sewerzuk
Member
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- 18
- Location
- Seaside, OR
So...
I purchased an -002A a few months back from Fort Lewis. It had taken a tumble at some point in its life and was pretty banged up, but for $180 I figured it would be good for spare parts for some other -002's and -003's that I own. It was missing the voltage regulator and a few other small parts, but after some tinkering I managed to get the engine running. I figured I might be able to use the engine for something...
I have this hydraulic log splitter that my grandfather built years ago; it worked fine, but it had an antique gas engine that occasionally required extra attention; after sitting, it required a shot of ether, a battery charge, points filed, etc. to get it running. So, I WAS planning on buying a newer engine to replace it with. My spare -002A engine got me wondering if I could make it work...
One long weekend and the project is finished...so far it works great.
Here's how I went about doing it:
I stripped off the old wiring harness and set it aside, then lifted the control box and fuel filter assembly off. I pulled the fuel tank off, and then lifted the engine and generator off of the skid. I separated the generator from the engine and then took a look at what I had spread out on the floor.
I took the rotor out of the generator; I set it in my band saw and cut the flywheel side off of it. It was about 2.5" in diameter, so I chucked it up in the lathe and turned it down to a little less than 1.5", to fit the hydraulic pump adapter. I pressed the adapter on and then welded it into place.
I sat the engine on the splitter chassis and then bolted up the pump, and shimmed up the engine mounts in order to line up the crankshaft with the hydraulic pump shaft. Then I made a mount for the flywheel side of the engine (I had to remove 1 pair of motor mounts from the generator head, so the motor needed another mount to keep it from rocking back and forth).
Once the motor was bolted down, I made up a bracket to hold the factory fuel strainer and one filter, and I bolted down the fuel tank.
I made up a battery tray and holddown out of some 1" stainless flat bar and bolted in a couple of group 51 batteries.
I took the wiring harness and cut off all of the plugs and wiring associated with the generator, and plugged in all of the engine control plugs. Then I got to work on the control box...
The cover of the control box is conveniently separated into engine and generator sides, but the rest of the wiring and components aren't as segregated. I thought about putting the entire box on the splitter, but the thought of a bunch of unused meters and switches didn't appeal to me. So, I broke out the saw and basically cut the generator section out of the box, and then TIG welded the box back together. I spent about 6 hours with a schematic, and pulled out all of the unnecessary wiring and components, and consolidated all of the connections to one terminal board. About 50 zip ties and a few ring terminals, and it was all back together. And, amazingly, it worked on the first try. I left the oil pressure and temperature safety features installed...basically, the engine operates the same was it did when it was part of the generator set. I made up a simple bracket to bolt the box to the splitter, and then bolted the throttle cable to the side of the box.
An hour or two with a body hammer and a couple of dollies took most of the major dents out of the tins, and a can of black paint covered all of the bare metal.
An air filter assembly from a skid steer filters the intake air.
Overall, the swap went pretty fast...probably 20 hours of my time. I only had to buy the batteries; the rest of the parts and materials were sitting around my shop. So far, the engine seems to work excellent in this application. I was worried that the loss of all of the mass in the rotor might cause the engine to "hunt" when it wasn't under load, but so far it seems perfect.
Here's a link to a video of the splitter in operation:
[media]http://www.youtube.com/watch?v=2ND56kvOrbk[/media]
I purchased an -002A a few months back from Fort Lewis. It had taken a tumble at some point in its life and was pretty banged up, but for $180 I figured it would be good for spare parts for some other -002's and -003's that I own. It was missing the voltage regulator and a few other small parts, but after some tinkering I managed to get the engine running. I figured I might be able to use the engine for something...
I have this hydraulic log splitter that my grandfather built years ago; it worked fine, but it had an antique gas engine that occasionally required extra attention; after sitting, it required a shot of ether, a battery charge, points filed, etc. to get it running. So, I WAS planning on buying a newer engine to replace it with. My spare -002A engine got me wondering if I could make it work...
One long weekend and the project is finished...so far it works great.
Here's how I went about doing it:
I stripped off the old wiring harness and set it aside, then lifted the control box and fuel filter assembly off. I pulled the fuel tank off, and then lifted the engine and generator off of the skid. I separated the generator from the engine and then took a look at what I had spread out on the floor.
I took the rotor out of the generator; I set it in my band saw and cut the flywheel side off of it. It was about 2.5" in diameter, so I chucked it up in the lathe and turned it down to a little less than 1.5", to fit the hydraulic pump adapter. I pressed the adapter on and then welded it into place.
I sat the engine on the splitter chassis and then bolted up the pump, and shimmed up the engine mounts in order to line up the crankshaft with the hydraulic pump shaft. Then I made a mount for the flywheel side of the engine (I had to remove 1 pair of motor mounts from the generator head, so the motor needed another mount to keep it from rocking back and forth).
Once the motor was bolted down, I made up a bracket to hold the factory fuel strainer and one filter, and I bolted down the fuel tank.
I made up a battery tray and holddown out of some 1" stainless flat bar and bolted in a couple of group 51 batteries.
I took the wiring harness and cut off all of the plugs and wiring associated with the generator, and plugged in all of the engine control plugs. Then I got to work on the control box...
The cover of the control box is conveniently separated into engine and generator sides, but the rest of the wiring and components aren't as segregated. I thought about putting the entire box on the splitter, but the thought of a bunch of unused meters and switches didn't appeal to me. So, I broke out the saw and basically cut the generator section out of the box, and then TIG welded the box back together. I spent about 6 hours with a schematic, and pulled out all of the unnecessary wiring and components, and consolidated all of the connections to one terminal board. About 50 zip ties and a few ring terminals, and it was all back together. And, amazingly, it worked on the first try. I left the oil pressure and temperature safety features installed...basically, the engine operates the same was it did when it was part of the generator set. I made up a simple bracket to bolt the box to the splitter, and then bolted the throttle cable to the side of the box.
An hour or two with a body hammer and a couple of dollies took most of the major dents out of the tins, and a can of black paint covered all of the bare metal.
An air filter assembly from a skid steer filters the intake air.
Overall, the swap went pretty fast...probably 20 hours of my time. I only had to buy the batteries; the rest of the parts and materials were sitting around my shop. So far, the engine seems to work excellent in this application. I was worried that the loss of all of the mass in the rotor might cause the engine to "hunt" when it wasn't under load, but so far it seems perfect.
Here's a link to a video of the splitter in operation:
[media]http://www.youtube.com/watch?v=2ND56kvOrbk[/media]
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