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Onan 2LK (experimental model) Has Come to Life!


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  #21  
Old 12-10-2017, 05:52:06 PM
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Default Re: Onan 2LK (experimental model) has come to life!

Quote:
Originally Posted by Kevin K View Post
--- snip ---

Measure the compression on your LK. The standard head gives you 100 to 110 PSI. The high compression head gives you about 135PSI.
I just did a compression check on a cold motor and came up with 105 p.s.i. See picture below.. That falls exactly mid range for the standard head.

JohnnyC
New Jersey
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Old 12-10-2017, 06:14:12 PM
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Default Re: Onan 2LK (experimental model) has come to life!

johnnyc, for what it's worth, my 2.5LK has 90 psi of compression dry and cold outside
and 115 psi of compression "wet" with several good "squirts" of wd-40 (what i had handy).
it has at least 900 hours on it, i haven't bothered yet to check what cylinder head it has.
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  #23  
Old 12-11-2017, 08:04:47 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Winter is here in New Jersey. We had 2" of snow Saturday night and more expected later this week. Temps will dip well below freezing on Wednesday and Thursday with a wind chill factor as low as 9 degrees. What does this all mean as for this 2LK project? It means I got to move my azz and get things moving because it will be too cold to work outside.

After work today in near total darkness I gunked and washed down the 2LK. It was not too oily to start with, but now it is cleaner and easier to work with. The first picture below shows 3 sides of the 2LK after a quick gunking. The oil pan base was the dirtiest, but cleaned up well. I was totally amazed that this 2LK started and ran without a single hiccup after a brutal power washing. After letting the 2LK run for about 10 minutes to dry it off, I drained the oil. This 2LK runs strong and extremely reliable. For most people, they would be done and have it ready for their next power outage. For me, I am now ready to take it apart.

After gunking and power washing, I was delighted to see some of the cheap rattle can spray paint coating removed from the oil base and the original green color peek through as seen in the second picture.

Questions:

Question #1 - Look at where the red arrows point to in the third picture below. Is that bent tubing or cradle an option for this 2LK? Under the cheap green paint, the original Onan green paint can bee seen although not in this picture. I believe it is Onan, but not sure if the 2LK had this available as an option. If the 2LKs came with the cradle, I will keep it.

Question #2 - Look at the forth picture. You will see a gas tank mounted on top of the 2LK. I seriously doubt this is original for the 2LK, but I can't verify since I can't find the appropriate manuals on the manual website. The tank in the picture fits perfectly on top of the 2LK, but it is not original I may remove it. Anyone know for sure?


So, what's my next step? Well, I already verified it runs extremely well other than a bad mechanical fuel pump and most people would not go any further, but I will now rip it completely apart, do any and all maintenance required, and paint it. As usual, I will post updates and pictures as I progress. I will also be asking questions too.

JohnnyC
New Jersey
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  #24  
Old 12-11-2017, 08:19:47 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Show us the dual point set-up.
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Old 12-11-2017, 08:24:29 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

C14 Is the option for a Day Tank. Your build sheet makes no mention of it but that doesn't mean it wasn't added later. Maybe look in the parts manual and see if it shows a similar tank.

Page 30 of 930-0221 Parts manual makes mention of the tank. No picture. It says it is a 1 quart tank but from the picture I would guess that is more like 1 gallon?
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Old 12-11-2017, 09:22:59 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Quote:
Originally Posted by Motorhead View Post
Show us the dual point set-up.
Here it is in the picture below. Duel points, a.k.a. flicker points (????) and 2 condensers.

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New Jersey
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  #27  
Old 12-11-2017, 10:07:32 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Quote:
Originally Posted by MBB View Post
C14 Is the option for a Day Tank. Your build sheet makes no mention of it but that doesn't mean it wasn't added later. Maybe look in the parts manual and see if it shows a similar tank.

Page 30 of 930-0221 Parts manual makes mention of the tank. No picture. It says it is a 1 quart tank but from the picture I would guess that is more like 1 gallon?
The tank is equivalent to 1/2 gallon plastic milk bottle or very close to it, but not close to 1 gallon. The tank mounting bracket fits perfectly on top of the 2LK. Maybe there was a larger tank option not listed in the manual? Or for a different spec?

As for the cradle, I see it in the 930-0221 parts manual. It is an optional carrying frame kit along with ground strap. Since it is confirmed that the carrying frame kit is OEM original for my 2LK, it stays.

I would like to see a picture(s) of any LK (2LK or 2.5LK) with the optional day tank and would like to know if larger tanks were available, but may not have been listed in the parts manual.

As you can see, I always like to know the history of anything I restore.

JohnnyC
New Jersey
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Old 12-11-2017, 11:14:59 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

the frame looks original.. although i have never seen one, but looks Ike a older briggs or tecumseh gen carriage as well... and the gas tank looks to be a briggs tank especially the petcock.. but who knows..

the old saying... if it aint broke dont fix it.. if it works for you use it.. if not, make your own to suit your needs.

the outlet box should have a autotype light bulb and glass cover on it as well.. my 1972 pull start only onan cck has one
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  #29  
Old 12-12-2017, 07:02:27 AM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Quote:
Originally Posted by JohnnyC View Post
Here it is in the picture below. Duel points, a.k.a. flicker points (????) and 2 condensers.

JohnnyC
New Jersey
Johnnyc , are both points connected to the ignition? As far as I know “flicker points” are connected into the Ac output on the generator and have no connection to the ignition. That is how my 1.0 aj is set up. 1 set of points under the flywheel for ignition and 1 set of points on the side of the block that are the flicker points. I don’t know how lk’s are usually set up (ie had points in 2 separate places) but I wonder if your dual point setup was a way to simplify the points arrangement on this model? Those little 1 cylinder 1800rpm units sure are nice to listen to!
Steve
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Old 12-12-2017, 09:42:15 AM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

I think the spec A and B LKs have the fat dual-points box, with one set being flicker and one for ignition.. Spec C and D LKs still have fat box, but only one set is used for ignition..

Those two wires that leave your points box - if they both go to a switch to select which set is connected to the spark coil, then its dual ignition points.. If one wire goes to the battery-spark coil (under the blower housing) and one wire to a flicker resistor - then it's a normal spec A/B LK setup.

Think "experimental" for testing.. most Onan fuel tanks I've seen on portables were square-ish... Original or not, I would get rid of that one - too small and definitely not a good location, at least for me.. The only LK I have with a fuel tank is a portable on a dolly, no fuel pump, not electric start. Photos of a spec B standby unit, and a spec E portable, as-found. Yours is a strange hybrid.
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  #31  
Old 12-12-2017, 07:30:45 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Quote:
Originally Posted by reid070 View Post
Johnnyc , are both points connected to the ignition? As far as I know “flicker points” are connected into the Ac output on the generator and have no connection to the ignition. That is how my 1.0 aj is set up. 1 set of points under the flywheel for ignition and 1 set of points on the side of the block that are the flicker points. I don’t know how lk’s are usually set up (ie had points in 2 separate places) but I wonder if your dual point setup was a way to simplify the points arrangement on this model? Those little 1 cylinder 1800rpm units sure are nice to listen to!
Steve
I haven't taken apart the LK yet to see how the points are connected. If I have spare time on Wednesday after work I may start tearing it down and will post what I find.

JohnnyC
New Jersey
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  #32  
Old 12-12-2017, 07:42:20 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Quote:
Originally Posted by gnucklehead View Post
I think the spec A and B LKs have the fat dual-points box, with one set being flicker and one for ignition.. Spec C and D LKs still have fat box, but only one set is used for ignition..

Those two wires that leave your points box - if they both go to a switch to select which set is connected to the spark coil, then its dual ignition points.. If one wire goes to the battery-spark coil (under the blower housing) and one wire to a flicker resistor - then it's a normal spec A/B LK setup.

Think "experimental" for testing.. most Onan fuel tanks I've seen on portables were square-ish... Original or not, I would get rid of that one - too small and definitely not a good location, at least for me.. The only LK I have with a fuel tank is a portable on a dolly, no fuel pump, not electric start. Photos of a spec B standby unit, and a spec E portable, as-found. Yours is a strange hybrid.
I looked closely at the fuel tank and noticed paint to match the original Onan color under the cheap paint job (see first picture below), but it looks as if someone painted the tank dark blue over the OEM color then the light green over the blue. The tank's mounting bracket and hardware seems to fit the width of the top of the control box perfectly as seen in the second picture.

Without doubt Onan did make cylinder type tanks because I have an identical tank on an Onan 105AK that came from a fire truck as seen in the third picture and has its OEM Onan green paint on the tank and genset. The forth picture shows the mounting bracket for the cylindrical tank which seems very unique for the Onan 105AK.

Well, if time permits I will start tearing down the LK on Wednesday after work and maybe I'll have an answer for the duel point system. As of now, I did not do squat to the LK other than bypass the faulty fuel pump and gave it a bath. It runs like a charm, but like all my other gensets I'll tear it apart.

JohnnyC
New Jersey
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  #33  
Old 12-13-2017, 12:17:46 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

It's a tough call to keep original or improve it.. I'm confused as to why they didn't offset the tank on the LK to avoid fuel fill-up spillage on the control box

Add: And I wonder how it ended up in New Jersey !

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  #34  
Old 12-13-2017, 01:35:08 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

I can answer how it got to New Jersey. I hauled it to New Jersey from Pennsylvania. I don't know if it started its life in Pennsylvania. As for the gas tank, I'm not sure if it added on sometime during its life or came from the factory.

JohnnyC
New Jersey
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Old 12-13-2017, 09:08:57 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Wednesday Status:

I had a great therapy session tonight ripping apart the 2LK. Lots of pictures to show, but I can only post 4 pictures per posting so this evening there will be several postings with lots of pictures and explanations.

To start with, there was discussion about the gas tank. I believe that the tank is made by Onan, but I am almost 99.99% sure it did not come out of the factory with the tank mounted on the control box cover. After removing the cover I found metal fatigue cracks in the cover around 2 of the tank's mounting bracket bolts. The cracks go all the way through the sheet metal. I show the underside of the control box cover and point out the metal fatigue cracks too. The tank will be eliminated and when I refurbish the cover I will weld the cracks and grind the welds to blend into the sheet metal.


JohnnyC
New Jersey
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Old 12-13-2017, 09:34:28 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

..... continuation from my last posting.

Tonight was the first time I closely examined the inside of the control box. I know many folks here say don't fix it if it runs, but I found a potentially big problem inside the control box that could have caused a fire, a battery explosion, or a huge firework display at minimum. Check out the first picture below. In the first picture I point out a cut wire, 2 wires that were replaced in the past or a possible wiring modification (I will have to check the schematics). In addition, look at the battery cable that I labeled DANGER. It shows bare copper wire that extends through the sheet metal rubber grommet. That grommet is old and dried up and is starting to crack. Guess what will happen if the genset is running and the grommet failed due to vibration and the cable bare wire rubbing on it . This has to be corrected.

The second picture shows the dual points. I was asked to trace the wires. I did, but forgot where they went. I will need to review the approx. 500 pictures that I snapped tonight to figure it out (to be continued).

I removed the bell end tin to expose the brushes and slip rings. All seems to look good but I have a QUESTION - Judging by the brush in its holder as seen in the picture would you think there is plenty of life left? These brushes and holders are different than the newer NH, CCK, BFA genset types that I know how to measure and determine how much life is left on a brush.

The forth picture shows on example of bent sheet metal on one of the tins. All of the tins have minor dents that can easily be fixed. I just wanted to show one example here.

JohnnyC
New Jersey
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Old 12-13-2017, 09:48:52 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

... continuation of pictures of the teardown.

So, I stopped at the point you see in the 2nd, 3rd, and 4th pictures below. I filled a box with parts as seen in the first picture. I will be going further on the teardown soon. I want to remove the head and the oil base

FYI - Mr. Onanparts.com, I hope you have gaskets for the 2LK motor in stock. I am not sure if the 2.5LK motor uses different head gaskets and oil base gaskets. I will have to look at my parts manual as this is the first day I really tore into this genset.

Oh, I almost forgot to mention - After I finished tearing apart the 2LK I though I'd have a little fun and try to fire up my 2.5AJ. I had it firing on starting fluid last week, but it would not run being fed directly with gasoline through the mechanical fuel pump. I spent 5 minutes and dropped the carburetor's float bowl, very quickly sprayed it down internally with carburetor cleaner, ensured that the float needle was operating properly, slapped it together, gravity fed the carburetor bypassing the mechanical fuel pump and the results were ......... (check out the video below)

https://www.youtube.com/watch?v=GKY5...ature=youtu.be


JohnnyC
New Jersey
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  #38  
Old 12-14-2017, 12:20:57 AM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Johnny, The brush has Y E A R S left on it. I saw somewhere on one of the older Onan repair books that when the wear hits the "ONAN" stamping on the brush that that is the max wear limit. How about welding some 1" to 1.5" wide by 3/32" to 1/8" thick strap steel on the underside of the plate where the tank bracket holes have cracked the sheet metal.
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Old 12-15-2017, 12:00:00 AM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Quote:
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Johnny, The brush has Y E A R S left on it. I saw somewhere on one of the older Onan repair books that when the wear hits the "ONAN" stamping on the brush that that is the max wear limit. How about welding some 1" to 1.5" wide by 3/32" to 1/8" thick strap steel on the underside of the plate where the tank bracket holes have cracked the sheet metal.
Thanks for the info on the brushes. I thought they did not look too worn. I will look further into it later. As for the control box cover, I am eliminating the tank. The cracks can easily be welded. As for the bolt holes (4) where the bracket was mounted, I will weld a plate on the underside of the cover and fill the holes before painting. The metal cover is a little bent at the edges and will need some work too, but that is unrelated to the tank mounts.

It should be a fun indoor winter project. BTW: currently 22F @11pm in North Jersey

JohnnyC
New Jersey
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Old 12-15-2017, 09:51:06 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Friday Status Update:

Well, I really wanted to continue working on the LK after work today, but temps are in the very low 20's and we had an inch of snow. The first picture below shows a light snow covering over the entire parking area at my house.

My intent was to give the LK another bath now that I removed all the tins, carburetor, fuel pump and other things as you seen in my last post. I bought some brushes and other crap at the dollar store today as seen in the second picture below, but with temps in the low 20's the water would freeze very quickly and would not be too effective. We may get temps above freezing over the weekend and hopefully I can give the LK it's last bath before I rip off its head and oil base.

So, since it is very cold and snowy outside I decided to stay indoors and start looking through the parts catalog and select all the gaskets needed as seen in the third picture below. Once I go through the parts catalog several times and mark what I need, I will place an order with onanparts.com.

Since it is so nice and cozy indoors and while drinking a pot of coffee, I decided to take a break from browsing the parts catalog and kicked back for a few minutes as seen in the fourth picture below (the feet in that picture don't smell. I took a bath sometime last week).

JohnnyC
New Jersey
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Last edited by JohnnyC; 12-15-2017 at 10:08:17 PM.
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