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Old 06-01-2012, 08:55 PM   #1
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Generator-Again!

I replaced the generator brush block 150 hours ago, and today when I went to do my monthly run, no run and trouble code 341.

Took the brushes out, and the top brush was down to nothing again! The top slip ring was nasty looking, as well.

I burnished the slip ring with some #200 emery cloth on a stick, replaced the bad brush with the one that I had saved from the original fuse block, and we'll see what happens! I still have three months of warranty left, so I'm going to be watching this closely!

I hate to take it back to the dealer and wait a month during the high season, but you gotta do what you gotta do!
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Old 06-01-2012, 09:31 PM   #2
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Originally Posted by Freds342 View Post
I replaced the generator brush block 150 hours ago, and today when I went to do my monthly run, no run and trouble code 341.

Took the brushes out, and the top brush was down to nothing again! The top slip ring was nasty looking, as well.

I burnished the slip ring with some #200 emery cloth on a stick, replaced the bad brush with the one that I had saved from the original fuse block, and we'll see what happens! I still have three months of warranty left, so I'm going to be watching this closely!

I hate to take it back to the dealer and wait a month during the high season, but you gotta do what you gotta do!
If the brush has burnt down that much in a short period it was not properly arched to the communtator and had a lot of arching under large load. I would also consider the spring on this brush may be too much for it. Have you compared the other brush assemble spring tention.
You may also have a main bearing going bad and the armature it hitting on this brush more when it is running.

So it may be something bigger than just a brush problem

Hope this helps you decide what you need to do.

Oh my first career was gas and diesel engine maintenance.
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Old 06-02-2012, 02:51 AM   #3
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When I installed my new brush block it wasn't arched at all. The brushes where flat on the ends. I figured it would wear into and arc in time.

Thankfully there isn't much current (or voltage) going through these brushes. Since it's only the field voltage on them I figured it would be OK.

Is there a procedure for arching the brushes before you install them? There wasn't anything in the service manual about it.
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Old 06-02-2012, 12:10 PM   #4
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Sounds like you did everything correctly. The only thing I can imagion is some type of shaft wobble or the springs are not pushing correctly and you are getting a brush bounce or one brush may be stuck.

I would replace the brushes again and springs. Hopefully you haven't removed too much from the slip rings or you may have to buy a new one.

You make to take it to a professional generator guy if the top brush is eaten up again.

Good luck
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Old 06-02-2012, 05:11 PM   #5
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Can I ask, what make and model genset?
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Old 06-02-2012, 06:57 PM   #6
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Originally Posted by jsutherl View Post
When I installed my new brush block it wasn't arched at all. The brushes where flat on the ends. I figured it would wear into and arc in time.

Thankfully there isn't much current (or voltage) going through these brushes. Since it's only the field voltage on them I figured it would be OK.

Is there a procedure for arching the brushes before you install them? There wasn't anything in the service manual about it.
Exactly. The shop manual just says to shove 'em in. These aren't old school with big brushes running a lot of current; just field current, and frequency sense for speed correction.

I just read my "Policy", and it looks as if the only parts covered are the lubed parts of the engine, and the "voltage regulator".

Hmmmm. I wonder if the field sli-rings would be part of the "Voltage Regulator".

Any thoughts, anyone?
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Old 06-02-2012, 06:58 PM   #7
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Can I ask, what make and model genset?

Onan Marquis 5500 gas. Kinda the Georgetown standard, of late.
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2005 Liberty Renegade 4X Toad
1989 Wrangler Sahara Toad
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D/W Carole and Maggie the Teacup Lab (Black Chihuahua)
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Old 06-02-2012, 07:44 PM   #8
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Onan Marquis 5500 gas. Kinda the Georgetown standard, of late.

I just looked at my manual and it looks very simple to replace the brushes. The only question I have is the + and the - wires in a plug or seperate? Just thinking what else could have been changed.

Was the original set of brushes burnt the same way?
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Old 06-02-2012, 10:05 PM   #9
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Based on this I just ordered myself a spare brush block with brushes. For $35 figure it's better to have a spare around.
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Old 06-03-2012, 02:48 AM   #10
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Onan Marquis 5500 gas. Kinda the Georgetown standard, of late.
Standard since at least 2009 is a Generac. Onan is an upgrade.
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