Generator brushes - how to replace this element yourself? Change generator brushes quickly and easily.

4 years ago

Brushes are an integral part of the generator. They are inexpensive and are replaced in just 20-30 minutes. Thanks to the brushes, the battery is charged, and the current from the generator is supplied to the on-board network. Failure is fraught with consequences: the car does not drive, the battery charge lamp immediately lights up, signaling the generator is not working properly and inspection is necessary. Do not operate a car with a glowing light on the tidy, because in the wrong place the battery will suddenly sit down, the car will stall and you are unlikely to start the car (the current stops flowing into the ignition system, and therefore the spark disappears and the air-fuel mixture stops igniting).

Note!
You will need the following tools: wrenches, sockets with a wrench, new brushes and screwdrivers.

Brush location

Located under the generator cover (indicated by the red arrow). Remove it and unscrew the screws securing the voltage regulator (the regulator is indicated by a blue arrow). It comes assembled with brushes, the screws are not attached directly to the brushes, but to the regulator, the brushes are inserted into it.

Time to change brushes?

In the photo below, the arrow indicates a lamp that indicates possible problems with the generator. If you see this, check the fuse going to the generator and replace if necessary. Is everything in order with the fuse, and even after replacement, this lamp does not stop burning while the engine is running? Proceed to remove the generator and check the brushes, diode bridge, etc.

Symptoms of broken brushes:

luminous battery charge lamp;

some devices turn off (for example, the turn signals stop working, although the fuse going to them is intact);

devices work worse (the light is dimmed, the stove blows weakly).

The above points are a clear signal: the battery will soon be discharged, be careful.

Replacement of brushes for VAZ 2110-VAZ 2112

Note!
There are two ways to replace:

the second is to disconnect the minus terminal from the battery (read in paragraph 1 of the article: " Replacing the battery on a car") and doing all the work on the installed generator on the car.

Perhaps the second option is not very convenient, however, by doing everything right, you will save a little time, and besides, removing the brushes is not difficult.

1. To change the brushes, first release the three latches on the sides of the alternator that secure the cover to it. By removing the cover (see small photo), you have access to the voltage regulator. It has two fastening screws (indicated by blue arrows), unscrew them and, by pulling the regulator, disconnect and thereby remove completely from the generator.

Note!
You can completely change the regulator with brushes, but in the absence of this possibility (for various reasons, for example, financial difficulties), replace separately the brushes that are attached to the regulator by soldering. More precisely, their wires are soldered to the terminals of the regulator - take a soldering iron and solder the wires coming from the brushes. Then remove them from the regulator and install new ones in the same way, using soldering, install them in place. We have attached a video for your reference.

2. After removing the regulator, inspect the condition of the brushes: the length should be at least 5 mm (photo 1), otherwise replacement is necessary. We recommend checking the regulator as follows: connect a 12 volt test lamp as shown in diagram 2 (to the brushes), and apply a voltage of 12 volts. It can supply a battery, run some thin wires from it “+” to the terminal, and “-” to ground. The lamp should light up. Perform a similar operation with a current not at 12 V, but at 15-16 V. An extinguished lamp means: everything is in order with the regulator and it does not need to be replaced.

Additional video
We have attached video materials on the topic of today's article, we recommend that you read it.

Alternator brushes are an important element of the automotive system for supplying and discharging electric current. Without their participation, the car's generator will not be able to generate voltage.

Generator brushes - element information

The brushes we are interested in are made of graphite, which is why they are often called carbon brushes. They are used not only on cars with an internal combustion engine, but also on a wide variety of mechanisms and machines equipped with an electric motor (machine tools, lifting equipment, urban public transport, and so on). Brushes are the most common EG-4.

This brand is suitable for installation on many cars of different years of manufacture, as it has standard operating parameters. Rarely used other products (for example, EG-61), which are characterized by a high margin of safety due to their impregnation with special compositions.

The generator and brushes for it on domestic cars are located under the right front headlight of your "iron horse". Finding them is easy. It is enough to open the hood to see the generator - its winding and two lids that look like tin cans come to the surface.

When should alternator brushes be changed?

It is noteworthy that you can check the brushes (and change them if necessary) without dismantling a rather bulky generator. In addition, the following symptoms may signal the need to look under the hood of a car and check the graphite brushes:

• unpredictable shutdown of electronic devices in the vehicle, occurring for unknown reasons;
• reduced illumination of the car interior and external light sources;
• voltage reduction;
• discharging unreasonably quickly, which, moreover, is then very difficult (and sometimes impossible) to charge.

Any of these symptoms tells the motorist that he most likely needs to remove the old brushes and install new ones instead. You can check old products for functionality very simply. It is necessary to fold the "minus" from the battery, remove the voltage regulator and visually assess to what height the graphite parts of interest to us protrude from their "shelter". Brushes need to be changed urgently when their height is less than five millimeters.

Alternator brush replacement - from A to Z

We must say right away that this operation is very simple and does not require special skills from the driver. First, as already mentioned, you need to fold the "minus" from the battery, then dismantle the regulator (it is located in relation to the generator on the opposite side), and then perform the following steps:

• Thoroughly clean soot and dust from the holder seat, as well as the clamping springs and slip ring. This operation is performed with a soft bristled brush. Sometimes it may be necessary to grind the graphite brushes to the commutator with glass fine sandpaper (its grain size should be about 100).
• Install new products and check that they move freely in the brush holder.
• Assemble the assembly in reverse order, and then connect the previously wrapped wire to the battery.

If you bought a prefabricated structure (regulator plus brushes), its installation also does not cause any problems.

Disconnect the “minus”, remove the cap made of rubber from the “positive” wire, and then dismantle the block by unscrewing the fastener nut. Then you will need to remove the plastic casing and remove the three spring clips located around the perimeter of the block. Using a Phillips screwdriver, unscrew the brushes along with the voltage regulator, and disconnect all the wires leading to it. Mount the purchased prefabricated structure in the vacant space. Operation completed!

In a VAZ 2109 car, replacing the generator brushes is necessary if they are at least a little worn out. Otherwise, the generator may fail.
And this will lead to the fact that it will be impossible to use the machine, since without a generator you can forget about normal functioning. Simply put, the car cannot be started.
And besides, the battery will be discharged too quickly. If any defects are noticeable in the operation of the generator, then they urgently need to be eliminated.
Replacing the brushes of the VAZ 2109 generator is a simple process and everyone can handle it.

Reasons for replacement

Generator brushes need to be changed in such cases:

• They have worn out so much that they have already ceased to fulfill their main function - to save battery power.
• The battery drains quickly.

Note: there are a lot of reasons why the battery is quickly discharged.
Therefore, this does not always signal bad brushes. But just in case, it’s better to check them all the same, since perhaps the reason is hidden in them.

Checking brushes at home

To check if the brushes are working correctly, you should:

• Remove the battery so that the generator is de-energized. Otherwise, a small short circuit may occur in the system.
• Disconnect voltage regulator.
• Visually inspect all brushes.
• If they are less than 5 mm long, they should be replaced immediately, as they no longer function as expected.

Quick brush change

To replace the brushes, you will need the following tools:

• Key for 8 (or head for 8).
• Flat screwdriver (to remove the cover).
• Open-end wrench for 13.

To replace the brushes quickly and easily, you should do this:

• Loosen the nut and bolt holding the alternator.
• Take off .
• Start the engine.

Note: By the way, a bad belt can also cause alternator problems.
It needs to be checked and replaced if necessary. To check, you need to bend it and see if there are any cracks on it.

• Disconnect the battery (to do this, disconnect its negative terminal). This must be done very carefully, as the battery contains acid, which can damage the skin if it comes into contact with it.
  This must be done in order to avoid a possible short circuit.
• Disconnect the wires from the generator.
• Remove the front crankcase cover.
• Loosen the bottom mounting of the alternator.
• Use a flathead screwdriver to block the rotor until it is completely stationary.
• Unscrew the pulley.

• Remove the generator cover.
• Remove the protective plastic cover to access the brushes.
• Use a screwdriver to hook on the small power plug coming from the brush holder.
• Pull it up. Pull until the plug is removed.

Note: The slower things go, the better. After all, it is impossible to allow the soldering to come off the voltage regulator, since after that it will be difficult to reconnect the battery.

• Disconnect the plug from the brushes.
• Unscrew the bolts with which the brushes are attached to the brush holder.
• Remove voltage regulator. Unscrew the brushes together with the brush holder. It comes off easily.
  Do not be afraid to damage it when taking it out, as it will be replaced soon anyway. But first you need to complete the removal of the generator.

• Unscrew the four bolts on which the halves of the generator are attached.
• Remove back cover. To do this, insert a screwdriver into the slot between the generator and the cover and pull up. After a few seconds, the cover will be removed.
• Screw the nut onto the rotor.
• Carefully remove the alternator (see).
• See if all of its parts are in usable condition.
• Unscrew the large bolt coming from the brush holder (but not completely, it only needs to be slightly loosened).
• Take new brushes and insert them in place of the old ones.
• Tighten with a wrench so that they hold well.
• Assemble the generator and insert it into place.

Replacing brushes without removing the generator

If the problem is definitely in the brushes, and not in the generator, then it is not necessary to remove it.
In this case, the replacement will be accompanied by the following actions:

• Disassemble the generator to get to the brushes (but do not remove it completely).
• The brush holder socket should be blown out with compressed air.
• Then clean it with a soft cloth.
• Gently remove the brushes (for this you need to use a soldering iron).

Note: you can remove the brushes in one more way - together with the brush holder. However, in this case, you will need to buy a new brush holder, and not just brushes. This will be much faster, but also more expensive.

• Clean all contacts.
• See if the springs have sufficient elasticity.
• Polish the slip ring if there are noticeable defects on its surface.

Repair takes place in the following sequence:

• Remove the generator, and then the plastic casing.

Note: since it is made of plastic, it can only be removed by hand, without the use of any tools. This may damage its surface.

• Loosen the screws securing the voltage regulator.
• Remove brush holder with brushes.
• Disconnect the battery terminal.
• Remove the block by unscrewing all the stator fasteners down.
• Remove the tie screws (there are 4 of them).

• Remove the generator cover (a screwdriver can be used for this).
• Clamp the rotor to a state of immobility.
• Loosen the nut that secures the pulley.
• Remove spring, pulley and thrust washer.
• Remove the rotor from the drive side.
• Remove contact ring. You can sand it down, but it's not necessary.
• Check rotor.
• Check out the stator.
• Assemble the generator in reverse order.
• finished.

You can replace the generator brushes with your own hands, since it is not difficult to do this even at home. The price of new brushes ranges from 300 rubles.
Of course, you can buy them together with a brush holder. In this case, the repair will become even easier, but you will have to pay a little more.
And in a car service you will need to pay two, or even three times more. Of course, before proceeding with the repair itself, it is worth reviewing the photos and videos on this topic.
The instructions don't hurt either.

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 urban transport engines, in machine tools and in a number of other mechanisms, the operation of which is based on the use ofelectric motor. Graphite electric brushes, no matter what the purpose of the mechanism, always perform their function in the same way. It is necessary to monitor how much they protrude from their "nest".If the brush protrudes less than five millimeters, then it means that it is time to change it.

The coal type is divided into a large number of models that 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, amount of strength and reliability. They often have to be changed, that is, they wear out quickly and cease to perform their functions, and this, in turn, suffers generator.

In some cases, drivers prefer to choose the most durable, 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 diagnosis and replacement

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

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

How to change them? Very simple. The holder socket must be blown and wiped, after which these parts should be disconnected. This is followed by cleaning the contacts, checking the spring, polishing the slip ring. The last procedure is not mandatory, but it is better to play it safe. It is equally important to know how to check the generator brushes. Their level of wear can be determined by sight. Also, how they perform can say a lot.This concludes 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 their holder itself. Then carefully install them, not forgetting the voltage regulator and grounding. Remember that each car has its own characteristics, so changing the alternator brushes is not the same for each model.

Many car enthusiasts are engaged in repairing their car on their own. But not everyone in this business is a professional, and many questions arise during the repair. How to change the alternator brushes on VAZ cars? There is nothing difficult in this. Replacing the generator brushes with a VAZ, for example, model 2114, is quick and easy. First you need to know how the generator works.

Structure

The generator consists of three windings, they are installed so that the voltage occurs on different windings each time.

Stator windings- they always need voltage, they get it from the battery. The windings act as magnets. They form a magnetic field, due to which the voltage is relieved. The voltage is removed from 18 V. But the maximum allowable voltage is 14.7 V. For this, a stabilizer is installed.

Stabilizer or brush mechanism- installed on the generator itself. Thanks to him, one voltage is maintained.

What role does

The generator is responsible for the movement of the car. It supports and is responsible for fueling when starting the car.

Replacement procedure for VAZ 2114

Before replacing the brushes on the VAZ 2114, it will be more convenient to remove the generator.

Removing the generator

• The car is put on the handbrake, chocks are additionally installed.
• Disconnect the negative terminal from the battery.
• Tension bolt drops.
• The wires under the rubber boot are disconnected and the connector is disconnected through which the voltage goes to the winding.
• Using a large screwdriver, you need to move the generator to the engine.
• After that, you can remove.
• The fixing bolt is dropped. To do this, first, using a 15 head, unscrew the bolts holding the bracket. Then turn the generator clockwise. You will be able to remove the axle mounting to the bracket.
• The nut is unscrewed with a 19 wrench and pulled out with a sleeve, the axle is knocked out of the bracket.
• The generator is easy to remove up.

Replacement

The generator for the VAZ 2114 has brushes that are responsible for regulating the voltage.

If it is time to change the alternator brushes, proceed as follows:

• The first thing to do is to disconnect the terminal from the battery.
• Next, you need to disconnect the block with wires.
• Then unscrew the clamp nut.
• Then the power wires are removed from the stud.
• The latches that hold the plastic cover around the perimeter are released.
• The cover is removed, and the brushes themselves are located.
• After the brushes are found, the bolts that secure the brushes are unscrewed.
• The brushes themselves are pulled out.
• Before installing new brushes, check the size of the graphite contacts, their normal protrusion is considered to be at least 0.5 centimeters.
• New brushes are installed and, based on the above procedure, we assemble the generator.

Photo instruction

Replacement for VAZ 2110

On VAZ 2110 cars, the battery charge mainly depends on the operation of the generator. If the battery charge light stays on after starting the engine, it means there is a problem with the alternator. And in most cases, this means that it's time to change the alternator brushes. Replacing the generator brushes is also not difficult.

What will be required

To replace the brushes, you will need a set of tools and gloves. In addition, you need stops for the rear wheels.

Before replacing the alternator brushes, it will be more convenient to remove the alternator.

Removing the generator

• It will be more convenient if you drive the car into a viewing hole. If the device is not being removed in a pit, jack up the front of the machine.
• Install wheel chocks.
• Opening the hood, turn off the power by removing the wire from the minus terminal.
• Unscrew the crankcase protection bolts and remove it.
• Slightly loosen the nuts on the top and bottom of the generator.
• The adjustment screw is loosened.
• The alternator belt is removed.
• The output terminal D is removed.
• The rubber cover is removed.
• The plug fixing nut is unscrewed.
• The plug is disconnected from the bolt with contacts
• The nut located at the bottom and top of the generator mounts must be unscrewed and removed.
• Then remove the tension bar, spacer sleeve.
• While holding the generator, remove the remaining mounting bolt.
• Everything - the generator is removed.

Brush replacement

It is best to disassemble the generator on a clean surface, you can lay a cloth.

• We put the generator so that the pulley is at the bottom.
• Seeing the springy holders, you need to snap them off with a flat screwdriver.
• Then you can remove the cover of the generator.
• Now you will need a Phillips screwdriver to unscrew the screws that hold the brush assembly.
• The terminal is removed from the brush holder.
• The nut is unscrewed from the contact bolt.
• Seeing two springy washers, remove them.
• Disconnect the capacitor wire.
• The screw attached to the capacitor is unscrewed.

Before replacing the brushes on the VAZ 2110, the size of the protrusion of the contacts is checked and the whole procedure is carried out in the reverse order.

Photo instruction

Replacing brushes on a VAZ 2107

The principle of operation of the generator on VAZ 2107 vehicles is the same as on the vehicles listed above. After starting the engine, the battery light is on, which means it's time to replace the generator brushes.

Since replacing the alternator brushes takes very little time, many motorists are ready to do it themselves.

When replacing the generator brushes with a VAZ 2107, you can remove the generator, but this can be done without resorting to these measures. Simply disconnect the wire from the negative terminal.

Changing brushes

• The wire is disconnected from the terminal.
• Two screws are unscrewed that attach the brush holder housing.
• The brush holder comes out.

Before replacing the brushes, it is better to check if they are the problem.

Checking the brushes

You will need a 12V bulb to check for brush failure.

We throw a plus on the terminal, we throw a minus on the mass terminal. The lamp lights up, we carry out the test further. We add voltage to 16 V, if the light continues to burn, this is the main sign of a brush failure.

In this case, before installing new brushes, it is worth checking the protrusion of the graphite contacts. A normal protrusion is considered to be at least 0.5 cm protrusion , after which new brushes are installed, and everything is installed back, based on the above actions.

It happens that the repair of the generator does not end only with the replacement of brushes. If the wear of the brushes is not detected in time, then the other parts of the generator are also worn out, since all the elements of the generator are interconnected. That is why after replacing some brushes, the malfunction in the generator will not completely disappear, but the signs of breakdown will disappear for a while.

When replacing brushes, it is best to remove the generator and examine it, trying to identify what kind of malfunctions it may still have.

Video

See below for instructions on replacing brushes without removing the generator: