Replacement of carbon brushes of the generator, voltage regulator

The voltage regulator is built into the carbon brush holder. Carbon brushes can be changed individually, but this requires a certain skill. The carbon brushes of the generator wear out rather slowly, on average after driving about 120,000 km. It is recommended to prudently replace them a little earlier.

Withdrawal (Bosch generator)

Remove the generator.

Unscrew the screws -1-, disconnect the spring clips and remove the protective cover -2-.

Unscrew the screws -4- and remove the regulator -5- to the side.

Replace the carbon brushes, for this you need to solder the wire core.

Check the slip rings for wear, if necessary, bore them slightly and polish them clean (work in a repair shop).

Installation

Insert the carbon brushes -A- and the springs -B- into the brush holder -C- and solder the connections.


So that when soldering new brushes, the solder does not rise too high along the multi-pin wire, wrap the end with pliers.

Attention! With a large grip on the end of the multi-contact wire with solder, the wire becomes rigid. and carbon brushes are unsuitable.

Install the voltage regulator and fasten it with screws When installing the regulator, pay attention to the fact that the protrusion for connecting to the housing -5- is adjacent to the regulator, see fig. Р15-400001.06.

After mounting the new carbon brushes, check that they move freely in the brush holders.

Put on and screw the generator cover.

Install the generator see paragraph 20.23.

Withdrawal (FORD generator)

Attention! Carbon brushes can only be replaced in conjunction with a voltage regulator.

Remove the generator.

Unscrew the four screws of the regulator and take it out.

Installation

Insert and screw the regulator -1-.

Pull out locking pin -2-.

Note! The replacement regulator has a locking pin to keep the carbon brushes in their original condition.

Install the generator see paragraph 20.23.