Question about Briggs & Stratton 11HP 6200W Es Generator

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Briggs & Stratton Burnt Brushes

I have a Briggs & Stratton EXL8000 generator. I keep having to replace the brushes. The "furthest in" brush (black wire) is always broken and it appears that the casing for the brush melts. What could be the problem?

Sometimes it will work for a month. Other times a few days and even less.

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I did find out that the inner slip ring was worn down. Still unknown why and the repair tech we took it to twice just replaced the brushes and never looked at the slip rings.

My solution, which has worked for over two months now (knock on wood) is as follows:

The slip ring on this unit can only be replaced by replacing the whole rotor assembly. I looked at the width of the brushes and the width of slip rings. The slip rings are twice as big as a brush. The solution was to move the brushes outward by one brush length. In order to do that, I had to turn the brush assembly around because of the extra plastic on the unit and space it out one brush length. Note: Still hook the wires as if the brush assembly was not turned around.

I used an old brush assembly and cut the two areas where the screws go through to make my spacers and it works perfectly.

Posted on Dec 03, 2008

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Are you running something that has a high startup current? A well pump, air conditioner, air compressor, etc.
All of these things draw more than the rated power from your generator for a little while, then settle down and draw the regular rated power they have on the dataplate. This higher level of power is called the surge rating of the generator ( think the EXL8000 is something like 8250 watts for 30 seconds, check your manual) - if you regularly go over the surge rating you'll burn brushes, mess up slip rings, and potentialy kill a voltage regulator once in a while.

When we calculate how large a generator to use for an emergency backup system we add up all of the currents required by all of the things that have to run, then we calculate the maximum surge power for all the loads that have this requirement. We try and get a generator that will supply the "regular" load at 80% of it's rated capacity and still be able to handle the expected surge load. Sometimes we have to use a larger generator than needed for the regular load to get the surge load to be OK.

So you might need to trade up to the 10Kw Briggs to handle your load.

Carl

Posted on Dec 03, 2008

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Need wiring diagram,from alternator to plug-ins for briggs & Stratton (3500) Elite series Model # 030208-0


No wiring diagram available from Briggs. Try re-magnetizing the rotor. No AVR or Capacitor listed in the parts list.

Disconnect the wires to brushes ( pay attention to the order) and apply 12vdc to brushes. Positive goes to brush closest to the bearing. Start the generator and check for output. If output is normal run the unit a few minutes to ensure re-magnetization then shut down normally. After shut down disconnect the 12 vdc source and re-install the previous disconnected wires. Now re start the generator and test for output should be okay provide there is no problems with the alternator. If no output during the above re-magnetization then your rotor windings my burned out.
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may be a bad breaker or a shorted wiring problem. not generating any power, I would ck. the brushes inside the generator.

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To remove engine from generator


Remove cover to the generator and remove the brush holder (if brush type) and any other parts bolted to rear. Remove wiring harness plug (most generators have an easy method to unplug all the wire from panel). Unbolt and remove the outer bell of generator leaving only the armature(use caution not to damage wiring, use camera to photo document the steps ). Remove the center bolt thru armature into crank. With piece of hardwood and large hammer, rap on one side of armature (metal part) then the other (careful not to miss the wood and damage the armature or wiring). The armature sits on tapered crank and will stick over time, may need to use penetrating oil. If your lucky, only takes a few hits on each side to break contact. Good luck

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1 Answer

I have a generator that does not produce any volts. I replaced the brush block because it was bad with no help. I took resistance readings of the rotor and stator. Are these in spec?? briggs and stratton...


As long as you have continuity through the stator and rotor windings, and no continuity from the windings to the core, you should be good.

If the brush block was replaced due to it being defective, take a look at the diode and capacitor regulator as well. Using a multimeter, the diode should indicate continuity in one direction, infinite resistance in the other. If you get this, then replace the capacitor. If not, then replace the diode, and likely the capacitor as well.

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1 Answer

I had it repaired about a month ago. it needed brushes. and now today it will run but not put no currant out put so it probaly the same thing. But where can i just buy the brushes myself. cant find...


Try starter / alternator rebuild shops. NAPA auto parts sometimes carries a small selection as well.

If you just had brushes put in a month ago, problem likely lies somewhere else. I have several hundred hours on OEM factory brushes on most of my generators, and no problems. Some sets have brushes that have outlasted the engine. Something else is going on.

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Generator was running and quit generating power but the motor is running good


brushs might need to be polarized-hook jumper cables to a 12v battery and touch to the brush contacts it should work and renew your power out.

Dec 21, 2009 | Briggs & Stratton Power Products 5,550...

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I have a Briggs & Stratton Generator 5550Watt model 030253 That is showing an output of only 4.6 Volts at the pannel. Suggestions???


Check to see if this unit has brushes and rings. If it does, then make sure that the brushes are making a good contact on the rings. If the contact is good, then your voltage regulator could be bad. This would require more troubleshooting.

May 04, 2009 | Briggs & Stratton Power Products 5,550...

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