What is the best way to replace the generator brushes. When the alternator brushes are replaced

Brush wear is the main and most common cause of voltage drops in the vehicle's electrical system. But thanks to free access to and its simple design, even the most timid car owner can replace the generator brushes. To do this, you just need to understand and clearly see how the generator brushes change correctly, and we will figure it out with this.

The main signs of brush wear are:

• voltage dips;
• headlights are weak / blinking in the dark;
• the battery does not charge;
• the radio turns off.

As a rule, during maintenance, few people pay due attention to the small elements of the generator, so the wear of the brushes always comes by surprise. But do not immediately change the generator brushes when the first signs of a malfunction appear. It is necessary from the beginning to make sure that no other reason is a malfunction, and only then proceed to disassemble the generator case ().

How to remove the generator brushes correctly?

In order to replace the generator brushes, you need to remove the voltage regulator in assembly with them, for this we remove the negative terminal of the battery and disconnect / unscrew the wires going to the plastic casing of the generator:

1. Disconnect the "D" connector.
2. Remove the protective rubber cap from the terminals of the wires of the "+" output. We unscrew the nut securing these wires, remove them from the generator block.
3. Next, we remove the plastic black casing of the generator itself. To do this, you need to disconnect the three spring clips located around the perimeter of the block.
4. We find the Voltage Regulator, and use a Phillips screwdriver to unscrew its fasteners.
5. We take out the voltage regulator assembly with brushes, and disconnect the block of wires from it.
6. Replace the generator brushes and install in the reverse order.

Pay attention to the wear on the brushes themselves. The brushes should be replaced if the remaining length of the rods is less than 0.5 mm in length. If the brushes are not worn out, but there is no charge from the genes,

Generator brushes - a part that is responsible for the removal and supply of electricity through direct interaction with the rotor. A brush of this kind is often used in trucks, in the engines of urban transport, in machine tools and in a number of other mechanisms, the work of which is based on the use ofelectric motor... Graphite electrobrushes, no matter what the purpose of the mechanism, always perform their function in the same way. It is necessary to monitor how far they protrude from their "nest".If the brush protrudes less than five millimeters, then it is time to change it.

The coal type is divided into a large number of models, which differ in purpose and configuration. The choice of such graphite parts depends on the principle by which the electric motor operates. A large number of generators use brushes with a standard set of characteristics, but they have a very modest, in my opinion, volume of strength and reliability. They have to be changed often, that is, they wear out quickly and cease to perform their functions, and from this, in turn, it suffers generator.

In some cases, drivers prefer to choose the most durable ones, or those that are impregnated with a special compound that protects them from rapid destruction. For example, high-speed electric motors are often used, for which they buy graphite elements adapted to work in special conditions.

Wear diagnostics and replacement

One of the most common causes of generator malfunction - malfunction of the brushes and voltage regulator, more precisely, their failure. The main function of the former is to remove voltage from the generator collector, as well as to further supply current to charge the battery and power automotive electrical circuits. Therefore, if it is necessary to replace them, then it should be carried out as soon as possible. e. Brushes have a number of characteristics. One of them - the material used in the manufacture, another one - type and sizes. Depending on the purpose and structure on modern market there is a very wide range of models. The brushes must be selected taking into account the principles of the engine. Best result can be obtained by choosing models endowed with increased strength and impregnated with a special solution that protects them from any destruction.expendablematerial that wears out over time. Therefore, these parts must be well looked after and their condition checked.at least every 4 years.

Knowing how to change the brushes on a generator is put into practice in several stages. First of all - de-energizing the generator. To do this, disconnect the negative cable from battery, then remove the voltage regulator. Equally important is how well they perform. If the size of this indicator is less than half a centimeter, they need to be changed as soon as possible.

How do you change them? Very simple. The socket of the holder must be blown out and wiped, after which these parts must be disconnected. This is followed by cleaning the contacts, checking the spring, polishing the slip ring. The last procedure is optional, but it's better to play it safe. It is equally important to know how to check the generator brushes. The level of their wear can be determined by sight. Also, how much they perform can tell a lot.This completes the preparatory work. Go to the replacement itself. First of all, you need to solder the wires to the new parts. It is important to check the freedom of movement on the holder itself. Then we install them carefully, not forgetting about the voltage regulator and grounding. Remember that every car is different, so replacing alternator brushes is not the same for every model.

All car owners know very well what a generator is. When inspecting a generator, you should always pay attention to its brushes, brush holder, slip rings. In the event that the brushes are worn out, they need to be urgently replaced. Our article will tell you how to change the brushes on the generator.

Procedure

1. First of all, you need to look at the readings of the voltmeter. In the case of faulty brushes, it will show a very low voltage of the network of your car. If so, prepare a set with wrenches and sockets, pliers and cardan joint(better with an extension cord). How to change the brushes of the VAZ generator? Very simple, because they are attached to the generator with just one bolt.
2. Next, you need to remove the battery from the car and try to reach the desired bolt with your hand. For your convenience, use pliers to disconnect the plastic connector from the generator, which has one terminal. It is also necessary to remove the wiring harness that is connected to the alternator and starter. Then you need to unscrew the bolt itself and pull out the "bad" brushes.
3. Now you need to install new brushes and tighten the removed bolt. If it is impossible to carry out this process, you need to raise the car using a jack. Now you need to move under the car and unscrew the fasteners of the mudguard and engine protection, and simply remove them. Then you need to find the nut that secures the generator bracket and the generator itself. In this case, it is necessary to ensure that the sealing washers are not lost.
4. Next, you need to disconnect the nut and belt in the hood. This nut secures the tensioning bracket. Next, remove the generator and disconnect the wires attached to it at three points, for which you need to move the cover and use a wrench to unscrew the fastening of 3 thick cores. The remaining wire must be disconnected by disconnecting the plastic block. Disconnect the last of the wires from the brush contacts.
5. Now you need to screw on the bolt, while the installed brushes will residually fall into place. Next, it remains to assemble the generator in the reverse order. Before starting the engine, it is necessary to check whether the generator is working and measure the indicators with a voltmeter.

Now you know how to replace generator brushes!

In order for the replacement of the generator brushes to be performed accurately and quickly, it is necessary to be able to accurately find and dismantle them. With the first point, everything is very clear: brushes, like the electric generator itself, practically on all cars domestic production, located on the right side of the bonnet, directly under the headlight. Therefore, opening the hood, you will immediately see the generator body, on which there will be a winding and two small cylindrical covers - these are the same brushes, or rather their upper part. Cm. video "Replacing the generator brushes" below

When replacing this mechanism, use one of its two brands:

• Standard brushes of the EG-4 brand;
• EG-61 brushes with a large margin of safety.

How long can generator brushes work?

According to the operating parameters set by the manufacturers, the generator brushes are subject to mandatory checks, and, if necessary, replace them after 50,000 km of run. However, in each specific case, the brushes may require immediate replacement earlier, and the main thing here is to know the "symptoms" that will signal us about the malfunction of these particular parts.

Here are four main reasons to check the generator brushes for performance:

• Car electronics start to fail unexpectedly;
• Drop in the lighting level of all lighting fixtures;
• Lowering the voltage in the car electrical network;
• Fast battery discharge.

Checking and replacing alternator brushes

The generator brushes are checked without removing the generator itself, which significantly reduces the time and complexity of work. This is done as follows:

• Disconnect the minus from the battery;
• We dismantle the voltage regulator located on the other side of the generator;
• We make a visual assessment of the lifting height of the brushes from their nests.

If the lifting height does not exceed 5 mm, then the alternator brushes must be replaced. If the lifting height of the brushes is greater, then they can be returned to their place, since the problem of a malfunction in the car's operation lies in something else.

ORDER OF REPLACING the alternator brushes:

1. After the brushes have been removed and checked, it is necessary to carefully remove all dirt from the nest in which the holder is located. Also clean the slip ring and hold-down springs. This is done with a soft bristled brush. In rare cases, you may also need a small grinding of the brushes to the collector, using an emery cloth;
2. Then new brushes are installed, along the way checking their unhindered movement in the holder;
3. Installing a voltage regulator;
4. We connect the previously disconnected wire to the battery ("minus").

Features of working with a prefabricated structure

Often, motorists prefer to buy both brushes and a regulator at once, coming in one set. In this case, replacing the generator brushes for this entire system will also be easy:

• Disconnect the negative wire from the battery;
• Remove the rubber cap from the battery cable going to "plus";
• We dismantle the block by unscrewing the fastening nut;
• Dismantle the plastic casing;
• We take out three spring clips that are located around the entire perimeter of the old block;
• Using a Phillips screwdriver, unscrew the brushes (along the way, the voltage regulator is also unscrewed, while all the wiring connecting them is also disconnected);
• We carry out the installation of a new structure, in a completely free space for it.

Video: Replacing the generator brushes

Among the many components and individual units of a car, a generator is distinguished, which is the main source of electricity in a car. Like many other devices, it periodically breaks down, and in some cases the reason is the wear of the brushes. In such a situation, a completely logical question arises: how to change the brushes on the generator and whether it is possible to cope with this task yourself.

The main signs of the need to replace brushes

During a routine examination vehicle attention is not always paid to small details, which is why their breakdown becomes an unpleasant surprise for the car owner. This fact also applies to those that have to be changed immediately. The question of how to replace the generator brushes is quite relevant, but first of all, it is necessary to understand exactly when a replacement is needed. Experts recommend checking the brush assembly every 50,000 kilometers(or once every four years), then there will be no problems with the generator brushes.

Note! It is possible to diagnose or even replace faulty generator brushes without dismantling the overall unit.

The following symptoms will indicate the need for such a check:

unexpected shutdown of the car's electrical appliances for no apparent reason;

Reducing the lighting level of the vehicle interior and external sources light (headlights, side lights).

Low voltage in the network;

Too fast (unnecessarily fast) decrease in the battery charge, which as a result is very difficult (if not impossible) to fully charge.

Any of these symptoms indicates that it is time to think about checking and possibly replacing the generator brushes. There are several ways to diagnose these elements, but the easiest way is to disconnect power from the generator(it is enough to remove the negative terminal from the battery) and dismantle the voltage regulator. After that, visually assess how far the graphite products "look" out of their shelter. If it turns out that it is less than five millimeters, then the parts need to be urgently replaced.

Where are the brushes

You can find the replacement object at the back of the generator, where it is attached to it with only one bolt. More specifically, the brush assembly is located on the cover of the unit from the side of the slip rings and is combined with a voltage regulator. The brushes are held close to the rings by the force of the springs. In most cases, finding them is quite simple, because knowing the location of the generator and its constituent elements, it is not so difficult to figure out where the brushes are on the generator.

What you need to replace

In order to replace the generator brushes, you will need a standard set of keys, a pair of different screwdrivers, new replacement parts, free space and time. If any of the fasteners are rusted, a solvent can be used to make it easier to remove the fastening bolts.

How to remove the brushes with the generator removed

There are two options for dismantling worn-out generator brushes: with and without removing the unit. Depending on the make and model of the vehicle, the owner himself decides which method is preferable, because in some situations it can be very difficult to get to the right place. So, let's first see how to remove the brushes from the generator on the dismantled device.

It should be noted that it is much easier to perform all actions on a removed generator, since there is more space for comfortable removal of the brushes themselves. Therefore, first you need to loosen the fastening bolt connecting the unit with the bracket of the generator belt tensioning mechanism, remove this belt, unscrew the fastening bolts between the generator and the housing power unit... Then you can remove the desired device from the engine compartment.

In the next step, be sure to pay attention to the seat of the brush holder and, if necessary, blow or wipe it off of dirt. After that, you can proceed to disconnecting the brushes themselves (you will need to unsolder the wires). In addition, it will not hurt to clean the contacts and check the elasticity of the holding springs. The next step is polishing the slip ring, which, although not a mandatory procedure, will still not be superfluous.

After completing the preparatory work, you can proceed to the direct replacement of the parts of interest to us. As a rule, changing the brushes on the generator is, in principle, not difficult, and all that is required of you is to unsolder the wires from the old set of brushes and solder them to the new one. After installing the brushes in the brush holder, do not forget to make sure they can move freely.

It is necessary to install the removed part in its original place very carefully, since it is very fragile, which means that all actions must be performed very carefully. As soon as the brushes take their place in the device, connect the "mass" to the battery and start the car. That's it, the generator brushes have been successfully replaced.

Important! After installing the brushes, the on-board system of the car often raises the alarm about a malfunction of the generator, which is the result of poor lapping of new parts. It will pass over time.

In some cases, it may turn out that the wear of the graphite rods is quite insignificant, and the problem lies in the sticking of the body due to dirt deposits. All that is required in such a situation is to clean the parts with compressed air, after which they can be further used. Before installing new brushes on the generator, do not forget to inspect them - it is quite possible that somewhere there is a manufacturing defect (cracks or chips), both of the graphite rods themselves and of the brush holder.

Installation of replacement brushes on the generator is performed in reverse order, and the installation process is completed by adjusting the belt of the unit. If you perform all the steps correctly, when exposed to 3-4 kg (for a V-belt) or 6-8 kg (for a flat belt) with your fingers, the belt should bend by 1-1.5 cm.Often motorists buy new brushes together with a regulator, which comes with them in one set. Therefore, it will be helpful to know how to replace the brushes on the generator in this case. As in the previous version, there is nothing particularly complicated here, and all actions are performed in the following sequence:

1. First, the negative wire is disconnected from the storage battery.

2. Then it is necessary to remove the rubber cap from the "positive" wire of the battery.

4. Next, you get three fixing springs, which were located around the entire perimeter of the old block.

5. Using a Phillips screwdriver, it is necessary to unscrew the brushes (along with them, the voltage regulator is removed, with disconnection from all the wiring connecting them).

6. All that remains is to place a new structure in the vacant space.

Interesting to know! The first alternator was presented by Neuville in 1946 in the USA. The unit combined in itself almost all the elements characteristic of the device direct current(the first working machine of this type was created in 1934): a separate alternator with an excitation winding, a separate unit of selenium rectifiers, a voltage stabilizer, etc. The main purpose of this device was to use it on special military buses and cars.

Replacing brushes without removing the generator

It is possible to replace the generator brushes without dismantling it from its seat. This option is especially useful if you have purchased new brushes with a voltage regulator as described above. In this case, the order of performing all actions is as follows:

1. Disconnect the negative terminal from the battery.

2. We unscrew the mounting bolts and remove the old voltage regulator together with the brush holder.

3. We measure the distance from the end of the brush holder to the edge of the brushes themselves (when installing new elements, it should be 13 mm, while the minimum allowable value corresponds to 5 mm).

4. Check if the brushes move easily in the brush holder.

5. We return the voltage regulator to its original place.

6. We tighten the fastening bolts back and connect the removed "negative" terminal to the battery.

Of course, in theory, everything looks quite simple, but in practice, many car owners often face certain difficulties, therefore, in any business, you need confidence in your abilities and a competent approach to solving a particular issue.