Z482 direct-drive build

[Henry W]

If your going to run one of these engines using pulleys I would recommend running between 2800-3000 rpm. Peak torque curve is around 2600 and it is best to be past the peak a couple hundred rpm on those engines.

[ArcticCogen]

This would be a great engine for a belt drive setup!  My original plan for this one was to build a 300A battery charger with a Balmar controller and a pair of 150A Zena alternators (same as the single Zena I have on the Listeroid).  Fortunately (or unfortunately?) my "off-grid" system turned into a "grid-backup" system and the second charger was not needed.  After tripping over this engine for two years I decided to just build a direct-drive genset and sell it off as a standby package.  I try to do a little bit of work on it every day so hoping to have it done here in a couple of weeks.

[ArcticCogen]

Wired up the control panel and mounted it today.  I always talk about doing a thorough testing BEFORE I ty-wrap everything but (as usual) I wanted to make it look pretty more than I wanted to double-check everything.  Nothing too complicated in there so I'm pretty sure it will all work as designed.  If not, ty-wraps are easy enough to cut off.

AC

[Carlb]

Looking good.

[ArcticCogen]

Getting closer.  Engine wiring and exhaust system are done, save for a 1-1/2" muffler clamp that no one in town seems to have.
Hoses and AC breaker stuff should be here this week but at the rate I'm going (very slowly) I won't have first smoke until the end of the month! 

Does anyone have any thoughts on what size of battery to use?  I was going to use a Cat 8C-3636 but apparently they are only available in the USA.  Lots of local choices here with batteries for ATVs and such but not sure now on how small I can go.  Most of the locally available batteries in this size are Yuasa.

AC

[ArcticCogen]

I found the answer to my own question about batteries.  Apparently the Yuasa web site has a battery selection chart that includes "Japanese Tractor/Generator" and Kubota T1600 in their vehicle list.  The T1600 mower uses a Z482 so their recommended 35aH battery 40B19L(S) should be the way to go.

http://www.yuasabatteries.com/battery.php?bID=I4&vID=5060

[ArcticCogen]

Well, I finally got around to installing the last few parts and doing the testing.  The simulated run testing of the automatic controls went pretty good but I found out the hard way that you can NOT share a wire between the two CTs feeding the volt/amp meters.  The meters both flashed on for a second and then went away, never to return.  I ordered two more meters on eBay and replaced the 6-conductor metering cable with a 7 (actually 8 ) conductor cable like I should have used in the first place (but didn't have handy when I wanted to wire up the meters ). 

I had been planning to route the injector return line back into the fuel filter but decided not to do that at the last minute.  Good call there as it took lots of priming to get all the air out and the return line is a full-flow deal, not "just a few drips once in a while" like on the Listeroid. 

I didn't use a run/idle solenoid so the throttle is held open with a spring.  The governor works well, only +/- 1 Hz from 0 to 66% load.

Fuel burn at 2/3 load was almost exactly 2 litres per hour.  I imagine this might improve slightly as the engine breaks in but it seems like this is in the right ballpark for this load.

[veggie]

Arctic,

That's a beautiful unit you built.
Nice job !
Thanks for the video.

What rubber isolators did you use under the engine mounts ?
Did you use isolators under the generator also ? Hard to tell in the video but it looks like the alternator is solid mounted.


Veggie

[ArcticCogen]

I got the isolators through Amazon http://www.amazon.ca/dp/B00MM01140
There's four under the engine and one more under the genhead right at the back.

Any progress on yours yet?  I had to learn a ton about these engines to build this one and ended up sourcing parts from all over.  If you need any info I'd be happy to help.

Cheers
John

[veggie]

Arctic,

I'm still in the design phase.
I sometimes stay in this phase for too long...overthinking things 

Thanks for the link. I ordered some of those isolators for my unit.

veggie

[ArcticCogen]

Arctic,

I'm still in the design phase.
I sometimes stay in this phase for too long...overthinking things 

Thanks for the link. I ordered some of those isolators for my unit.

veggie

Yeah, I know what that's like.  This one was in the "design phase" for 4 years AFTER I decided not build it as a battery charger...