Field Service
Air Filter Upgrade on Reach Stacker Generator Set
The generator air filter was too small for the extremely dusty conditions the Reach Stacker was running in. This meant our team had to constantly blow the air filter out. During the dry season, it could be necessary to do this 2-3 times a day, which was not a very cost-effective solution for our customer.
First things first – we needed to inquire as to whether the manufacturer offered upgrade kits for extreme conditions. Without a timely response, our Bulk technician went into problem-solving mode. He was confident he could inexpensively build a customized assembly that could possibly fix the problem permanently. And then he proved it.
After purchasing the appropriate filter assembly and mounting bracket, it was found to be too large to fit inside the enclosure. To remedy that, it was mounted on the top and adjusted so that the 90-degree elbow from the inlet tube would land in between the generator and the engine on the top cover. The Bulk technician then had a double-sized bulkhead connector made, with hose beads and a mounting flange. After this, it was off to the auto parts store for some heavy rubber hose. Finding one with a couple of different bends allowed him to cut it to fit the way he needed it to.
A hole was cut into the top of the generator cover and holes were drilled to accommodate the mounting of the adapter bulkhead. After that, both ends of the hose were attached at the bulkhead connector to see how it would lay out if it were cut in different places. It was then removed, put on the engine side, and both ends were tried. The hose was cut in half, leaving enough straight at each end to have a jumper pipe made and every end was mounted with hose clamps.
He was confident he could inexpensively build a customized assembly that could possibly fix the problem permanently. And then he proved it.
Once fully assembled and operational, the benefits gained from replacing the previously existing air filter with the customized air filter assembly design include:
Cutting down the need to blow out the air filter to once a week maximized the generator’s function and the Bulk team’s time.
Engineering a unique solution to reduce the amount of hours being spent tending to the ineffective air filter ultimately provides long-term cost savings.
