Isuzu engine on powertech generator exhaust problem need help

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Isuzu engine on powertech generator exhaust problem need help

May 12, 2021, 08:35:55 pm

I'm up at texhub's place in uvalde and we are trying to pull my 10 KW power tech generator with Isuzu engine to change out the end bearing and the motor mounts along with a new voltage regulator and breaker. Having issues with getting the unit out of the coach due to the exhaust pipe. The back side of the exhaust manifold has a 90° elbow that connects to the flexible exhaust that's covered in a heat shield cloth. While trying to remove one of the four exhaust bolts one of the studs broke. Everything is very Rusty back there. PB blaster was used but I didn't let it sit overnight cuz I'm in a hurry. What I'm trying to find out is how the flexible exhaust is connected to the 90°. I can't really tell for sure cuz it looks to me like it's just shoved into the 90° elbow but I can't imagine how it would have been secured that way. I'm thinking of cutting the pipe below the 90° elbow and trying to figure out how to join the two after it's out. If I can get the other nuts out once everything is out and I can work on it then I would try to do that and just replace those parts, but then I would have to get that stud drilled out and retapped and I'm not sure that I have time for that nor do I have the tools for it although there may be somebody local that could do it but then I would probably have to take the exhaust manifold off and that opens up another whole can of worms that I don't want to deal with.

So the question is how is the flexible exhaust pipe connected to the 90° is there another pipe there that I'm not seeing maybe the exhaust pipe goes over it?
I need somebody who has done this job to tell me how they did it. I just spoke to David also known as John 44 and asked him about how his went but he doesn't remember other than thinking that he just was able to get the nuts off the studs.
Thanks
Bob

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #1 – May 12, 2021, 09:12:00 pm

Pretty sure that pipe is welded to the nipple that is screwed into the elbow. That flex pipe is also some type of stainless.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #2 – May 12, 2021, 09:20:46 pm

Quote from: red tractor – May 12, 2021, 09:12:00 pm

Pretty sure that pipe is welded to the nipple that is screwed into the elbow. That flex pipe is also some type of stainless.

Thanks red tractor. So you think that the flexible pipe is welded to the nipple elbow?

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #3 – May 12, 2021, 09:26:14 pm

I was working on a 8000 kw with the Isuzu engine but it looked like yours.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #4 – May 12, 2021, 09:40:16 pm

Sorry for your troubles Bob, my exhaust was wrapped so I can't answer your question on how the flex connects to the 90 however I would suggest carefully working on the other 3 nuts and get the Genny out and evaluate from there.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #5 – May 12, 2021, 10:22:11 pm

Thanks. Found a wire brush and put it to both the nuts and the exhaust hose. I think it's welded, so will try the nuts after the PB blaster does it's work overnight.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #6 – May 12, 2021, 11:49:41 pm

All I did was pulled the generator out on the slide to change the bearing. The voltage regulator can be changed the same way
and I don't see why the motor mounts can be done with just pulling the generator out on the slides. I hope this helps.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #7 – May 13, 2021, 07:16:42 am

On my '99 with the same Isuzu generator it will only pull out enough to change the oil. Unless you disconnect the 2 fuel hoses in front, mark them so you'll know when you hook back up. With the hoses disconnected the generator will slide out further which might give you enough room to change the bearings.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #8 – May 13, 2021, 10:13:29 am

On my 99 when I went to change the bearing I realized that my 12kw generator is different than the lower kw models and it has an external exciter coil on the end. Removal looked a bit daunting and getting further past that looked impossible (there was just a bolt hole thread but no bolt in the end). If anyone has the 12kw and does this, please make a video, take pictures, etc.. Anything to help. I simply reassembled and ignored the problem for the last few years but I have the new end bearing ready to go in and I really should go after it again. I was actually with Paul Yasbeck when we attempted it and even he was a bit confused. I'd presume he's seen just about everything.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #9 – May 13, 2021, 10:31:09 am

Quote from: Mark D – May 13, 2021, 10:13:29 am

On my 99 when I went to change the bearing I realized that my 12kw generator is different than the lower kw models and it has an external exciter coil on the end. Removal looked a bit daunting and getting further past that looked impossible (there was just a bolt hole thread but no bolt in the end). If anyone has the 12kw and does this, please make a video, take pictures, etc.. Anything to help. I simply reassembled and ignored the problem for the last few years but I have the new end bearing ready to go in and I really should go after it again. I was actually with Paul Yasbeck when we attempted it and even he was a bit confused. I'd presume he's seen just about everything.

My 10K has the same exciter coil you describe. Look at the pictures and let me know if the coil looks like what you have.

How not to change voltage regulator in genset

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #10 – May 13, 2021, 10:42:27 am

Just talked to Bob,it's pulled out enough to change bearing,he will deal with the exhaust bolts later,hoping exhaust won't leak
with the one broken bolt.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #11 – May 13, 2021, 10:52:00 am

Okay so I pulled the end of the generator off and yeah I have the kind with the Exciter at the end. Getting to the bearing is going to be a little more challenging than I thought. At this point I'm not quite sure whether to proceed or not.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #12 – May 13, 2021, 10:52:54 am

I worked on a power tech generator last year and replaced that flex pipe. Called power tech and sent a new flex pipe. Power tech welds a pipe threaded nipple on each end of the flex. I just put a new elbow on that 4 bolt flange and threaded the flex pipe into the new elbow.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #13 – May 13, 2021, 10:57:30 am

Quote from: Journey, Roam, Explore – May 13, 2021, 10:52:00 am

Okay so I pulled the end of the generator off and yeah I have the kind with the Exciter at the end. Getting to the bearing is going to be a little more challenging than I thought. At this point I'm not quite sure whether to proceed or not.

Bad things happen when the bearing fails - it can take out the entire generator end $$$

Kubota electrical generation failure

(sorry that the YouTube link doesn't work anymore, but it showed that the entire thing was wobbling and parts had "destructively contacted each other")

If you have parts and you're close to the changeout interval, I would bite the bullet and do it.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #14 – May 13, 2021, 11:35:37 am

You just need to undo the wires from the exciter in the box. Mark the them so they go back the way the way they are pull them
out. Then remove the 4 allen head cap screws and pull off the exciter. The bearing is now easy to remove.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #15 – May 13, 2021, 01:52:51 pm

Here is a link to a thread from awhile ago that has a reply as to how to remove the exciter.
tech bearing replacement

Mike

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #16 – May 13, 2021, 02:09:50 pm

Quote from: oldguy – May 13, 2021, 11:35:37 am

You just need to undo the wires from the exciter in the box. Mark the them so they go back the way the way they are pull them
out. Then remove the 4 allen head cap screws and pull off the exciter. The bearing is now easy to remove.

I did remove all eight of the Allen bolts the four smaller ones in the middle and the four outer ones that are larger using the torx tip socket. Then I tried to remove or budge and it wouldn't budge. I didn't remove the two wires at that point because I wasn't sure I was going to proceed any further I just wanted to see if I could get it loose and I could not without maybe hitting it with a hammer or a mallet to loosen it up a little bit and I didn't want to do that. There was a lot of debris inside the generator and including flaking paint dirt and other tidbits. Two previous owners ago, Paul Smith used to take my coach down to Cancun in parts South regularly, so I think maybe there is some corrosion there that's holding everything together. That's when I decided at that point that it was no bueno!
I really understand about changing the end bearing so maybe I will go back out and take those four outer bolts out again and try it with the rubber mallet if I could find it. Also on the end there is a little bolt do I need to take that out? It's in the middle. Or is that part of the spindle shaft and will be exposed when I take the Exciter part off? I've already decided that I've had it with this generator and if I blow it up I'm going to remove it and use that space for an additional 600 amps of lithium batteries and increase my solar capacity from 1400 watts to 2000. That would allow me to run my air conditioners off of lithium during the day with solar and it's rare that I would use the generator all night anyway. Even though my coaches in all electric coach my 600 amp so lithium gets me several days with solar even more so doubling that capacity Plus going with a victron DC to DC charger 100 amp would give me both air conditioners running down the road off of solar and off of upgraded alternator.
Anyway I don't know if that's going to happen but at this point I'm a little bit frustrated with the whole thing.
Just a little picture to show the difference between the old breaker that power tech put in and the new one good. They're both 50 amps 240 volts but they're made by different companies. The old one was made by Eaton heinemann and it's much larger. The new one is made by Carling. I forget exactly how much right now that power tech charge me but it was well north of $100 I could have bought the same one on eBay brand new for $38. It may have been north of $200 for the power tech one. Just a little rant to make you smile.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #17 – May 13, 2021, 02:41:42 pm

Quote from: Pamela & Mike – May 13, 2021, 01:52:51 pm

Here is a link to a thread from awhile ago that has a reply as to how to remove the exciter.
tech bearing replacement

Mike

Thanks. I read that I remember thinking that if I had to re-exite the generator head, how would I know if it was a male or female generator?
I will try it again....

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #18 – May 13, 2021, 02:46:31 pm

Okay and looking at the picture again of the generator Exciter there are inter bolts that are torques and outer bolts which ones do I remove to get to the bearing? Now bear in mind LOL that I removed all eight of them and nothing budged...
So reference picture and do I take the bigger torques bolts out on the outer frame or the inner ones? Thanks

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #19 – May 13, 2021, 02:54:40 pm

Remove the nuts on the Q & R leads and move them out of the way. Make sure you mark which is which as if you put them back wrong it will let the smoke out when started. Then remove the center bolt and washer that you can see behind them. That should let the rotor portion of the exciter come off by pulling on it. Now if it is stuck on the shaft you will have to encourage it to come off.

Mike

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #20 – May 13, 2021, 02:58:06 pm

Thanks Mike but how do I get to the bearing once those wires are off?

Never mind I've read the post again and I think I got it. Thanks for the advice I'll give it a try hopefully I will not let any smoke out!

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #21 – May 13, 2021, 03:01:13 pm

Are you talking about the bolts on the wires plus the 3 that hold the exciter on?

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #22 – May 13, 2021, 03:52:09 pm

Quote from: rbark – May 13, 2021, 03:01:13 pm

Are you talking about the bolts on the wires plus the 3 that hold the exciter on?

I removed the wires and mark them I removed the center bolt and marked it. I removed the three nuts that were on the inner part. But there's six wires going to that do I remove those too? What is supposed to come off is it just a very center which is made out of a composite type material or the windings that are around it as well? I don't see how I would be able to get to the bearing by just taking the middle out.
I got a call into Jeff for tech support but don't know if I'll get a call back today or not mean while my generator sitting out there.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #23 – May 13, 2021, 04:23:11 pm

I forgot all about the center wires. The 6 wires don't need to be taken off it all comes together. I should half taken more pictures
when I did mine it would have help.

Re: Isuzu engine on powertech generator exhaust problem need help

Reply #24 – May 13, 2021, 04:48:01 pm

Quote from: oldguy – May 13, 2021, 04:23:11 pm

I forgot all about the center wires. The 6 wires don't need to be taken off it all comes together. I should half taken more pictures
when I did mine it would have help.

Old guy can you be more specific in how you got the Exciter and rectifier off? I really would appreciate it did you have to apply any pressure to it? If so how did you do that?
Still waiting on a call back from power tech I don't expect to get one today unfortunately the way things are going I might have to call him back tomorrow meanwhile the end of the generator is open to everybody that can see it I should at least put a pair of panties on it.
Thanks
Bob

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