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I own a Coleman 7kw generator. It came with a few features that made it attractive to me. First is a filtered, pressurized oil system, second, a fuel pump and finally an electric starter. Otherwise it's a conventional air cooled small gasoline powered generator. The oil system is a plus for long engine life and the fuel pump makes it practical to draw fuel from an external tank without relying on gravity. I've modified the generator with a fuel trap bowl and a transfer valve so fuel can be taken from either the on board  5 gallon tank or an external 30 gallon tank. The external tank is on wheels and can be located up to 20 feet from the generator. The trap bowl will catch any water and sediment before it can go upstream to the fuel filter. I replaced the built in muffler with an adapter to standard 2 inch exhaust plumbing. A length of 2 inch flex pipe connects to a conventional auto muffler for quieter running. It also is part of the solution to keeping the machine cool while it runs in an outdoor enclosure since the muffler will be outside the building. I added a metal baffle to keep hot cylinder cooling air from blowing over the generator. A couple of over-sized wheels makes moving the generator a lot easier.

 

Four lengths of 2x2 insert into the white pvc pipes and support a plywood "table top" over the generator during field day - just in case of rain. The V twin is smooth running and has good transient load response.

 

A pressurized, filtered oil system is a real plus. The exhaust is just the other side of the sheet metal from the filter. I made the baffles from ordinary galvanized flashing. It keeps the radiant exhaust heat off the tire and filter.

 

I added this baffle to keep the very hot cooling air coming off the cylinders from blowing over the generator.

 

The exhaust adapter. That's the 1" exhaust header on the left. On the right it exits at 2". A length of flex exhaust pipe slides over the large end of the adapter and clamps on.

 

The fuel filter is plumbed to the pump on the left. I tested the pump by running the engine from a small container of gas at ground level. This required the pump to draw gas from 18" below.

 

This is the fuel transfer panel. The trap bowl is at the left. The transfer valve selects either the top 5 gallon tank or any external source connected to the nipple under the valve. The trap bowl plumbs in after the selector valve so it's in line for any gas source.

 

The fuel plumbing behind the transfer panel. The stop valve for the top tank is at the top of the picture. The line coming at you from the trap bowl leads to the fuel filter.

 

How it all fits together.

 

 

Electric start makes cranking this puppy a breeze.

 

 

The business end. Sufficient electrons for almost anything!

 

 

Last Edited: 05 Dec 2005
By: Mike Murphy, WA4BPJ
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