Onan Field Winding Repair  
Improvised coil-winding setup
Improvised coil-winding setup
Viewed: 1420 times.

Closeup of the sensor for the counter. It senses the passing of the radiator hose clamp screw.
Closeup of the sensor for the counter. It senses the passing of the radiator hose clamp screw.
Viewed: 1148 times.

Viewed: 1035 times.

An HP universal counter in totalizer mode.
An HP universal counter in totalizer mode.
Viewed: 1084 times.

Viewed: 1075 times.

Four of these in series will add up to exactly the resistance of the original assembly.
Four of these in series will add up to exactly the resistance of the original assembly.
Viewed: 1078 times.

Modifying the assembly to accept externally-wound coils
Modifying the assembly to accept externally-wound coils
Viewed: 1084 times.

Removing the "ears" that retained the original coil.
Removing the "ears" that retained the original coil.
Viewed: 1082 times.

Viewed: 1030 times.

The welding rod serves as a stake to hold the coil down. It will insulated later.
The welding rod serves as a stake to hold the coil down. It will insulated later.
Viewed: 1149 times.

This is the specimen from which we are working. Thanks to Mike Teets for showing this to us.
This is the specimen from which we are working. Thanks to Mike Teets for showing this to us.
Viewed: 1150 times.

Our coils inserted and staked in place in preparation for a test run.
Our coils inserted and staked in place in preparation for a test run.
Viewed: 1051 times.

It is difficult to see but there are EPDM rubber spacers between the pole piece and the ID of the coil.
It is difficult to see but there are EPDM rubber spacers between the pole piece and the ID of the coil.
Viewed: 1062 times.

Making the inter-coil connections on the test assembly.
Making the inter-coil connections on the test assembly.
Viewed: 1084 times.

Viewed: 1073 times.

Viewed: 1018 times.

Viewed: 1079 times.

Checking armature clearance. And putting some lube into the very dry tail bearing
Checking armature clearance. And putting some lube into the very dry tail bearing
Viewed: 1114 times.

Viewed: 1104 times.

5kW load test. Meter scales are incorrect, the actual readings are 125 V @ 42A.
5kW load test. Meter scales are incorrect, the actual readings are 125 V @ 42A.
Viewed: 1056 times.

Test configuration. Field coil leads hanging out of the bell housing for series-wired and series-parallel test.
Test configuration. Field coil leads hanging out of the bell housing for series-wired and series-parallel test.
Viewed: 1072 times.

Test article. Ammeter on bottom shelf of table is measuring field current.
Test article. Ammeter on bottom shelf of table is measuring field current.
Viewed: 1225 times.

Coils shown in other pictures were wound externally and then placed into the field. This is another approach - winding them in place using an adapted CNC mill.
Coils shown in other pictures were wound externally and then placed into the field. This is another approach - winding them in place using an adapted CNC mill.
Viewed: 1131 times.

Viewed: 1047 times.

Viewed: 1098 times.

Rev 2 of the in-situ coil winder. Had clearance problems with previous setup; this one has a smaller diameter "snout".
Rev 2 of the in-situ coil winder. Had clearance problems with previous setup; this one has a smaller diameter "snout".
Viewed: 1130 times.

Viewed: 1103 times.

Viewed: 1091 times.

Viewed: 1169 times.

Coils coated with Glyptal and then baked. Ready for insertion into the assembly.
Coils coated with Glyptal and then baked. Ready for insertion into the assembly.
Viewed: 1175 times.

Powered by Gallery v1 RSS