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Fordson Tractors Discussion Forum

Building a generator

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Chris Vowles

01-23-2004 07:30:19




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I have a super major engine from a clayson combine .Does anyone have experience of matching it directly to an alternator?




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Bill S.

01-25-2004 21:55:57




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 Re: Building a generator in reply to Chris Vowles, 01-23-2004 07:30:19  
Do you have the electrical end already? Is it a single bearing or a two bearing unit? A great many are single bearing units delending upon the engine's flywheel and the torque plate to provile all the support. Commercial generators/alternators are usualy fitted with an SAE bolt flange but you must know the number designation as in SAE #2 or such. I'm not so sure that the Fordson engine will have an SAE spec bellhousing either. Some measurements of the flywheel and a talk with the generator dealer will determine the torque plate needed. He too should be able to reference the engine bellhousing spec. Taking diameter, # and size of bolts as well as perhaps a photo if it is not concentric will help too. I seem to recall my FSM having a bulge for the starter that carries into the bolt surface. It's too dang cold to walk out into the falling snow now to have a look. Of course everything must be aligned precisely onto a rigid subframe. The other concern is whether the governor in the FSM pump will hold the rpms steady enough thru the range of loads, low cycles can be damaging to motors. If your electrical end is the two bearing type only a torque coupling is needed and a solid subframe and as careful alignment as possible to keep stresses of the coupling and bearings. How many KW electrical end do you plan to use? I would do some web searching for engineering specs for Lima, Kato, or Marathon generation units. Some of those should have the data online. Good luck, Bill S.

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Chris Vowles

01-26-2004 08:40:29




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 Re: Re: Building a generator in reply to Bill S., 01-25-2004 21:55:57  
Thanks Bill S.My engine has has a bellhousing with pulley on already it seems I need a 2 bearing alternator and then as you say line up carefully. The engine has an unusual injection pump. It's a SIMMS (Old type,not minimec)but has a mechanical governor on the (flywheel)end of it as opposed to the vacuum setup. I am sure this will keep the revs/load in balace.Thanks again for your help



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Jonathan Blackmore

02-19-2004 02:20:49




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 Re: Re: Re: Building a generator in reply to Chris Vowles, 01-26-2004 08:40:29  
Hi
I picked up a compressor last week with what I am told is a fordson bellhousing attached to it , does any one know of this compressor. Will supply pics if you need more clues.



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Bill S.

01-26-2004 09:44:00




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 Re: Re: Re: Building a generator in reply to Chris Vowles, 01-26-2004 08:40:29  
Yes indeed Chris, much is simplified for you with those fixtures already in place. The choice now is mostly just which end to install. Interestingly, I just today got the annual Electrical Generating Systems Association buyers guide so I can reference web links and/or other contact info for most serious units manufacturers and distributors. If you want any of those just ask, I'll look them up. I would suggest going with a three phase end even if now you only have single phase loads. By splitting the circuits up you can get full output and balance the load while still having the ability to power up three phase equipment in the future. There will be a wrinkle there if you need full output and the gen set is a standby for power failure. Then you may be better off with a single phase end. If you find a bargain on a generation end that is over sized for your engine I would still use it and put a main breaker on to prevent overloading the engine. I'm guessing about 30KW is right for your engine. It would be a shame to decline an opportunity to a 40 or 60 KW end if just using the right breaker would safeguard the engine. I assume you will connet end to end and run 1800 rpm for 60 cycle power. There are some 1200 rpm ends but your KW would be reduced considerably. Elelectrical generation service for an engine is not so hard. I had a 3-71 GM running 1800 rpm run 80,000 hours before the first overhaul as a shipboard unit full time operation. I see no reason the Fordson would not perform quite well with proper care. Bill S.

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Chris Vowles

01-26-2004 13:43:43




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 Re: Re: Re: Re: Building a generator in reply to Bill S., 01-26-2004 09:44:00  
My plan was for 3 phase(to run crop drying fans on my farm)and someone also said you pick off single phases for domestic standby/emergency use.Going oversize was also on my mind.The engine has only done about 1800 hrs from new and been well looked after so I expect many thousands of hours are left in it.As I live in England we are 50 cycle and therefore the generator has to be 1500rpm. If I drive sideways on then I could gear up or down with different pulley sizes to get the ratio exactly right to match the load of the fans which could be quite heavy.It doesn't often snow here but it is forecast tomorrow. Thanks again Chris Vowles

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Bill S.

01-26-2004 18:52:48




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 Re: Re: Re: Re: Re: Building a generator in reply to Chris Vowles, 01-26-2004 13:43:43  
It sounds as if you've thought of about everything. I was unsure if you meant to pulley ratio to the gen shaft or between the motors and fans. I only mention that because I'm not fond of belt driving AC generators. Would 1500 RPM produce enough KW for your drying fans? If not then I'd consider a gear reducer inline to the generator end giving about 1 to .83 ratio thereby putting 1500 RPM into the gen while allowing 1800 at the engine. Personally I would consider a truck transmission with a mechanical gear ratio at or near .83 in an upper gear. Because the loads would be touque in, torque out, The bearings would be suited to this. The input shaft would however need support as a pilot bushing offers. I'm imagining a counterbore of the power unit output shaft permitting this function, then it's just a coupling of the spline input to the keyed shat of the power unit. I'll be interested in this project as you advance, keep us informed. Best wishes, Bill S. in USA (60 cycle territory).

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Chris Vowles

01-27-2004 03:29:28




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 Re: Re: Re: Re: Re: Re: Building a generator in reply to Bill S., 01-26-2004 18:52:48  
Hi. The fans are usually direct drive. My plan is to source poly-vee pulleys/belts(several vee belts "siamesed" together which appear from the outside to be one flat belt). I think this setup will keep the cost down and still be reliable and also easy to maintain-especially as the kit is not for continuous use.First job now is getting a radiator and the 12v system into the 21st century! Chris Vowles

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RAR/IA

01-28-2004 17:52:23




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 Re: Re: Re: Re: Re: Re: Re: Building a generator in reply to Chris Vowles, 01-27-2004 03:29:28  
Can you use the waste heat from the radiator and exhaust (via heat exchanger) to aid in drying of the crop? You mentioned fans for drying.

Roger (in Iowa USA where it was -6 degrees F this morning.)



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Chris Vowles

01-29-2004 08:11:54




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 Re: Re: Re: Re: Re: Re: Re: Re: Building a generat in reply to RAR/IA, 01-28-2004 17:52:23  
Thank you Roger. We normally use ambient air to cool or chill the grain in the autumn(fall) this works well but sometimes heat is used but the only way I can think to use the waste heat would be to have the generator shrouded to the fan intake but this would involve making the whole unit mobile or at least liftable . It's 28degrees F here (Bristol, England) that's quite cold for us . I was up in the mountains in Utah last March and the temp was 18deg F- that's about as cold as I've ever been.

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RAR/IA

01-29-2004 09:20:36




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 Re: Re: Re: Re: Re: Re: Re: Re: Re: Building a gen in reply to Chris Vowles, 01-29-2004 08:11:54  
You are right. It would have to be shrouded. Thought you might be sitting it near the grain storage area. (gets noise away from residence) Here in Southern Iowa we usually have to dry our grains, corn and soybeans, but mainly corn (maize) down to 14.5% moisture for safe storage. Harvest moisture can be in the low 20% but it is costly because of propane price. Try to let nature dry as much as possible.

I have been to Nottingham area twice, 1975 and 1976 to the John Deere facility at Langar. Traveled to the Fens and near Stonehenge and other areas. Interesting country. My ancestors came from England. Sir Thomas Russ was knighted by Queen Ann Bohlyn (sp).
e-mail at tractorrar@yahoo.com

Roger Russ

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