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Topic: Generator Modifications- Radiator and Primary Fuel Filtration (Read 652 times) previous topic - next topic

Generator Modifications- Radiator and Primary Fuel Filtration

I would like to give a huge thanks to MAZ (Mark) for the wonderfully detailed post he had here-

Generator Radiator Modification

since I don't think there is any way I would have had the cojones to chop off the engine frame supports for the radiator if he hadn't done it first. 

I had some unistrut parts lying around so my installation is a little bit different but with the same ideas that Mark had. 

Rather than reusing the chopped off radiator frame which had some really mangled radiator mounting holes that someone before me must have tried to enlarge and/or move, I scrapped it.  I used 2 unistrut base mounts

Morris Products 17450 Post Base Single Channel, 2 Hole, Standard, 3-1/2"

with 2 90 degree brackets attached to it.  These are extremely common building materials if you are an electrician, plumber, or HVAC tradesman and are available at Home Depot or supply houses.

Amazon.com: Genuine Unistrut P1325-EG 4 Hole 90 Degree Angle Connector for All

Depending on where you drill your base holes you will need to make adjustments with unistrut square washers to get the fan shroud centered on the fan.  Rather than trying to reuse the 16 year old hardened rubber radiator isolators, I modified a couple of soft neoprene expansion plugs from the hardware store for vibration absorption and the radiator sits directly on top of them with a screw coming up from the bottom of the 90 bracket. 

On the radiator air intake side, I used 2 pieces of all thread with a coupling between them to make the essential supportive 3rd leg and the coupling in the middle allows me to take everything apart quickly, if needed. 

I replaced my Cummins primary fuel filtration setup and had the old filter base leftover so I decided to use it as a primary fuel filter on the generator since my FT only had the on engine filter when I bought it.  It mounted perfectly to the 2x2 steel frame member right next to the generator with a u-bolt similar to this one (this is not the right size so don't use this part).  This primary fuel filter can be seen as the red Baldwin filter on the outside left of the generator enclosure.

Amazon.com : Sq U-Bolt 1/2x3-1/16x3-13/16 (Threaddia.Count: 1/2-13

I wanted to add that at 1100 hours on the generator, the valves were all much tighter than the 0.020 specs called for in the manual.  This is quite easy to do on the Isuzu generators and is supposed to be done every 1000 hours.  Maybe your results will be different but based on how out of spec mine were, I'll probably be checking every 500 hours.



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Robert
Build # 5304
1998 34' U270 Cummins 6CTA8.3

Re: Generator Modifications- Radiator and Primary Fuel Filtration

Reply #1
Robert I am glad it worked out well for you. Does it vibrate much less now? It made a huge difference in ours. And I don't have to deal with anymore radiator leaks either. Good job.

Mark
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Mark and Tanya
Milton , Florida
US Navy Veteran (DV)
1999 U270 Special 40' CAI , 2015 Jeep Wrangler Sahara

Re: Generator Modifications- Radiator and Primary Fuel Filtration

Reply #2
Robert I am glad it worked out well for you. Does it vibrate much less now? It made a huge difference in ours. And I don't have to deal with anymore radiator leaks either.

Mark

I guess I forgot to mention the results of the modification. :))  Yes, the vibration is not an issue at all now.  I didn't think that the Isuzu engine would run this smoothly. 

However, I do still have a trickle leak that comes and goes due to poor manufacturing of the bottom radiator elbow.  The leak only occurs at startup/shutdown when the engine has a large lunge and the leak stops (with a little help from Bar's) once the engine is running.  Liberal use of JB Weld has mostly closed it up but I can't get it to truly go away.  It is just a few drops now at startup and I can easily live with it.  I had the radiator replaced about 100 hours ago and I'm not paying for another this soon.  If/when I do replace the radiator, I'll probably not use the Powertech unit for it and just buy a universal radiator from Summit since I would guess that they are constructed better and just make any modifications necessary to fit it in there.

I'm removing the injectors on the generator and the Cummins tomorrow for testing at a local shop on Monday and that will be it for maintenance this year.  Next year will be the replacement of the insulation and some painting and *fingers crossed* nothing but basic maintenance for awhile ;) but I think we all know how that works out. 
Robert
Build # 5304
1998 34' U270 Cummins 6CTA8.3