Jim's Big A## Generator Project

[Jim Clark]

Like a lot of members on the forum I have more tools and surplus equipment lying around the house than most normal humans. I am a fan of all the goof shows which show some one picking through the trash and building a useful item. It is in this spirit I will attempt this project. I welcome suggestions and idea from forum members.

I have inherited a 4kw Onan Emerald Plus Generator with only 41 hours on it. This model Onan is a beast 216 lbs. 2 cly 1800 RPM. Meets National Park Standards and can be run 24/7 if necessary. This unit was and may still be the standard used in many mobile homes and is normally mounted on a slide out rack. One nice feature is it has a remote start and shutdown, I will mount a panel in the trailer.

I will have to rig a system to load this rig in my truck so suggestion on how to rig a 12 volt winch in the bed of the truck would be appreciated.

Thanks Jim



The Beast, this is no Honda. I wish it were. Cost: Free Donation





Garden Cart. Cost $70.00 Lowes Rated for 1200 Lbs."Right"




Water Proof Case. Cost $10.00 Surplus after Katrina


Broken Gen Set, Will use Distribution Panel. Engine Good Gen End bad.
Cost; $50.00 to brother-in-law.


Generator on cart. Notice gray primer I had to weld a section of angle iron to strengthen the 1200 lb capacity cart.

[zamboni]

I suppose a used "Tommy gate" would work great, or you could use an electric winch (run off the generator) to pull itself up ramps and into the back of your truck. I'd make sure to cover the flywheel though.
I removed the 4k Onan from our MH last week, (I never use it), and am considering putting it on a cart with 30amp plug...I could use it for power outages at home or put it back into the MH if going somewhere w/out power.

[Jim Clark]

Originally Posted by zamboni

I suppose a used "Tommy gate" would work great, or you could use an electric winch (run off the generator) to pull itself up ramps and into the back of your truck. I'd make sure to cover the flywheel though.
I removed the 4k Onan from our MH last week, (I never use it), and am considering putting it on a cart with 30amp plug...I could use it for power outages at home or put it back into the MH if going somewhere w/out power.

I will reinstall the flywheel cover, I had to have it off to setup the exhaust. The unit will be in the weather proof case when it is all together. I will cut the case down to the proper size.

Good tip on letting the Genset power the winch.

Thanks Jim

[overlander63]

How about one of those 12v mini cranes like they use for the (heavy) electric wheelchairs?
Mounts on the rear corner of the bumper, lifts 500 pounds.

[Jim Clark]

Originally Posted by overlander63

How about one of those 12v mini cranes like they use for the (heavy) electric wheelchairs?
Mounts on the rear corner of the bumper, lifts 500 pounds.

That also sounds like a good option. I do carry ramps in my truck bed tool box so may go with the winch. I carry a set of folding ramps for a couple of reasons, one to run one tire up on to fix a flat, and the second to get a the trailer out of a frame dragging situation.



Thanks Jim

[mistral blue]

What kind of ramps do you use for your genwagon?

[Jim Clark]

Originally Posted by mistral blue

What kind of ramps do you use for your genwagon?

I purchased a set of cheap ramps at Sam’s. Made in China, fold up and can be set at varying heights. They work very well and can be set to run the front of the truck up on to change the oil and such. I have seen the ramps at Walmart also.

Thanks Jim

PS I have not ran the cart up them yet as I have not finished the cart yet.

[overlander63]

Originally Posted by Jim Clark

PS I have not ran the cart up them yet as I have not finished the cart yet.

Looks like Lowes uses the same mathmatics to figure weight capacity as truck manufaturers do for tow ratings...
The front axle on our 1200 pound cart started bowing out after using it for a few days with an 800 pound load on it. I hope you don't have the same problem.

[doorgunner]

Chopper one to Jimbo: ready the cargo sling, pop a smoke for ident, your smoke color is..

[mistral blue]

As you might be guessing, I am interested in this project of yours. Please keep the pics coming.
Are you going to be using something to dampen the vibration between the gen and the cart?
Thanks.

[overlander63]

Originally Posted by mistral blue

Are you going to be using something to dampen the vibration between the gen and the cart?
Thanks.

From his photos, looks like he has rubber mounts on his damaged genset that he can use, if he wants to.

[Jim Clark]

Originally Posted by overlander63

Looks like Lowes uses the same mathmatics to figure weight capacity as truck manufaturers do for tow ratings...
The front axle on our 1200 pound cart started bowing out after using it for a few days with an 800 pound load on it. I hope you don't have the same problem.

I think I will come it at 300 Lbs. The genset is 213 lbs, I also have a welding machine and material to fabricate reinforcements. The cart was bought as a base, I felt by the time I fabricated a new cart with wheels it would of cost me more than starting with something cheap.

Thanks Jim

[Jim Clark]

Originally Posted by mistral blue

As you might be guessing, I am interested in this project of yours. Please keep the pics coming.
Are you going to be using something to dampen the vibration between the gen and the cart?
Thanks.

As I do work I will bump up the pictures. I am not in a hurry and working as I have time, I do have a real job. I also have a couple of other gensets if needed, which are not as nice which means very loud, but can be used if needed.

The ONAN has a 3-point rubber mount it is sitting on. One reason I used the cart with the wire mesh is the ONAN is designed to pull air across the engine using the vanes on the flywheel. I have the shroud off of the flywheel at this point so I can work with the exhaust which is on the other side of the unit. The weatherproof box will sit over the genset when completed, which is the plan at this time. I have a concept in my head and did rough measurements but no detailed drawing. I like to do fit and cut much like you see on American Chopper, Gorilla fabrication.

Thanks Jim

[HiHoAgRV]

Several years ago a co worker showed me his in-laws tow rig that had the genset mounted in the bed of the TV and the exhaust plumbed through through the floor. The remote start was mounted in the TRUCK and he towed with the Shore power hooked to the genset. 1/2 an hour before arrival at a camp, he would start the genset and the air in the camper would start the cooldown.

[Jim Clark]

Originally Posted by HiHoAgRV

Several years ago a co worker showed me his in-laws tow rig that had the genset mounted in the bed of the TV and the exhaust plumbed through through the floor. The remote start was mounted in the TRUCK and he towed with the Shore power hooked to the genset. 1/2 an hour before arrival at a camp, he would start the genset and the air in the camper would start the cooldown.

The thought occurred to me. My plan is to have the control panel moveable. The panel has the hour meter in it and I want to keep track of use. I will have the panel setup to be directly on the genset for use at my home or to operate radio gear for field day. I will also have a mount in the trailer with a pigtail to the exterior with a plug in extension from the trailer exterior to the genset to setup the panel for remote start from the trailer interior. The start sequence of the ONAN is that you press down the start side of the toggle switch, all the safeties are overridden, when the generator is up to speed a light on the center of the switch comes on and the unit is good to go with the safeties engaged.

Thanks Jim

[HiHoAgRV]

Yup, the startup is exactly like the one in a SOB class A I owned. If you do decide to remote start with any kind of load, I'd recommend a transfer switch like a class A RV's that has a timer. It will let the generator run for about 60 seconds prior to engaging the load. Available at most RV dealers

[Jim Clark]

Thanks for the heads up, I will look for one.

Jim

[Mike Lewis]

my suggestion for somthing that heavy---Rent a boat -- have friends help load into boat...row to deepest part of lake-----punch hole in center of boat---swim to shore-----pieman

[Jim Clark]

Originally Posted by Mike Lewis

my suggestion for somthing that heavy---Rent a boat -- have friends help load into boat...row to deepest part of lake-----punch hole in center of boat---swim to shore-----pieman

Mike, I like heavy and quality. I already have a boat; it is one of the few that survived Katrina because she is heavy. I have a collection of Ham Radio Gear known as boat anchors which I can’t get enough of. I know I am not right it is a sickness.







Thanks Jim