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.

Posted by kevinper on


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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


Carl Gehrke

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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.


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.

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Cummins generator set will occasionally encounter generator failure in the process of use that Cummins generator set is not generating electricity. What is the cause of it? And what to do about it? In fact, there are a lot of reasons that Cummins generator set is not generating electricity.
1. Wrong connection of generator set. Processing: check and correct by wiring diagram.
2. Generator speed is too low. Processing: measuring speed and keeping it at rated value.
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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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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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