Gas to Diesel Generator conversion - Dutchmen Owners

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Old 01-19-2017, 11:21 AM   #1
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Gas to Diesel Generator conversion

Getting ramped up to remove my 5500 gasser and replace it with a 7500 Quiet Diesel unit.

That part is straight forward and easy. The more involved part will be disabling the Load Management System. I will be my own LMS as I am not at all happy with the lack of proper functioning of the LMS. Precision Circuits have been as helpful as they can be, but ultimately, Dutchmen installed it and we all know how great they are at assembling our rigs!

Any thoughts or personal experience in doing this? I will post pics as I go - this will be an ongoing project until ready to go on the first trip this spring.

That being said, there will be a 5500 Onan for sale with, I believe 378 hours on it (I will confirm).
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Old 01-19-2017, 04:38 PM   #2
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There can't be much more you could possibly do to outfit\upgrade your castle.

But this upgrade is sweeeet.
How much quieter? Night and day, or just substantial?

I haven't heard the latest quiet diesels in generators. But the latest trucks are crazy quiet standing right next to them. Eerily quiet.
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Old 01-19-2017, 04:45 PM   #3
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Not really any more quiet. I mainly want to be able to go the whole race weekend without having to lug gas cans as both tanks will be used for diesel. Plus I have a 91 gallon tank in the bed of my truck with a pump just in case. My in laws have a diesel and the sound is not really all that noticeable when you are surrounded by hundreds of generators running 24/7 at the track.

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Old 01-19-2017, 10:00 PM   #4
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Don,

I followed a thread about exchanging a gas for a diesel generator on another forum and it was mentioned that some modifications would also need to be made the fuel tank to switch it over... I can't remember exactly what was said but maybe something to check into???

Also I installed a 5500 Onan into a generator prepped toyhauler back in 2013 and can offer some advice about the hard way vs the easy way. We finally had to unscrew the bottom of the sheet metal generator box on the door side and pull it back to get the generator to fit in and the easy way to do that was to set it on the tailgate of a truck backed up to where you could use a plywood ramp to slide it off so you didn't damage the lip of the door frame.
Also before I put it in it was an easy job to line the box with Dynamat heat / soundproofing.

The reason I was following that thread was that I've considered doing the same, but I'll probably wait until my next toyhauler and order it just with the generator prep so I can install what I want.
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Old 01-19-2017, 10:03 PM   #5
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Good idea on the mat. The only mood to the fuel tank/system should be the addition of a return line. Thank you for chiming in!

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Old 01-19-2017, 10:03 PM   #6
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Good idea on the mat. The only mood to the fuel tank/system should be the addition of a return line. Thank you for chiming in!

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Mod, not mood. LOL

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Old 01-31-2017, 07:39 AM   #7
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Generator recieved

Got the diesel unit delivered last night. Used with 493 hours on it for a lot less than new. Install is going to be a long and slow process given the limited time I have, but I don't really need it until June for MIS. Will update as I go.
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Old 02-01-2017, 07:38 AM   #8
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Test run last night on the floor of the barn with a 5-gallon can of fuel and a set of jumper cables - once primed she started right up and ran great. Quieter than expected. It also throttled back from the full 3200rpm to 1600rpm after running about a minute. So the no load, throttle down works as well.
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Old 02-07-2017, 08:48 PM   #9
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Quote:
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Test run last night on the floor of the barn with a 5-gallon can of fuel and a set of jumper cables - once primed she started right up and ran great. Quieter than expected. It also throttled back from the full 3200rpm to 1600rpm after running about a minute. So the no load, throttle down works as well.


That's awesome I bet the longevity and the economy of the diesel should be outstanding... what model # and did it fit nicely with no mods?... how was it hooking up ?.. was it drain and rinse tank then plugn play?


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Old 02-07-2017, 10:09 PM   #10
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Got an Onan QD7500. My measurements show it will fit fine, but thinking I'll go from below to install it due to clearance issues thru the compartment door. Will drain what is left in the tank and let it dry. Will have to run a return line too. Planning to drop the tank as the gage has never worked

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Old 04-01-2017, 09:16 AM   #11
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Slowly getting there - over the winter months, I purchased the exhaust tailpipe adapter, wiring harness and remote panel, and an adapter harness to connect the new generator to the Magnum Remote panel. Yesterday, I removed the battery bank and the Onan 5500 generator in prep for the install. Some measuring and planning to do and once we return from Florida should actually start the install. Will be sure to get pics as I go along. The plan is to cut a hole in the generator bay floor big enough to install from below and bolt in good sized C channel to the I Beam frame on either side of the camper to hold it in place. Going thru the generator access door is just too tight a fit in my opinion with just under a half inch of clearance. Between and pallet jack and dunnage lifting the new one in place and the camper jacks to lower the rig onto the generator I feel this was the best method and also for removal in the future if ever required.
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Old 04-11-2017, 08:45 PM   #12
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Removed the generator and the enclosure...lots of room in there now! LOL. Going to shift the generator to all the way to the left. There was a gap on that side that always bothered me as wasted space and we all know how valuable space can be in our rigs...
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Old 05-04-2017, 03:13 PM   #13
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Installed a new water pump belt and put all of the housing panels back on last night. Also picked up the new steel that will be the new subframe and should start fabricating that tomorrow morning. Pics to come.
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Old 05-06-2017, 09:15 AM   #14
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After more thought and measurements, I decided not install from below. I removed the big compartment door and have plenty of clearance. I made a cardboard template to cut the necessary holes in the compartment floor. I also made a "saddle" from a 2x4 to protect the lip of the compartment frame from being damage during the install. This morning, will be welding in a heavy gusset to beef up the floor - cutting away the material to fit the new generator weakened the floor. Hoping to slide the QD into the compartment today.
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Old 05-06-2017, 04:31 PM   #15
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I also made a "saddle" from a 2x4 to protect the lip of the compartment frame from being damage during the install.
I like that idea. I'm going to steal it for when I load in my heavy toolbox in the pass through area.
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Old 05-06-2017, 05:09 PM   #16
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I like that idea. I'm going to steal it for when I load in my heavy toolbox in the pass through area.


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Old 05-07-2017, 10:08 AM   #17
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Got the generator in the compartment yesterday by sliding it across a set of ramps from the bed of the truck into the compartment. Ran new diesel rated fuel lines and wire for the second "pusher" fuel pump. Have to get long battery cables made as the terminals on this generator are on the opposite side of where they were on the gasser.
Had to weld in a subframe or gusset once I cut away the metal floor to fit the holes in the bottom of this generator. It really strengthened it up. This will end up being my mounting point for the JT Strongarm stabilizers I have yet to install.
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Old 05-07-2017, 10:16 AM   #18
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More pics.

Once I have the new battery cables installed, I will take the generator off the blocks you see it on and slide to the right to bolt it to the floor. The blocks were used to keep the rear of the generator from dropping into the compartment when sliding it in and having the top front hit the compartment door frame.
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Old 05-11-2017, 03:59 PM   #19
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Got it bolted in place yesterday and the fit is great - the factory exhaust pipe lined up perfectly with the flange in the QD7500. Got the "pusher" fuel pump installed and connected back by the tanks. I will be wiring it up and welding in another 3" C-Channel gusset between the frame rails at the rear of the generator as I just don't trust the Dutchmen tack weld job holding the sheet steel in place. I have one hole in the floor to cover up as I shifted this unit further to the left side. Makes more room on the right for storage and on the OE install there was a bunch of what I consider wasted storage space to the left of the generator enclosure when the gasser was in there - others may call it a black hole - drop some things in there and you couldn't easily reach in there to retrieve them.


Lastly will be fabricating a new enclosure for it in the coming weeks.
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Old 05-12-2017, 05:58 PM   #20
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She's in and running! Just have to wire up the remote panel and paint everything up underneath

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