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Dan Osborne · 08-23-2016, 10:18 PM

Took on the task of replacing the slip rings on my diesel Kohler. Not a job for the faint of heart. Was able to do it without removing the generator, total labor time around 8 hours. Parts included new slip ring, new brushes, new brush holder cost about $100.00

LDMcL · 08-24-2016, 11:34 AM

Good Afternoon Dan

I am just going through the same process on my 12.5 kw Kohler/Perkins.

I was not so lucky with the price of my parts in Canada - Approx CAN $250 including taxes. At least they had them in stock at the Kohler Dealer.

Plus there was the purchase of the puller and some other tools.

I am not sure what was the cause and what was the effect on mine but the brush holder on the engine side slip ring was worn, causing the brush to be misaligned and shortened to 1/3 the length of the rear brush. Also, the engine side slip ring had a .060 deep groove in it. This is in comparison to the rear slip ring and brush which was just polished without any evidence of wear.

I hope to get it together today

Dan Osborne · 08-24-2016, 06:53 PM

Quote:

Originally Posted by LDMcL

Good Afternoon Dan

I am just going through the same process on my 12.5 kw Kohler/Perkins.

I was not so lucky with the price of my parts in Canada - Approx CAN $250 including taxes. At least they had them in stock at the Kohler Dealer.

Plus there was the purchase of the puller and some other tools.

I am not sure what was the cause and what was the effect on mine but the brush holder on the engine side slip ring was worn, causing the brush to be misaligned and shortened to 1/3 the length of the rear brush. Also, the engine side slip ring had a .060 deep groove in it. This is in comparison to the rear slip ring and brush which was just polished without any evidence of wear.

I hope to get it together today

Mine had the same goofy grove on the ring closest to the armature. The generator had 1025 hours in it. Now that I see how easy the brushes are to replace, I will check them often and bought one additional set to keep in the motorhome. Partsfortechs.com is the best place to get a great deal on parts. Good luck!

jelag · 08-24-2016, 07:48 PM

Its common to polish the slip rings and just replace the brushes... would you share the length of the old brushes you removed in relationship to the new brushes... 30% - 40% etc.. and please share why you decided to replace the slip rings and not just service them.....

Dan Osborne · 08-24-2016, 09:41 PM

Quote:

Originally Posted by jelag

Its common to polish the slip rings and just replace the brushes... would you share the length of the old brushes you removed in relationship to the new brushes... 30% - 40% etc.. and please share why you decided to replace the slip rings and not just service them.....

One brush was still at 80% the inside brush (nearest motor) had broken apart and the remaining spring had torn up the slip ring. No way to service a gouged up slip ring.

LDMcL · 08-24-2016, 09:53 PM

Jelag:

Here are photos of my old (top) and new (bottom) brushes, old (black) and new (white) brush holders and the slip ring. If you look closely at the black brush holder, you may see the highly worn slot which allowed the brush to flop around with the resulting extreme wear on the brush and the slip ring.

Dan Osborne · 08-24-2016, 10:25 PM

Quote:

Originally Posted by LDMcL

Jelag:

Here are photos of my old (top) and new (bottom) brushes, old (black) and new (white) brush holders and the slip ring. If you look closely at the black brush holder, you may see the highly worn slot which allowed the brush to flop around with the resulting extreme wear on the brush and the slip ring.

Looks like you got it done! Scariest part for me was pounding (lightly) the new slip ring on the shaft. I used a deep socket but met a lot of resistance for the last 1/2 inch as the shaft cuts grooves as you install.
Ran mine tonight for an hour under max load with both AC's on high.
I am a drag racer and AC is very important on long weekends

LDMcL · 08-25-2016, 06:00 AM

Dan:

My service manual described what was to be done, but was woefully inadequate on saying how it was to be done.

I went out and bought a 3' piece of 1/2" all-thread and used it along with a socket as a puller to pull the slip ring and bearing back onto the shaft.

Dan Osborne · 08-25-2016, 07:47 AM

Quote:

Originally Posted by LDMcL

Dan:

My service manual described what was to be done, but was woefully inadequate on saying how it was to be done.

I went out and bought a 3' piece of 1/2" all-thread and used it along with a socket as a puller to pull the slip ring and bearing back onto the shaft.

That was smart!