Home » Public Forums » GMCnet » [GMCnet] Onan Field-assy repair: success
| [GMCnet] Onan Field-assy repair: success [message #217658] |
Sat, 10 August 2013 12:20  |
Jim Miller
Messages: 501
Registered: March 2008
Karma: 10
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Senior Member |
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As many of you know (or have experienced!) the Onan field-coil assemblies seem to be failing at an increasing rate over the past couple of years. Here at the "Miller Compound" we have spent a couple months working on various ways to repair and improve these assemblies.
As of today we have been successful at:
1) re-winding the assembly using copper wire which is mechanically stronger and also has an improved insulation coating compared to the OEM's varnished aluminum
2) keeping the re-wound assembly within the OEM electrical specs so that the original reactor/bridge excitation system can be used
3) eliminating the reactor/bridge excitation system and replacing it with an electronic regulator that has both under/over-voltage and under/over-frequency protection as well as tighter command of output voltage.
I have posted pictures of our project at:
http://www.jcmco.com/gallery/onanfieldassyrepair
We would like to thank all of those in the GMC community who have assisted us in this project.
--Jim Miller
1977 Eleganza II
1977 Royale
Hamilton, OH
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Jim Miller
1977 Eleganza II
1977 Royale
Hamilton, OH
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| Re: [GMCnet] Onan Field-assy repair: success [message #217669 is a reply to message #217658] |
Sat, 10 August 2013 13:43  |
Mike Teets
Messages: 299
Registered: January 2004
Location: Dublin, OH
Karma: 0
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Nice work Jim! That is an impressive accomplishment.
On Sat, Aug 10, 2013 at 1:20 PM, Jim Miller <gmcnet@jcmco.com> wrote:
> As many of you know (or have experienced!) the Onan field-coil assemblies
> seem to be failing at an increasing rate over the past couple of years.
> Here at the "Miller Compound" we have spent a couple months working on
> various ways to repair and improve these assemblies.
>
> As of today we have been successful at:
>
> 1) re-winding the assembly using copper wire which is mechanically
> stronger and also has an improved insulation coating compared to the OEM's
> varnished aluminum
>
> 2) keeping the re-wound assembly within the OEM electrical specs so that
> the original reactor/bridge excitation system can be used
>
> 3) eliminating the reactor/bridge excitation system and replacing it with
> an electronic regulator that has both under/over-voltage and
> under/over-frequency protection as well as tighter command of output
> voltage.
>
> I have posted pictures of our project at:
>
> http://www.jcmco.com/gallery/onanfieldassyrepair
>
> We would like to thank all of those in the GMC community who have assisted
> us in this project.
>
> --Jim Miller
> 1977 Eleganza II
> 1977 Royale
> Hamilton, OH
>
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://temp.gmcnet.org/cgi-bin/mailman/listinfo/gmclist
>
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Mike, GMCing since 2002
77 Palm Beach, 260, 403
Dublin, OH
http://teamteets.com/gmc/
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| Re: [GMCnet] Onan Field-assy repair: success [message #217701 is a reply to message #217699] |
Sat, 10 August 2013 20:49 |
Ron77
Messages: 91
Registered: August 2012
Karma: 0
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Sorry to hijack a thread, but I am working with an ipad and can't figure any other way. I am at Bonneville and the GMC motorhome ran and got a top speed of 108 and change. I don't know if that's a record, but it's a very good average. Looks good too, it's all good!!!
Ron Johnson
On Aug 10, 2013, at 7:19 PM, Dan Gregg <gregg_dan@hotmail.com> wrote:
>
>
> Stick Miller wrote on Sat, 10 August 2013 15:10
>> From one Miller to another, I stand in awe.
>
> Stick, those two Miller men in Ohio are something when it comes to stuff like this.
> Dan
> --
> Dan & Teri Gregg
> Dexter, Mo.
>
> http://danandteri.blogspot.com/
>
>
>
>
> _______________________________________________
> GMCnet mailing list
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| Re: [GMCnet] Onan Field-assy repair: success [message #217703 is a reply to message #217701] |
Sat, 10 August 2013 20:58 |
sgltrac
Messages: 2797
Registered: April 2011
Karma: 1
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Senior Member |
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One of the sponsors is our very own crazy Kanomata and Applied!!
Todd Sullivan
Sully
77 royale(soon back on the highway thanks to three Jims)
On Aug 10, 2013, at 6:49 PM, Ron77 <ron77@gltcinsurance.com> wrote:
> Sorry to hijack a thread, but I am working with an ipad and can't figure any other way. I am at Bonneville and the GMC motorhome ran and got a top speed of 108 and change. I don't know if that's a record, but it's a very good average. Looks good too, it's all good!!!
>
> Ron Johnson
>
> On Aug 10, 2013, at 7:19 PM, Dan Gregg <gregg_dan@hotmail.com> wrote:
>
>>
>>
>> Stick Miller wrote on Sat, 10 August 2013 15:10
>>> From one Miller to another, I stand in awe.
>>
>> Stick, those two Miller men in Ohio are something when it comes to stuff like this.
>> Dan
>> --
>> Dan & Teri Gregg
>> Dexter, Mo.
>>
>> http://danandteri.blogspot.com/
>>
>>
>>
>>
>> _______________________________________________
>> GMCnet mailing list
>> Unsubscribe or Change List Options:
>> http://temp.gmcnet.org/cgi-bin/mailman/listinfo/gmclist
> _______________________________________________
> GMCnet mailing list
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Sully
77 Royale basket case.
Future motorhome land speed record holder(bucket list)
Seattle, Wa.
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| Re: [GMCnet] Onan Field-assy repair: success [message #217705 is a reply to message #217703] |
Sat, 10 August 2013 21:03 |
 |
USAussie
Messages: 15912
Registered: July 2007
Location: Sydney, Australia
Karma: 6
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If you want to comment I've created a thread:
Subject: GMC at Bonneville
Regards,
Rob M.
-----Original Message-----
From: gmclist-bounces@temp.gmcnet.org [mailto:gmclist-bounces@temp.gmcnet.org] On Behalf Of Todd Sullivan
Sent: Saturday, August 10, 2013 8:59 PM
To: gmclist@temp.gmcnet.org
Subject: Re: [GMCnet] Onan Field-assy repair: success
One of the sponsors is our very own crazy Kanomata and Applied!!
Todd Sullivan
Sully
77 royale(soon back on the highway thanks to three Jims)
On Aug 10, 2013, at 6:49 PM, Ron77 <ron77@gltcinsurance.com> wrote:
> Sorry to hijack a thread, but I am working with an ipad and can't figure any other way. I am at Bonneville and the GMC motorhome
ran and got a top speed of 108 and change. I don't know if that's a record, but it's a very good average. Looks good too, it's all
good!!!
>
> Ron Johnson
>
> On Aug 10, 2013, at 7:19 PM, Dan Gregg <gregg_dan@hotmail.com> wrote:
>
>>
>>
>> Stick Miller wrote on Sat, 10 August 2013 15:10
>>> From one Miller to another, I stand in awe.
>>
>> Stick, those two Miller men in Ohio are something when it comes to stuff like this.
>> Dan
>> --
>> Dan & Teri Gregg
>> Dexter, Mo.
>>
>> http://danandteri.blogspot.com/
>>
>>
>>
>>
>> _______________________________________________
>> GMCnet mailing list
>> Unsubscribe or Change List Options:
>> http://temp.gmcnet.org/cgi-bin/mailman/listinfo/gmclist
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://temp.gmcnet.org/cgi-bin/mailman/listinfo/gmclist
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Regards,
Rob M. (USAussie)
The Pedantic Mechanic
Sydney, Australia
'75 Avion - AUS - The Blue Streak TZE365V100428
'75 Avion - USA - Double Trouble TZE365V100426
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| Re: [GMCnet] Onan Field-assy repair: success [message #217706 is a reply to message #217701] |
Sat, 10 August 2013 21:06 |
Jim Miller
Messages: 501
Registered: March 2008
Karma: 10
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Senior Member |
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On Aug 10, 2013, at 9:49 PM, Ron77 wrote:
> Sorry to hijack a thread, but I am working with an ipad and can't figure any other way. I am at Bonneville and the GMC motorhome ran and got a top speed of 108 and change. I don't know if that's a record, but it's a very good average. Looks good too, it's all good!!!
C'mon guys, all you have to do to start a new thread is compose an email to gmclist@temp.gmcnet.org and say whatever you want to say. We're trying to discuss Onan field assembly repairs in this thread and a lot of people who have dead fields may be interested in same.
Jim
--Jim Miller
1977 Eleganza II
1977 Royale
Hamilton, OH
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Jim Miller
1977 Eleganza II
1977 Royale
Hamilton, OH
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| Re: [GMCnet] Onan Field-assy repair: success [message #217710 is a reply to message #217670] |
Sat, 10 August 2013 21:27 |
Jim Miller
Messages: 501
Registered: March 2008
Karma: 10
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Senior Member |
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On Aug 10, 2013, at 2:50 PM, Robin Hood wrote:
> Does that mean longer service lives for these old power plants?
In my opinion it does - I feel the Onan is the quietest and most reliable option available for the GMC. Inverter-based units may be quieter and more fuel efficient however they contain a significant amount of electronics that cannot be bypassed or cheated if they fail while you are on a mission. As many have seen a breaker-point-based Onan can be operated with nothing more than an alligator clip lead from +12 to the coil.
The Onan prime mover is a rock-solid 1940's engine design that will run indefinitely if taken care of. Unfortunately the life-limiting factor for the Onan genset as of late is not the engine but rather the irreplaceable field-coil assembly comprised of varnish-insulated aluminum wire that, if nicked, will eventually corrode into white powder and render the unit useless. This vulnerability is what my father and I have spent three months trying to find a workable solution to. We think that the use of copper wire encapsulated in baked Glyptal will result in something that will last longer than we will.
--Jim Miller
1977 Eleganza II
1977 Royale
Hamilton, OH
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Jim Miller
1977 Eleganza II
1977 Royale
Hamilton, OH
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| Re: [GMCnet] Onan Field-assy repair: success [message #217711 is a reply to message #217710] |
Sat, 10 August 2013 21:38 |
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ljdavick
Messages: 3548
Registered: March 2007
Location: Fremont, CA
Karma: -3
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Senior Member |
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Jim,
Are you thinking of refurbishing these Onans for sale, maybe through the Jims on either coast and you in the middle?
It seems that you could do for the Onan what Manny does for transmissions.
Larry Davick
On Aug 10, 2013, at 7:27 PM, Jim Miller <gmcnet@jcmco.com> wrote:
> On Aug 10, 2013, at 2:50 PM, Robin Hood wrote:
>
>> Does that mean longer service lives for these old power plants?
>
> In my opinion it does - I feel the Onan is the quietest and most reliable option available for the GMC. Inverter-based units may be quieter and more fuel efficient however they contain a significant amount of electronics that cannot be bypassed or cheated if they fail while you are on a mission. As many have seen a breaker-point-based Onan can be operated with nothing more than an alligator clip lead from +12 to the coil.
>
> The Onan prime mover is a rock-solid 1940's engine design that will run indefinitely if taken care of. Unfortunately the life-limiting factor for the Onan genset as of late is not the engine but rather the irreplaceable field-coil assembly comprised of varnish-insulated aluminum wire that, if nicked, will eventually corrode into white powder and render the unit useless. This vulnerability is what my father and I have spent three months trying to find a workable solution to. We think that the use of copper wire encapsulated in baked Glyptal will result in something that will last longer than we will.
>
> --Jim Miller
> 1977 Eleganza II
> 1977 Royale
> Hamilton, OH
>
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://temp.gmcnet.org/cgi-bin/mailman/listinfo/gmclist
_______________________________________________
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Larry Davick
A Mystery Machine
1976(ish) Palm Beach
Fremont, Ca
Howell EFI + EBL + Electronic Dizzy
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| Re: [GMCnet] Onan Field-assy repair: success [message #217726 is a reply to message #217658] |
Sun, 11 August 2013 01:55 |
Ken Henderson
Messages: 8726
Registered: March 2004
Location: Americus, GA
Karma: 9
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Senior Member |
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Jim,
I love it! That's a great project. I've gotta meet Y'All. Maybe I can
make your next WORK rally.
Ken H.
On Aug 10, 2013 10:20 AM, "Jim Miller" <gmcnet@jcmco.com> wrote:
> As many of you know (or have experienced!) the Onan field-coil assemblies
> seem to be failing at an increasing rate over the past couple of years.
> Here at the "Miller Compound" we have spent a couple months working on
> various ways to repair and improve these assemblies.
>
> As of today we have been successful at:
>
> 1) re-winding the assembly using copper wire which is mechanically
> stronger and also has an improved insulation coating compared to the OEM's
> varnished aluminum
>
> 2) keeping the re-wound assembly within the OEM electrical specs so that
> the original reactor/bridge excitation system can be used
>
> 3) eliminating the reactor/bridge excitation system and replacing it with
> an electronic regulator that has both under/over-voltage and
> under/over-frequency protection as well as tighter command of output
> voltage.
>
> I have posted pictures of our project at:
>
> http://www.jcmco.com/gallery/onanfieldassyrepair
>
> We would like to thank all of those in the GMC community who have assisted
> us in this project.
>
> --Jim Miller
> 1977 Eleganza II
> 1977 Royale
> Hamilton, OH
>
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://temp.gmcnet.org/cgi-bin/mailman/listinfo/gmclist
>
_______________________________________________
GMCnet mailing list
Unsubscribe or Change List Options:
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Ken Henderson
Americus, GA
www.gmcwipersetc.com
Large Wiring Diagrams
76 X-Birchaven
76 X-Palm Beach
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| Re: [GMCnet] Onan Field-assy repair: success [message #217763 is a reply to message #217710] |
Sun, 11 August 2013 10:19 |
Mr ERFisher
Messages: 7117
Registered: August 2005
Karma: 2
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Senior Member |
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Wow
Too cool
I might buy one just To encourage you
Need to get you on bdub
Coming to GMCWS ?
FREE WIFI @ Mickey DN43.370328, W124.211817
On Aug 10, 2013, at 7:27 PM, Jim Miller <gmcnet@jcmco.com> wrote:
> On Aug 10, 2013, at 2:50 PM, Robin Hood wrote:
>
>> Does that mean longer service lives for these old power plants?
>
> In my opinion it does - I feel the Onan is the quietest and most reliable option available for the GMC. Inverter-based units may be quieter and more fuel efficient however they contain a significant amount of electronics that cannot be bypassed or cheated if they fail while you are on a mission. As many have seen a breaker-point-based Onan can be operated with nothing more than an alligator clip lead from +12 to the coil.
>
> The Onan prime mover is a rock-solid 1940's engine design that will run indefinitely if taken care of. Unfortunately the life-limiting factor for the Onan genset as of late is not the engine but rather the irreplaceable field-coil assembly comprised of varnish-insulated aluminum wire that, if nicked, will eventually corrode into white powder and render the unit useless. This vulnerability is what my father and I have spent three months trying to find a workable solution to. We think that the use of copper wire encapsulated in baked Glyptal will result in something that will last longer than we will.
>
> --Jim Miller
> 1977 Eleganza II
> 1977 Royale
> Hamilton, OH
>
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://temp.gmcnet.org/cgi-bin/mailman/listinfo/gmclist
_______________________________________________
GMCnet mailing list
Unsubscribe or Change List Options:
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| Re: [GMCnet] Onan Field-assy repair: success [message #217765 is a reply to message #217726] |
Sun, 11 August 2013 10:30 |
Ken Burton
Messages: 10030
Registered: January 2004
Location: Hebron, Indiana
Karma: 10
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Senior Member |
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| Ken Henderson wrote on Sun, 11 August 2013 01:55 |
Jim,
I love it! That's a great project. I've gotta meet Y'All. Maybe I can
make your next WORK rally.
Ken H.
On Aug 10, 2013 10:20 AM, "Jim Miller" <gmcnet@jcmco.com> wrote:
> As many of you know (or have experienced!) the Onan field-coil assemblies
> seem to be failing at an increasing rate over the past couple of years.
> Here at the "Miller Compound" we have spent a couple months working on
> various ways to repair and improve these assemblies.
>
> As of today we have been successful at:
>
> 1) re-winding the assembly using copper wire which is mechanically
> stronger and also has an improved insulation coating compared to the OEM's
> varnished aluminum
>
> 2) keeping the re-wound assembly within the OEM electrical specs so that
> the original reactor/bridge excitation system can be used
>
> 3) eliminating the reactor/bridge excitation system and replacing it with
> an electronic regulator that has both under/over-voltage and
> under/over-frequency protection as well as tighter command of output
> voltage.
>
> I have posted pictures of our project at:
>
> http://www.jcmco.com/gallery/onanfieldassyrepair
>
> We would like to thank all of those in the GMC community who have assisted
> us in this project.
>
> --Jim Miller
> 1977 Eleganza II
> 1977 Royale
> Hamilton, OH
>
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Ken,
Jim and James Miller and their wife/mother are great people. Jim (senior) always gets on my case if I do not show up for the work rally. I know you will always be welcome to come.
They have been working on this Onan project for a while and Jim jr. has been sending out updates as they progressed along with it.
I hope to see you next year in Hamilton, OH.
Ken B.
Ken Burton - N9KB
76 Palm Beach
Hebron, Indiana
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