Onan QD 10 brushes

[sflabrkr]

I have a problem with my RV generator. It works fine unless I'm using my fancy espresso machine. It will not work on the generator but will work off invertor or shore power.
I talked to Cummins at a show and they said to check voltage at the generator. I did and it bounces a lot, 107-147 on my digital volt meter.
They told me at the show that it is probably the brushes.
I checked the brushes and I believe they need to be replaced. I have not removed them but I stuck a wire inside and it goes in about an inch.
One of the wires going to the carbon brush looks burnt.
I believe the brush kit is 0212-1285 I called Cummins support and the tech I talked to I don't think he ever saw a generator. I talked to parts and they transferred me 3 times and I finally hung up after 45 minutes.
The generator model number is 10HDKCA-12607G
and the serial is F160963146

My next question is, if I have to clean the rotor, I saw they used a pencil eraser. How do I turn the rotor, do I spin it with the starter?

[TandW]

Looks like the carbon is shattered. Better stop using it before you blow the voltage regulator!

[sflabrkr]

Originally Posted by TandW

Looks like the carbon is shattered. Better stop using it before you blow the voltage regulator!

How can you tell?

[2004Horizon]

Is a QD10 a 10,000W generator that uses "inverter technology?"

I have heard of Qd7500/QD8000, but not QD10. What is this?

[TandW]

No. From the spec sheet listing it has a brush type AC alternator.

[sflabrkr]

Originally Posted by TandW

No. From the spec sheet listing it has a brush type AC alternator.

Does that mean an invertor type does not have brushes? Never thought about it

[Twomed]

Google your part number... $93 to $246 Brush Block Kit. I did just brushes not the holder a few years back about $15.

FROM THE 10K SHOP MANUAL
Brushes and Slip Rings
Access: Remove the brush block access cover
(Figure 4-2) for access to the brush block assembly
and slip rings.
Checking for Wear: Check brush wear by marking
off a piece of wire at 1 inch (25 mm) and inserting it
into each of the two holes in the top of the brush
block from which the pig tails exit. Replace the brush
if the wire can be inserted more than 1 inch (25 mm).
(Make sure the wire rests on top of the brush and not
on part of the spring.)
Cleaning Up Slip Rings: If the slip rings are
grooved or pitted, try cleaning them up with a commutator
stone while cranking the engine. (Connect
the starter motor directly to a battery and the starter
solenoid to a remote start switch.) The rotor will
have to be removed if the slip ring assembly has to
be replaced.
Replacing Brush Block: When replacing the brush
block assembly, center the brushes on the slip rings
before tightening the two mounting screws. Make
sure to reconnect the lead marked F1 to the outboard
brush and the lead marked F2 to the inboard
brush.

IF NEEDEd
ADJUSTING VOLTAGE
The controller has a voltage set mode that is enabled
by rapidly pressing START 6 times during the
first minute after startup. To adjust voltage:
1. Disconnect all genset loads and connect accurate
meters to measure AC output voltage.
WARNING HAZARDOUS VOLTAGE!
Touching uninsulated live parts inside the
genset or connected equipment can result
in severe personal injury or death. For your
protection, stand on a dry wooden platform
or rubber insulating mat, make sure your
clothing and shoes are dry, remove jewelry
from your hands and use tools with insulated
handles.
2. Start the genset and let voltage and frequency
stabilize for 5 to 10 seconds.
3. Rapidly press START 6 times. The status lamp
will start to blink once a second to confirm that
the controller is in voltage adjust mode.
4. To adjust voltage up, press START and release
quickly. Each time START is released,
voltage will increase approximately 0.6 volt.
5. To adjust voltage down, press the control
switch to START and release in approximately
1 second. Each time START is released, voltage
will decrease approximately 0.6 volt.
6. Normal operation will resume in 20 seconds after
the last adjustment. The last adjustment will
be saved by the controller.
Note: Voltage adjustments will not be saved if a
fault shutdown occurs or STOP is pressed while
in voltage set mode.

[sflabrkr]

I replaced the brushes today. What a pain in the a$$. You have to remove the front of the generator housing to get to the brushes. To do that you have to remove the bolts and the 2 hidden screws and then pry it off. It doesn't come all the way off so you have to support it out of the way.
The brushes were good and the slip rings were also OK.
I installed the new brush block. Everything works like before.
I also replaced the air filter. It was very dirty

[Twomed]

PIA?? Wait until you need to replace the belt!

[sflabrkr]

Originally Posted by Twomed

PIA?? Wait until you need to replace the belt!

What belt? I thought it was direct drive

[mackwrench]

Originally Posted by sflabrkr

What belt? I thought it was direct drive

Engine coolant water pump belt.

[Bruce Anthon]

If you are going to the trouble of replacing the generator fan belt… I replaced my water pump at the same time. It was not expensive and you are right there.