Carrier APU question

...So I'm in the backyard during my extended 'vacation', taking care of a few problems. While I was removing the oil pan and front timing cover to access the thermostat housing because the alternator mount bracket was loose, (as if things weren't involved enough already) the AC generator fell off into the oil bucket.

Yep. That 60-odd lb generator hanging at the back apparently wore through both the mounting tabs and fell off. The long bolt that it hangs from is fine. My alternatives so far seem to be:

a) have the mounting tabs welded/repaired, or
b) have the generator replaced with a new unit (i'm afraid to ask what Carrier wants for it), or
c) find an aftermarket generator, if possible.


Hence the question; does anyone know of an aftermarket 4000w single phase AC generator that would be a drop-in replacement for the current unit used by Carrier in the ComfortPro 6000? The part number on the unit is 0504122396, no manufacturer markings, no markings at all save for the Carrier pn/barcode. And you know how secretive Carrier is with their replacement parts.

I'm sure glad the thing didn't fall off while on the road.

 

it looks to be cast aluminium housings at either end of the generator. just my luck.

As for the Tripac, at the moment i have a basic Tripac; the unit will run, charge the batteries, and heat the engine. I could always put the 1500 watt inverter back under the bunk.

 

did peek at the NT link (not spam to me, just a helpful reference), but all their heads are meant to be mounted either on the motor or bolted on a base, like the Rigmaster generator head. The Carrier APU generator head looks like a large heavy arsed J-mount alternator, and is suspended from the lower frame. If i had kept the Rigmaster on the truck frame, I could bolt on one of those inexpensive NT heads and actually increase my power a bit. No such luck for me.


Took the head to a rebuilder, who just 'happened' to have end housings from a few scrapped Carrier units available. Sadly, he checked the windings before removing the ends, and discovered my windings are grounded out to the generator body. Since Carrier quoted me about $1800 for a new generator (stuff falling off is not covered by their extended warranty, apparently), i'm having the old unit rewound and the end caps/bearings replaced for about $700.

A word of warning to other Carrier ComfortPro owners; check the bolt that suspends the generator to ensure it isn't rusted into the steel mount; the only reason my generator came off is that it fell off. The mounting bolt was so badly rusted into place that it required a 30 ton press and lots of acetylene to remove its remains. Had I been able to tighten the bolt, it would've reduced vibration and prevented the wearing through of the ears on both ends. Since I couldn't move it with a wrench, i assumed everything was tight when it was actually loose enough to allow the generator to bounce itself to death.

It seems that corrosion is just as much a problem with ComfortPro as it was with the old Rigmaster. Bolts are rusting, housings are swelling and cracking (the $500 alternator is also shot), both covers and the inner frame are covered in rust (so much for the longlife powdercoating).

The adventure continues.