Would you replace this generator?

belfert · October 01, 2020, 01:47:22 PM

I have a Powertech 8CSI (enclosed 8KW) generator with serious voltage issues. Even with a brand new regulator the voltage will be 127 volts at no load and drop below 110 volts with minimal load. Would you just replace this generator, or still try to fix it? It has a Marathon pancake head with brushes.

The back story is I take my bus out on the Blackrock Playa every year (home of Burning Man). The soil is a very fine highly alkaline dust like talcum powder. The drive across the Playa generates huge clouds of dust. I used to run the generator while driving through the dust so the generator probably ate a ton of dust. I have had to replace the brushes at least once from the dust. (I no longer run the generator during the drive in.)

One suggestion I got today is that the slip rings might be dirty. I talked to Powertech support today and parts are getting scarce for this generator. No more brushes available even though Powertech could order me a new generator head for around $3,000. I still have a set of brushes as I ordered multiple sets just in case.

chessie4905 · October 01, 2020, 02:55:57 PM

IF you go for a new head, switch to brushless. But for 3 grand, I dont know, maybe get a new outfit, or maybe itll get you several hundred hours of use.

thomasinnv · October 01, 2020, 02:59:41 PM

Sounds like slip rings to me too. How about replacing the head with a brushless?

belfert · October 01, 2020, 05:28:29 PM

The generator is in a sound enclosure. A brushless generator end is too long for the enclosure. The current generator end is only about 10" long.

I talked to Marathon about a replacement head a few years ago and they said the part number was special for Powertech.

richard5933 · October 01, 2020, 05:41:51 PM

Have you talked to Wrico about a replacement head? The one I got from them was quite short and worked great. It was much smaller than the one it replaced.

belfert · October 01, 2020, 07:07:51 PM

I believe Wrico uses Mecc Alte generator heads. Mecc Alte has a head that is 11" long.

I'll contact Wrico tomorrow.

richard5933 · October 01, 2020, 07:12:45 PM

That's what we got - the 13K version and I couldn't have been happier with it.

Of course, if you're replacing the head you'll probably have to reconfigure the engine controls and auto shutdown for things like low oil pressure and high temp. I did those using Murphy Switchgauges.

Made my own panel and mounted everything to the control box that came with the new head. Worked like a champ. You can see how small the 13K head is in this photo.

chessie4905 · October 02, 2020, 03:49:36 AM

Though you had a Kohler, but maybe the one pictured was on the 4106?

richard5933 · October 02, 2020, 04:03:06 AM

Quote from: chessie4905 on October 02, 2020, 03:49:36 AM
Though you had a Kohler, but maybe the one pictured was on the 4106?

Yes and yes.

That was the generator on the 4106, and it did have a Kohler head on it prior to the transplant. The main reason I switched was mice destroyed the control box. It was basically the same generator that I have in my current bus, the 4108, which is still running the Kohler head on it.

Saying that reminds me that if the control box on the Powertech is in good condition, it might be possible to use it again to control the engine after the head transplant.

chessie4905 · October 02, 2020, 05:21:00 AM

That was my thought, but he should take the generator to a place that specializes in this work. Not all of them charge outrageous prices. To bad he doesn't live in PA. There are some Mennonite outfits that are good at that work.

richard5933 · October 02, 2020, 05:33:49 AM

When I ordered the replacement head from Wrico it arrived all set up with a flex plate adapter and ready to bolt directly to the engine. The head install was easy and it was ready to make electricity as soon as I got the engine going.

Nothing really too complicated in setting up engine controls either, if needed. The complications come from tying things to the existing setup in the coach so that the interior controls/gauges will continue to function. But, that's not that difficult either.

Anyone able to keep an old bus running can do this with a little research.

oldmansax · October 02, 2020, 06:12:22 AM

I have re-headed 3 generators with new ones from Central Georgia Generator. Good people, reasonable prices (about $1300 for a 13KW brushless head) and they back their products. Lots of people on the Wanderlodge board have used them.

TOM

belfert · October 02, 2020, 07:11:04 AM

Quote from: chessie4905 on October 02, 2020, 05:21:00 AM
That was my thought, but he should take the generator to a place that specializes in this work. Not all of them charge outrageous prices. To bad he doesn't live in PA. There are some Mennonite outfits that are good at that work.

I talked to a place yesterday about fixing the generator head. One of the issues is they want the generator removed from the bus. They also recommended a second place that could do the work. It takes a forklift to get the generator out and it is hard for me to find someone with a forklift.

I think it makes more sense to replace the generator head since I have found them for less than $2,000. I would probably still need to remove the generator to change the head.

belfert · October 02, 2020, 07:15:15 AM

Quote from: richard5933 on October 02, 2020, 04:03:06 AM
Saying that reminds me that if the control box on the Powertech is in good condition, it might be possible to use it again to control the engine after the head transplant.

I don't believe there is anything wrong with the engine controls on the Powertech. They use a small ECU to control the engine. I think the governor is mechanical, but not sure.

The engine controls might be the hardest part of the head swap if I had to redo the engine controls.

Jim Blackwood · October 02, 2020, 08:53:03 AM

Can't the slip rings be cleaned or turned? Seems like there should be enough copper there to take a light cut and restore them.

Jim