Dewey Battery Charging Aux Power Unit - Generator Head Swap

[yertnamreg]

I got the generator head swapped on my BAPU unit. Everything went VERY smoothly! Only "fab" work needed was drilling two new holes for the rubber generator head mount. I think this video covers most of the work needed. The only things omitted were I used a 3 jaw puller to get the bushing off (there was no adhesive, thank god), and I used a vacuum bleeder to bleed the fuel system.

 

[strycnine]

What size gen head you go with?

 

[yertnamreg]

I used the 6kW model:
https://www.northerntool.com/shop/tools/product_200395478_200395478

They say you need a 13hp engine for that model, but given this is a diesel with a bit more torque than a gas equivalent I think it should be fine. The engine itself is rated for 6.8kW mechanical output.

 

[strycnine]

Sounds good. Can't wait for the sequel

 

[Light in the Dark]

Ok so with this modification, the factory gauges are rendered useless correct? Is there any way to gauge what kind of amperage is being drawn? I'd love some more info (i.e. fine detail) on this swap. Thanks

 

[yertnamreg]

Well there really aren't any factory gauges on this generator, so you're not really losing anything. The remote/local start capabilities still work fine. I literally did nothing to the wiring. Simply disconnected the wiring to the alternator and connected 28V to the same place you would normally connect the battery to be charged.

 

[Light in the Dark]

Ok then I guess I am the one confused. I thought the BAPU was the same thing as an MEP-501A (which has voltage and load gauge).

 

[yertnamreg]

They are similar, but have a few differences. The BAPU is a 3.5kW unit and uses the L100 instead of the L48 Yanmar engine. The other difference is that font panel you're thinking of. The BAPU just has a small box with a few LEDs and a Hobbs meter. It would be easy to add gauges if you wanted though.

 

[Light in the Dark]

Grabbed both BAPUs up today... look forward to doing this swap!

 

[Chainbreaker]

Grabbed both BAPUs up today... look forward to doing this swap!

Oh, so your the one who got em! I was watching those contemplating putting in a bid on 1 and forgot about them due to other priorities. When I went back they were gone. Glad they went to another SS member!

So what do you plan to use as a pwr distribution box?

If I ever purchased a BAPU I would considering taking off my Hubbel Spider box that I mounted on my MEP-002 trailer to use on a BAPU for distribution since it has some really nice features for handling 120/240.

 

[Light in the Dark]

I only wanted one... seems they are on the wrong coast for me. So I did some figuring, if I tucked the second one on the same skid, the freight went up $3... so thats why I have two!

Not sure what I want to do on power termination at this point.... got at least a week to figure it out

 

[Light in the Dark]

My new fun arrived on a skid earlier today. Care to share the bolt sizes and extended lengths chose to replace (that you called out in the video)? Thanks

 

[Light in the Dark]

For those interested, I have been able to obtain a copy of the Dewey issued commercial manual for this unit (not a gov document). See attached. One of my units came with a hard copy of it, not sure of the second. I do see at least one connecting cord for the remote unit (but I don't think the remote box is with it). Will probably have some more time to unpack and play this weekend.

 

[Light in the Dark]

After you did the head swap, were you able to put the stock alternator cover back over the new AC head?

 

[yertnamreg]

The bolts I used are M8. I think the ones I got are ~25mm, but I'm not sure off the top of my head. There's a L100V pdf brochure which has the specs for the mounting flange:
https://www.yanmar.com/media/global/2016/catalog/ln_series.pdf

The original alternator cover doesn't fit over the generator head because it is so much larger in diameter. There also wouldn't really be a convenient way to mount it.

 

[Third From Texas]

My BAPU will be here in about 10 days.

 

[Light in the Dark]

Great to hear. Whole mess went off in the last two days. If I didnt already have two, I would have been bidding (some of those units have the remote control box... which would be nice to have).

 

[Third From Texas]

Well after GP "lost" my BAPU (after 7 freight pickup attempts over three weeks and then took another 5 weeks to refund my money), I purchased (from *another* auction house) a surplus Yanmar LV100 (same engine) genset with a bad power head. It ran flawlessly and I finally got around to ordering the powerhead (Northstar 6000).

The powerhead arrived today,so it's time to tear the old one off and slap this big bastard on there.

Fingers crossed...

 

[tt2468]

Just wanted to say thanks to everyone here for all your various info. Theres nearly nothing else online and they are dumping these BAPU's off for so cheap.

 

[Third From Texas]

Just wanted to say thanks to everyone here for all your various info. Theres nearly nothing else online and they are dumping these BAPU's off for so cheap.

Well, "cheap" being subjective here (they typically fetch twice what they went for before they all ended up in CA). Used to get them all day long under $500. Now it's rare to see one sell under $800.

I had a ujoint failure during a recovery this week. That gen saved my ass. The 6kw powerhead worked flawlessly and ran our heat, hab, power tools, chargers, and lighting.





Dirty Dozen was on while awaiting parts...