Onan Field Winding Repair  
Improvised coil-winding setup
Improvised coil-winding setup
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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.
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An HP universal counter in totalizer mode.
An HP universal counter in totalizer mode.
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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.
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Modifying the assembly to accept externally-wound coils
Modifying the assembly to accept externally-wound coils
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Removing the "ears" that retained the original coil.
Removing the "ears" that retained the original coil.
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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.
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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.
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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.
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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.
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Making the inter-coil connections on the test assembly.
Making the inter-coil connections on the test assembly.
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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
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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.
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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.
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Test article. Ammeter on bottom shelf of table is measuring field current.
Test article. Ammeter on bottom shelf of table is measuring field current.
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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.
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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".
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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.
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