Yanmar Genset reassembly

dlsmith

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BX2230, LA211
Nov 15, 2018
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Goshen, IN
After I finished up building the Yanmat 3TNA72 powered generator I have been working on for 20 years, I took it all back apart and took the frame work to the local fab shop and got it powder coated Kubota ROPS gray. I picked it up yesterday and it looks great.
Today I started putting it back together, and got the generator and the engine aligned coaxially and bolted down. So sometime soon the project will finally be finished up.

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JimmyJazz

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Steiner 425
Aug 8, 2020
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Pittsburgh, Pa
After I finished up building the Yanmat 3TNA72 powered generator I have been working on for 20 years, I took it all back apart and took the frame work to the local fab shop and got it powder coated Kubota ROPS gray. I picked it up yesterday and it looks great.
Today I started putting it back together, and got the generator and the engine aligned coaxially and bolted down. So sometime soon the project will finally be finished up.

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What did it cost to have the frame powder coated? I have never had anything powder coated. Do most fab shops have the ability to powder coat?
 

GeoHorn

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M4700DT, LA1002FEL, Ferguson5-8B Compactor-Roller, 10KDumpTrailer, RTV-X900
May 18, 2018
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Texas
What is the expected output and run-time of your creation?
(and Congrats on beautiful work!)

Do you have soundproofing plans?
 

dlsmith

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BX2230, LA211
Nov 15, 2018
748
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Goshen, IN
What did it cost to have the frame powder coated? I have never had anything powder coated. Do most fab shops have the ability to powder coat?
I supplied the powder, but the blasting, coating and baking was $248.00. There were also several other pieces that were included, axle subframe rails, hitch tongue, radiator mount and some small parts.
When I had the body parts (seat pan, engine side panels and grille)from my JD430 and 47" snow blower (all parts except main auger) done, it was $162.00 and $180.00 respectively.
Also, they bake on a primer coat before the color coat, so it is very thick and durable.

I don't know about other fab shops, but this one added the powder coat shop a couple of years ago at the request of several customers who were having problems getting their parts done elsewhere. They are very busy now, as other customers have heard about their shop.
 

dlsmith

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BX2230, LA211
Nov 15, 2018
748
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Goshen, IN
What is the expected output and run-time of your creation?
(and Congrats on beautiful work!)

Do you have soundproofing plans?
The generator is a 10KW unit, so the 20hp Yanmar handles it no problem. I'm not sure about the run time on a tank of fuel, but I would guess at 50% load, and with the 14 gallons in the tank, it would be in the area of 20-30 hours.
It will be set up inside my shop to feed power to the house, and will run the exhaust out through the wall. Most of the noise from the Yanmar seems to come from the intake, and I have an air filter off the JD430 on it, which is what it came out of, but it really produces a loud drone.
Once I get it assembled and running, I'm going to try the air filter assembly off my BX on it to see if the plastic housing suppresses the drone better than the metal JD housing.
I had wanted to cover the sides with louvered panels, but haven't been able to find a source for suitable ones so far. The closest I have found are large (24" X 24") cold air return grilles, but I doubt they would tolerate the vibration very well. The search continues.
 

Tughill Tom

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B3200
Dec 23, 2013
389
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28
Turin, NY
The generator is a 10KW unit, so the 20hp Yanmar handles it no problem. I'm not sure about the run time on a tank of fuel, but I would guess at 50% load, and with the 14 gallons in the tank, it would be in the area of 20-30 hours.
It will be set up inside my shop to feed power to the house, and will run the exhaust out through the wall. Most of the noise from the Yanmar seems to come from the intake, and I have an air filter off the JD430 on it, which is what it came out of, but it really produces a loud drone.
Once I get it assembled and running, I'm going to try the air filter assembly off my BX on it to see if the plastic housing suppresses the drone better than the metal JD housing.
I had wanted to cover the sides with louvered panels, but haven't been able to find a source for suitable ones so far. The closest I have found are large (24" X 24") cold air return grilles, but I doubt they would tolerate the vibration very well. The search continues.
For A Louvered panel check with a Custom hot rod shop, a lot of them make their own.
 

dlsmith

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BX2230, LA211
Nov 15, 2018
748
215
43
Goshen, IN
In the last couple of days I got the wiring all back on and hooked up, the radiator in, the exhaust system on, fuel tank on, and the sub-frames, axle, tires and hitch installed. I'm waiting on a new air filter assembly to arrive before I finish hooking up the fuel system as it may require removing the fuel tank. I also added a radiator overflow line with clamps to fasten it to the radiator frame, and a longer fuel tank vent line with a couple of clamps to hold it where it belongs.
One other thing I need to make is a stand or jack on the hitch to hold it level when not hooked up.
I did get the axle positioned in the correct place. When it's setting level there are 30-40 lbs of weight on the hitch.

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dlsmith

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BX2230, LA211
Nov 15, 2018
748
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Goshen, IN
For A Louvered panel check with a Custom hot rod shop, a lot of them make their own.
The only one in the area that can make them is modifying the press that uses the dies to make louvers, and has no idea when it will be functional.
 

ctfjr

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L3800HST
Dec 7, 2009
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central ct
XCLNT project DL! you definitely have more patience than I do :)

How do you control the motor speed?
 

dlsmith

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BX2230, LA211
Nov 15, 2018
748
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43
Goshen, IN
XCLNT project DL! you definitely have more patience than I do :)

How do you control the motor speed?
Thanks.
The throttle is operated by a linear actuator connected to a DPDT switch that will retract the actuator to open the throttle and extend it to go back to idle. The stroke on the actuator is 2" and the throttle only takes ~1" to go to full throttle, so I had to fabricate a spring loaded link to take up the excess travel. The governor is set to 3600 rpm, and when I hooked up about 5 kw of load it kept the rpms at about 3580. I modified the spring assembly after the last picture with a guide that keeps the linkage coaxially aligned.

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dlsmith

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BX2230, LA211
Nov 15, 2018
748
215
43
Goshen, IN
Thanks, it's been quite a project.

I fabbed up a castering trailer tongue jack that plugs into the hitch receiver on the front of the genset. Bought the jack from TSC, made a matching plate out of some 1/4" plate I had, welded a piece of 2"X2" tubing to it, then blasted and painted it.
Put it together this afternoon and it works really well to roll it around where ever I want it.
I'm pondering a way to stow the tongue when it's not in use. It might work to fasten it down to the cage where it's lying under the front of the engine in the picture.
As soon as I get the new air filter assembly I can connect the fuel lines and get it running.
Once it's finished up, it's time (finally) to get started on the Nova hanging on the rotisserie in the background.

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