and the side of the tray and the rust is pretty extensive. Sandblasting resulted in a pock marked finish.

We replaced the fuel pump and the radiator hoses and belt. I had done fluids and valve previously. I have the whole set documented if you desire to do this project however it is very nicely explained on the previously cited links and this is pretty much a redo of those. I originally planned to do this one but was very fortunate to team up with this vendor.

Re: Gen set redux MAZ method

Reply #10 – April 17, 2017, 07:24:30 pm

George, nice job! Looks great!
John M.

Re: Gen set redux MAZ method

Reply #11 – April 17, 2017, 10:51:14 pm

George,
In the first picture it shows the mount where you cut it. It looks as though the radiator has been raised higher than the old position. Do you still have the proper clearance for the fan inside the shroud ?

Mark

Re: Gen set redux MAZ method

Reply #12 – April 18, 2017, 08:59:54 am

Good eye Mark,

We removed one of the small mounts and that brings it level.

Re: Gen set redux MAZ method

Reply #13 – April 18, 2017, 10:55:53 am

George,can you get us info on that stabilizer bar,looks like they used a engine mount on top,would probably help with vibration.

Re: Gen set redux MAZ method

Reply #14 – April 18, 2017, 11:08:05 am

Quote from: John44 – April 18, 2017, 10:55:53 am

George,can you get us info on that stabilizer bar,looks like they used a engine mount on top,would probably help with vibration.

George,
From the experience with my mod the radiator being separated from the engine isolated any vibration to the radiator. The only connection now is the hoses and they don't really transmit any vibration to the radiator.

Mark

Re: Gen set redux MAZ method

Reply #15 – April 18, 2017, 12:25:49 pm

Mark that was attached with an extra mount we had and allowed us to extend out a bit. The bar is a repurposed control arm from an ATV.

Re: Gen set redux MAZ method

Reply #16 – April 18, 2017, 12:32:32 pm

George.
Was there anything done to the generator it's self, as far as bearings or general service stuff. I've heard of a major service on the gen at 1000 hours that included replacing bearings or something.

We are at 1400 hrs and may be overdue for this service.

Re: Gen set redux MAZ method

Reply #17 – April 18, 2017, 02:48:02 pm

Quote from: John44 – April 18, 2017, 10:55:53 am

George,can you get us info on that stabilizer bar,looks like they used a engine mount on top,would probably help with vibration.

Agree with MAZ about there being basically no vibration transmitted to the radiator assembly once it is separated from the engine frame. I used a piece of all-thread for the third support when I modified mine.

Re: Gen set redux MAZ method

Reply #18 – April 18, 2017, 04:48:32 pm

Bob I am not aware of the bearing maintenance. I will check the manual again and drop you a PM. I did belt, fuel pump, hoses, valve lash, all filters and fluids.

Re: Gen set redux MAZ method

Reply #19 – April 21, 2017, 08:14:47 am

Bob,

I haven't heard back from Powertech on the maintenance of the bearing. I have received PMs from other forum members stating the maintenance recommendation at 1000 hours. Because of other commitments and not being able to wait for parts I will do this one in Florida. Here is a link to Barry's post on this process for our 8s. I am very fortunate that Barry and I have the same coach.

Important to check generator brushes... & have a good Phoenix generator shop.

Re: Gen set redux MAZ method

Reply #20 – April 22, 2017, 11:39:19 pm

With the help of our friends, Michelle and Lee Troupe we finished the interior of the bay. Soundown requires spray adhesive and we felt the overhead surface needed hangers as well. Redoing the bay by removing the old and its adhesive is a slow and tedious process. As we finished removing the adhesive, I realized we probably could have used a 3M wheel like is used in removing decals and had it finished in an hour or so instead of seemingly endless process we used.

We used a kit from Jamestown Distributors https://www.jamestowndistributors.com/userportal/product.do?process=checkout&part=109513 if you use this kit you will need two additional cans of adhesive, a roll of Mylar tape instead of what's in the kit and every piece of material.

To set the top panel, we constructed a jig. Originally we were going to use a board, a 2x4, and a bottle jack to hold the insulation in place with pressure while it finished bonding, 30 minutes, BUT then realized that would fold over the hangers. Being engineering geniuses, we drilled holes to mark the pattern on the sheet metal. Then screwed the hanger bases in. Well the large drill holes in the board were not the solution we thought they might be when we did a dry run. It bent some of the hangers. Ok now we decided bigger holes were the answer and cut them with a hole saw...thanks Wayne for the loan. The dry run worked. The sides were fine with the bonded adhesive. Enter the sewing mavin Michelle who cut the remanants and fit the and finished the taping.

I personally would not attempt this insulation installation without pulling the generator. The engine compartment isn't as bad and we will contain it not replace it.

Re: Gen set redux MAZ method

Reply #21 – April 22, 2017, 11:48:58 pm

Looks like a nice mod that is well done.

I attacked the vibration phenomena, but I decided against the re-work because the cost benefit isn't there for me. One reason being I don't put that many hours on the generator. Another being, once I replaced the broken smaller mounts, relocated the over-flow coolant bottle to a different location (the extra weight increased movement of the radiator), and slightly increased the RPM of the generator to about 62HZ no load, the vibration reduced noticeably.

If I fail a radiator, then I'll address the issue. But strong chance it will last fine.

Re: Gen set redux MAZ method

Reply #22 – April 22, 2017, 11:49:34 pm

We finished up putting it all back together. Wayne's skill is obvious on the genset and I am more than pleased with the final outcome. He will be an excellent addition to a growing business. OTMs labor was a bit over a coach buck not including the send out for sandblasting and painting. I did not powder coat the tray. Thanks to Mark (MAZ), Robert (rhsinhld), Barry (Beam-alarm)and others for their posts of how they finished their projects.

Re: Gen set redux MAZ method

Reply #23 – April 23, 2017, 12:28:28 am

Krush, we expect to put a lot of running miles on the genset this summer with AC an no dash AC and considering the radiator cost, ordering etc. the cost at OTM was reasonable. Really did not want to go down that road. Mark sums it up with his description of a lost season pretty well. With the air intake up against the powdering insulation it was the right time to suck it up and just do it for us. The tougher part was the reconditioning of the bay.

Re: Gen set redux MAZ method

Reply #24 – April 23, 2017, 12:02:29 pm

Glad you are pleased with the end result. It looks very nice.

Mark

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