Your last generator Maintenance Run

   / Your last generator Maintenance Run #4,031  
Thought you guys would enjoy this bit of history. This is Cummins Power Generation (Onan Corp) 100th anniversary.


Much like Clessie Cummins, D.W. Onan was a man of humble beginnings. Born in Moorhead, Minnesota (USA) on July 4, 1886, D.W.’s love for mechanics came from his father, a railroad worker who enjoyed tinkering with things around the house.

After his father’s death, D.W. dropped out of high school at 14 to support his family and started his first job at a power plant. He then briefly worked at a skating rink, but the dream to someday own a business pushed him toward the growing automobile industry.



He began working for P.J. Downes Co and later the Reinhard Brothers Company, where he shared his vision of starting a business focused on repairing broken parts of an automobile. The owners loved the idea and put Onan in charge of this new department. Within 10 years, Onan was supervising 50 mechanics and completing between 100-125 repairs a day. He personally trained each of the mechanics working for him.

However, Onan’s dream of owning his own business was still a passion he longed to fulfill. So much so that as he designed and built specific tools to help his mechanics complete repairs quicker and safer, he insisted that the Reinhard Brothers owners know that he maintained the design rights and they were not allowed to manufacture or sell his tools. Eventually Onan left the Reinhard Brothers and with $100 borrowed capital to start his own business manufacturing and selling auto repair shop tools and equipment out of his basement. In 1920, the Onan Corporation was established and shortly thereafter, Onan moved into a larger building for his growing business and continued to increase his portfolio of tools.

In the summer of 1926, one of DW’s fishing buddies, George VanWagenen, asked him for a favor. He had a fishing cottage on Lake Mille Lacs, and he needed electric lights at it. He said he didn’t want to fuss with kerosene lamps nor batteries all the time. He asked D.W. to design a generator with a gasoline engine that he could use when he was at the cottage and ‘forget about it’ when he wasn’t. D.W. was intrigued with the idea, and set about with his partner, his 16-year-old son, Bud, to design and build a gasoline- driven generator set. D.W. and Bud worked for several months to create this generator and presented Mr. VanWagenen with a 300-watt, 115-volt direct current generator set. After a few more tweaks, the Onans increased the power to 350-watts, and called the generator the “Onan Ten-Lite Generator” as it had enough power to provide for ten 30-watt light bulbs. They sold the generator for $99 plus $12 for the ten 30-watt light bulbs and wiring. Thus, the first Onan generator was born.

DW onan.jpg
 
   / Your last generator Maintenance Run #4,032  
Thanks for that. Like so many companies, I wish Onan had just stayed ONAN.

I borrowed an inspection camera yesterday from a friend, in hope of finding a 4-40 size terminal block screw, I dropped into the Rotor region of my ONAN Silent 7.5, with Permanent Magnet Rotor. After a ton of time, effort and money, I dare not start it until that screw is found!!!
 
   / Your last generator Maintenance Run
  • Thread Starter
#4,033  
Good hunting IT :thumbsup:, we'll try and keep Murphy busy while you track it down....

That was a great read CM, thanks for posting. I first noticed years ago the # of successful companies that were founded just before, or during the Dirty 30's...... survive that..... Strength from Adversity !

Rgds, D.
 
   / Your last generator Maintenance Run #4,034  
This is the second time that I had no luck using an inspection camera. Maybe if you knew approximately where something was, you might find it. Reminds me of some underwater footage on TV. I looked as closely at the Rotor as possible and at the air flow. It's not quite as I thought and probably won't suck a small screw through it. I am more worried about it lying within the varnished windings and eventually causing a short. Anyway, I just have to proceeed with fingers crossed.

Helping a friend with a most interesting genset out of a lighthouse (Back-up). Lister 3 cyl, air cooled 1800 rpm with Stamford 12 KW end. Engine has a 15 Gallon Sump and then is further circulated through a 45 barrel drum. For exceptionally long service intervals. I guess he is not going to use that external feature.

He is having issues with the Voltage Regulator on this Brushless Alternator. I don't have any brushless sets, and only looked into the matter for him. I am surprised that the industry would opt to have two more windings just to get rid of the brushes. That adds a lot of complexity and initial cost as well as repair costs. I can change my brushes in twenty minutes.
 
   / Your last generator Maintenance Run #4,035  
Yes, I guess I would pull it apart on a large dropsheet if I had to if I didn’t find if I were in your position. That could be a costly bit of hardware.

Brushes are the most common failure point especially on generators that sit or are in poor environments and that’s a big reason they’ve gone away. Two additional windings and a 6 diodes or a diode pack are pretty cheap when mass produced and will last almost indefinitely.
 
   / Your last generator Maintenance Run #4,036  
Brushes are the most common failure point especially on generators that sit or are in poor environments and that’s a big reason they’ve gone away. Two additional windings and a 6 diodes or a diode pack are pretty cheap when mass produced and will last almost indefinitely.
Especially for a lighthouse where conditions may not be optiomal and when it's needed, it has to work.

Aaron Z
 
   / Your last generator Maintenance Run #4,037  
Okay you all got me guilted in going out to my shed and do a rare summer run of my generator.

Didn't put a bunch of load on it but I confirmed I had a full tank of ethanol free gas, the battery tender was on and doing its job, and after pulling the choke, it key started before I could say one one thousand. I suppose I should try the pull cord but the electric start has been flawless ever since I had a dead on board battery and decided 'Battery Tender' made sense. Since then my second battery is on its second decade!

Gotta love my Honda EU3000is gen. One of the best tool purchases I have ever made. I am sure I praised it here on this thread at some point or two... but this thing has been solid for 15 plus approaching 20 years I think. Super efficient, extremely quiet and although not exactly portable... it can be. It is the only generator I have and it backs up my house power when necessary and I can haul it to wherever whether it be camping, a remote worksite, etc.

I don't normally rave about a particular product but this is worthy. My only wish would be that it could somehow be the same size and weight and had double the power for welding or well pump surge... but nothing is perfect.
 
   / Your last generator Maintenance Run
  • Thread Starter
#4,038  
I don't normally rave about a particular product but this is worthy. My only wish would be that it could somehow be the same size and weight and had double the power for welding or well pump surge... but nothing is perfect.

DiLithium Crystals ! That's the answer :)

I look at gens like hammers...... sometimes you need a BFH, sometimes a tack hammer is (much) better.....

That 3000 of yours hits a nice balance. Not as portable as one of the Honda suitcases, but has that extra bit of capacity...... buddy of mine bought one used, and ran it for many summers at motocross tracks.... provided all the support he needed, and would run his (small/med) A/C in a pinch.

IIRC, Honda came up with a Jenny Craig version of that gen...... trades off weight for slightly less noise suppression. Thinking Mr Onan would get a kick out of what we have to choose from today :D

Complexity can add failure points (living in a land where vehicle wiring likes to rot, I really understand that issue.....), but in high volume production (reputable manufacturer) should be mitigated to a reasonable level.

I'm old enough to remember problems with GM HEI ignition drivers. Not fun if that put you on the side of the road..... but I don't hear many of us lamenting the time we don't put into changing points today.....

Vapour pressure sensors in-tank..... Cavalier era (not picking on GM, just another example.....) platforms would often react to an overfilled tank by taking down the digital control bus. Car towed-in, NoStart, first test is unplug that sensor..... Starts Right Up.... order new sensor, then keep checking.....

General trend is to reduce maintenance requirements as much as possible. I don't always agree with that trend either...... just changed the fuel filter on my old Civic (nice design, placed high on firewall), while many/most modern gasoline vehicles no longer have one at all. I don't drive a GDI yet, so am not up to speed on what is common there today.....

I like where small gens have moved to in the last 15 years.... lots of interesting choices. One good use of consumer tech IMO, is the ability to linked up 2 smaller gens to increase power delivery - retains the light weight feature, yet gives you ability to safely increase capacity. Small and quiet generators - lots more options in the market today, than 20 years ago.

Does tech always progress in the direction I want ?

No. A $300 generator has Low-Oil Shutdown, yet a $30,000 or $100,000 vehicle does not ?

Another recent thread on Battery Testers had me thinking...... A typical 2020 vehicle has how much more computing power on-board than the first Apollo rocket, yet we have no (production issued) way to do on-board battery (or alternator/starter) analysis ? At the same time..... Quality of on-board vehicle power is significantly more important than 30 years ago.....

Rgds, D.
 
   / Your last generator Maintenance Run #4,039  
If you own a vehicle and never have issues with the technology, that of course is a winning situation. If you have all manner of cost, inconvenience and expense, all beyond your control, then the thought of you being able to open the hood and change a distributor cap and points, seems quite appealing. It's the same appeal I feel for my brushes in my generator. So far, they have never given me any trouble, but if they did, I could deal with that in a few short minutes. AND, feel really good that there is something I have control over.

With most Diesel powered equipment now having fuel solenoids, it's unfortunate that they all don't have Murphy Style shutdown for critical conditions. How do you put a novice on a machine to cut grass and tell them to watch the gauges?
 
   / Your last generator Maintenance Run #4,040  
A few points I these recent posts I can comment on from the big company perspective.

Whether it’s brushes, points or many other modern updates, the changes are ultimately driven by cost. Cost to produce but also very largely warranty cost. If the law of average says you will reduce failure costs by $100 by getting rid of brushes and it will cost $50 to upgrade to brushless you are far ahead to make a machine brushless (and that’s a reasonable estimate). The down side to much of this is however that even though the law of average says that customer IT Dave is 99% less likely to experience a failure, if he does, there is little he can do on the spot to get things back up and running. That’s where we are today... Dave shivering, wishing he had brushes to change while the other 99 of us aretoasty warm.

One thing that has actually detracted from reliability that is starting to be addressed is the overwhelming level of monitoring and protection that was made possible with digital controls. As every aspect of unit or vehicle operation has moved to computer controls the trend has been to add fault algorithms to everything. Many digital controlled brush machines for example won’t allow the unit to run with the field resistance out of spec or start when battery voltage or cranking speed too low.

For the guy out in the cold with a nearly dead battery he may have gotten 1 start out of, he’s stuck in the dark. Fortunately this is being recognized and much of these type of faults are becoming “informational”. The lawyers unfortunately have final say on much of this so don’t hold your breath if allowing it to start would increase liability.

As for battery diagnostics, most industrial ECMs have had this for as much as 20 years with the increasing detail. Newer vehicles have the alternator output controlled by one of the ECMs and have some level of battery condition monitoring. My 15 escape has a battery lifetime (not level of charge) remaining parameter that estimates the overall condition though I don’t know how it is determined.
 

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