4106 Diesel Generator Install....

OneLapper · July 25, 2013, 02:01:57 PM

Normally I use a single "beer" as a unit of time measurement. To the disgrace of all the beer drinkers in busnut land, this entire project did not include any beer at all. Sorry. This was a serious thrash to get AC running while going over the road.

That disclaimer being disclosed, I removed the gas generator and purchased a used and slightly smokey Westerbeke BT8.0 diesel genset from a boat owner that replaced the unit while repowering his boat. The engine runs great but it smokes just a little. I kept the heat exchanger in place and plan to use it to heat the bus and hot water when the genset is running. I stripped the OTR condenser bay and installed the supports for the generator.

I welded the frame to the supports that I installed.

I installed the radiator in the bay behind the left front wheel, cutting a hole in the floor behind the mud flap (very important) and in the front axle bulkhead. The mudflap creates a low pressure area and works extremely well to pull the hot air out while driving. I don't have a picture of the shroud between the front bulkhead and the radiator but that's essential as well to prevent hot air from being pulled around the fan back into the radiator.

I used four small air suspension bellows to isolate vibrations.

Generator going in....

All the connections terminate on the leading edge, creating a tight packaging issue. Turns out the exhaust isn't very hot. The water cooled exhaust manifold take care of most of that heat evidently.

Lots of exhaust bits and pieces

Super generator helper brings over the final piece

I used 1.5" exhaust piping to a 2" muffler. I have the complete sound shield that will enclose the entire generator. It won't be whisper quiet, but it's much quieter inside the bus and there's nearly zero vibration. YouTube video to follow when I get those posted....

Nearly finished install.

TedCalvert · July 25, 2013, 08:33:55 PM

Very nice.

scanzel · July 26, 2013, 05:24:08 AM

Looks great, nice install. I am hoping to do mine this fall. Working on the main electrical right now.

TomC · July 26, 2013, 09:05:21 AM

Looks good. But the big question is, how noisy is it for your neighbor? There's no such thing as a too quiet generator. Good Luck, TomC

Don4107 · July 26, 2013, 09:17:06 AM

The first thing I would do when you get it completed is put the max load on it and work it hard. Bet that will clear up the smoke.

Nice install and great pix.

Good luck
Don

Lin · July 26, 2013, 10:57:13 AM

If you didn't already do it, put some mesh over the hole in the floor to keep rodents out.

OneLapper · July 26, 2013, 01:29:18 PM

Quote from: TomC on July 26, 2013, 09:05:21 AM
Looks good. But the big question is, how noisy is it for your neighbor? There's no such thing as a too quiet generator. Good Luck, TomC

I don't really know yet. I haven't installed the last two sound enclosure sides yet. Right now with the open mesh panel and the exposed engine, I don't think my neighbors would like me at all!! I should have the install finished this weekend. We used the gen OTR for AC. You could hear it at all over the bus engine.

OneLapper · July 26, 2013, 01:33:09 PM

Quote from: Don4107 on July 26, 2013, 09:17:06 AM
The first thing I would do when you get it completed is put the max load on it and work it hard. Bet that will clear up the smoke.

Nice install and great pix.

Good luck
Don

Don, I agree. I doubt the PO put much of a load on this unit. Diesels don't like light loads. Even with my setup Ill need to add some electric heaters and run the AC to get to 8kw!

OneLapper · July 26, 2013, 01:45:42 PM

Quote from: Lin on July 26, 2013, 10:57:13 AM
If you didn't already do it, put some mesh over the hole in the floor to keep rodents out.

Done!