Replacing the brushes in the Bosch voltage regulator

LADA Granta VAZ 2190 (engine 21126)

  • Unscrew six screws, remove engine guard.
  • Through the wheel arch opening remove belt from alternator pulley, crankshaft.
  • Unscrew power cable of alternator from the back side.
  • Unfasten the lower mount, take out the bolt.
    Remove the converter from its regular place.

Further we conduct preventive maintenance, replace worn out details, install in the reverse order.

Repair of Bosch alternator

We brought faulty alternator from Logan 1. Almost stopped charging.Autopsy showed that the patient had a dead ring and brushes.The alternator is like this:

Take off voltage regulator and brushes. One brush ate, the second is more alive.You can see the diode bridge:

The diode bridge in the alternator is crimped around the terminal windings loops (no soldering or welding, just crimping) gently unwind 6 loops, and remove the diode bridge.

Next, you need to unscrew the head 8 on 4 bolts on the alternator body and remove the rear part with two screwdrivers (from the side of current collector rings).Here is the view of the rotor. the bearing and the armature rings. The bearing is removed with a two-fingered puller, I used a three-fingered (I had to sharpen it a bit).

Next, you need to remove the current collector rings themselves. first disconnect the windings from the rotor to the current collectors.( a scalpel is handy).

On the plastic from below current collector rings is shoulder. put new rings according to this shoulder!The stripper rings peel. if the stripper does not grasp. then break it gently with a screwdriver / scalpel, plastic is brittle and breaks quite well.

Rings on the alternator, I bought in advance CARGO 135172 in an amount of 2 pieces (in stock).So, the rings are taken off. Slightly grease the shaft, and press in new armature rings. It is convenient to do with the end of a wooden handle of a hammer at 150 grams. We correct the wires and lead them to the alternator leads.As shrunken. run the soldering iron and solder everything. This alternator uses welding of the windings to the contacts of the rings. t.к. The weld will withstand high temperatures. Solder the smaller. You can use high-temperature solder. Most correctly weld the ends of the windings.Then use a 17 head to press the bearing in place. After pressing dress the rear case and tighten with bolts. Polish the surface of the rings with null compoundWe put on the diode bridge and press the ends of the windings (6 places in the old places, pre-scratch them. For the gourmets, you can solder.

Now the most painful part. replacement of brushes in the regulator. As a replacement took the brushes from VAZ 2110 are fine. except for the length of the wire from the brush (this is solved by soldering or crimping a copper sleeve longer wire).Fits all regulators of this type

Remove the cover covering the brushes. it is removed hard. use a scalpel or screwdriver

After is necessary to remove the entire adhesive layer

After we removed the sealant (using an engraver is convenient), you can see the aluminum contacts and the plastic stops of the brushes

Turn the regulator upside down with the brushes up. and knock the brushes down. Should come out. plastic brush bed, spring and brush.

After cleaning install the spring on the brush and on the bed, wire from the brush through the hole in the bed and install it in the regulator assembly. The voltage regulator contacts are made of aluminum, so the copper wire from the brush is welded at the factory. In my case I used special aluminum flux:

How to change brushes in Bosch alternator regulators.

Instructions for using this flux:1) grind the place of soldering2) drop the flux (will be seen how it reacts with the surface of aluminum) 3) apply and rub the solder on the surface of aluminum4) solder wire5) admiring the result

After soldering you need to fix the plastic brush beds in the regulator. you can do this with a drop of epoxy.Т.к. tightness of the cover is now in question. fill aluminum contacts with sealant (I used black ABRO gasket sealant and pushed the cover into the sealant. Remove excess sealant and send it to dry on the towel rail:) Install it on the car and enjoy the result))

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Bosch voltage regulator BR28-N1.

Bosch. F00M144123. Alternator regulator MB Actros 613 D614 D615 D616 D (668.331668.332)618 D818 D818 DA 4×4810 DT812 DT (670.398)813 D814 D815 D816 D (670.331670.332)813 DA814 DA 4×4815 DA816 DA 4×4 (670.431670.432)O 810O 814O 815 (670.373670.374)

BR28-N1, F 00M 144 123 for alternator 4892318, 4892320 Bosch Cummins engine 4ISBe185, 210, 285, 300.

Bosch. F 00M 144 123. EL. VOLTAGE REGULATOR F 00M 144 123

SCANIA 1900934
MERCEDES-BENZMercedes Benz Actros A0001543805, 000 154 38 05
  • Alternator connector
  • Radiator of the integral relay
  • Holes to attach voltage regulator to alternator, also serves as ground
  • Brush holder
  • Voltage regulator connection to alternator terminal B
  • two brushes
  • integral relay
  • alternator phase output to pin W (tachometer)

Most repair of an alternator is limited to replacement of brushes. But sometimes it is necessary to interfere more deeply. And there is a need for more information. Some technical information you will find on this page.

replacing, brushes, bosch, voltage, regulator

About brushes and why to change them

it is clear that an alternator with defective brushes will not work properly. Brushes themselves are made of graphite. That is why they are also called carbon brushes.

By the way, using of carbon brushes is not limited to auto systems They are also widely used in other types of equipment, such as electric motors.

It will be interesting to consider the varieties of brushes used today:

  • EG-4 is the most sought-after group of brushes, suitable for automotive GPTs of various years of manufacture;
  • EG-61. inferior to EG-4 in popularity, but also quite famous. Their advantage is a high degree of reliability.

According to the experienced motorists, it is better to install the brushes, blotted with a special compound. They do not deteriorate quickly, since a special chemical composition protects them.

Brush block location on an alternator

The strength of the brushes is also important. The graphite elements need to be strong to last longer.

The location of the brushes can also be different. For example, in domestic cars, they found a place just below the right lamp of the front optics, on the GPT. It is easy to reach them by opening the hood of the vehicle. The two covers that look like a tin can and the winding of the brushes are always in view.

So, the brushes should be urgently replaced as soon as they fail, because the generator suffers from this. The elements directly interact with its rotor. Experienced motorists and specialists recommend checking how the brushes are sitting, or rather, how far they protrude from their “socket. So, if the brush protrudes less than 5 mm, it means that it needs to be replaced.

It is noteworthy that the GPT most often fails because of the brushes. This is the most real consumable. That’s why you need to take care of the brushes periodically, diagnose their condition every 50,000. km of vehicle’s mileage.

One of popular ways of testing battery and at the same time HPT together with brushes, is to connect multimeter to the battery. The measuring device in this case is needed to measure the level of charge, necessarily taking into account the turned on elements of the car. headlights, interior lights, heater and other consumers.

Voltage regulator LADA Granta

Initially check the voltage regulator without removing the alternator from the car. To do so:

Put aside the rubber cover and connect the “plus” wire to the volt, and the “minus” wire to the body of the generator.

Start the engine and turn on headlights of the car.

After 15 minutes of running the engine at medium speed, measure the voltage, it should be 14.4-15.1 V. If you have incomplete or overcharged (the voltage is not within the specified limits), replace the voltage regulator on the alternator.

Disconnect negative battery terminal.

Remove the alternator from the vehicle as described here.

Remove the brush holder from the alternator voltage regulator relay assembly as described here.

Check that the brushes can move easily in the brush holder and are protruding.

If the brushes are protruding less than 5 mm from the brush holder, replace the voltage regulator with the brush holder.

Check that the voltage regulator is functioning properly. Connect the 12 volt test lamp to the brushes. Connect the 12V “plus” voltage to the terminal and the minus voltage to the brush holder “mass”. The control lamp should be illuminated.

Set the voltage to 15-16V. The light should go out. If the light is on or off in both cases, then the brush holder regulator is defective and must be replaced.

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Install a new voltage regulator (if necessary), reassemble the alternator and install it in the order reverse to the removal.

If necessary you can check and replace the voltage regulator without removing the alternator from the car.

Repair of generator, charging relay, rotor collector (contact rings)

Tired of collecting information in pieces, I’ll start with the main parameters: Information on the batteries for information (choice of battery, battery device, charging the battery, battery recovery), (we begin to work with the generator only when the battery limps) Conditions for the battery Black horse: to 14,4 V charge current of 10% of the nominal capacity. 75 A/h current 7.5 A Above 14.4 to 16. 16.2 V current 5% of rated capacity. 75 A / h current of 3.75 A The charging voltage on the car for our digital voltage regulator with the included consumers must not exceed 14.5 V, and with the turned off consumers 13.8 V. If the alternator gives out less (more) then repair of the alternator (replacement of the relay, repair of the diode bridge). ), or problems with the battery or the load. Ideally, it would be as follows: in summer. 13,8V (to avoid overcharge), in winter 14,5V, normal mode. It is unacceptable to run the battery for a long time (more than 1 month) in overcharged conditions, t. е. at charging voltages higher than 14.5V, as this causes the entire stored electrolyte to decompose and may cause the battery to explode and ruin. it is NOT ALLOWED to operate the battery in a NOT CHARGED mode. е. at voltages below 13.8 volts. In summer, my battery at 14.5 V starts to boil a lot, on a long trip. In winter at 14.5 V I feel a decrease in capacity. Battery leakage current not more than 0.030 A, taking into account all consumers such as clock, alarm, on-board computer. (in order not to blame the alternator unnecessarily). and this is very low! Percentage of battery charge, % / Battery voltage for open circuit (at least 7 hours after charging) 100 / 12.6 or higher 75 / 12.4 50 / 12.2 25 / 12.0 0 / 11.8

Bearing replacement in Bosch 140A alternator Bosch Esitronic program by VAG code. 06F 903 023F Bosch alternators. 0 124 525 050 0 124 525 066 0 124 525 091 Also our alternator is named Bosch E8 14 V 75-140A and parameters: Standard alternator contact ring diameter 15.4 // minimum. mm 14.4 Maximum allowable radial run-out of the pulley // contact rings // alternator rotor, mm 0.4 // 0.02 // 0.087 Minimum permissible length of alternator brushes, mm 7.5 Resistance of the generator rotor winding, ohm 2.6 Dependence of output current of Bosch E8 alternator on crankshaft speed RPM // Current, А 1800 // 75 6000 // 140 DFM. Indicates fraction of current consumption in relation to available current. “L”. output to alternator operability indicator lamp B. understandable Battery 12

Spare parts, installed in alternators, see alternator number on this site: FRONT European producers 6303 2RS 17x47x14mm, REAR European producers 6003 2RS 17x35x10mm, in Russian 303 and 103 and with two contact rubber-metal seals. I was sold Slovakia KINEX 6303 2RSR and 6003 2RSR Total 200r. SKF manufacturer is twice as expensive. Replace the rear bearing bush also Ika 1.3686.0

Removing the generator, replacing the clutch (pulley) and tensioner on my generator 0 124 525 066 FORCE puller F-678 (T-50) Please write in the topic who has a set of removers on the generator.

Alternator diode bridge, compatible looking at this site Installed these diode assemblies Bosch F00M133218 F00M133229 F00M133247 F00M133259 For these alternators Bosch 0124525066 0124525091 Transpo IBR 215 Diode Bridge Utm BHP12064HD Diode Bridge

Contact ring for the alternator 0 124 525 066 was not available ordered Cargo 135172 through the store. Bosch 1 124 303 007 Wood auto SLR39121 Cargo 135172 Outer diameter 16mm Inner diameter 7.25 mm Depth 52 mm

Alternator voltage regulator original VAG 06F 903 803 B Brush regulator Ika 0.1083.1

On my alternator, the winding leads to the diode bridge are not soldered, but crimped. There was no contact on one winding. 1. Unscrew diode bridge from alternator. 2. Open the taps from the bridge to take out the bridge. 3. Clean the bridge and stator taps, tin the bridge taps and stator winding taps. 3. Install the bridge back, but do not lead the taps of the windings into the bridge taps, but unbend them a little. 4. Bend it back to its original place and solder. It was possible to solder without removing the bridge and without unbending the taps, but the problems with the next repair are frightening.

Repair of gernerator photo-report. The alternator is removed. Alternator coupling removed. Remove back plastic cover. Voltage relay. The red arrow on the photo shows a greenish compressed contact of the diode bridge (which was loose). using thin screwdriver bend winding connection to diode bridge. These connections should be soldered during reassembly. But not putting winding wires into ring that formed, but overlap. Remove diode bridge. There are 6 winding leads in the photo, which must be unclamped. Unscrew bolts fastening the two halves of the housing of the generator. Pull the alternator halves apart. remove the rotor with the front half of the alternator housing. (picture shows one rotor with the front half of the alternator case already removed). To remove the front half you need to remove 4 screws fixing the front bearing. The holes where they are mounted are shown in the picture. Remove the bearings. Rear bearing should be removed carefully so as not to bend the shaft on which sits the contact rings. Removed back bearing with two screwdrivers and two wrenches, putting them between the bearing and the rotor. I cut off the front bearings with an angle grinder, carefully, so as not to touch the shaft as much as possible. Also carefully grind contact rings, so they easier come off the shaft. Then we sawed off the slip-ring connections at the rotor winding connection to re-solder them afterwards. Using a screwdriver we pick up and remove the remnants of the contact part. Put on the ring contact Cargo 135172, carefully, so as not to bend the shaft, put in one position. Solder the winding to the rings. Putting on bearings and assembly.

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Three-level voltage regulator in a Bosch A alternator. logbook Opel Vectra on DRIVE2

The following description is for a Bosch alternator Ampere, catalog number and type can be considered without disassembling.

In general, we will need or may need: With the reassembly should not be a problem if you can remove the alternator, and rebuild it will not be a problem: Next, everything is simple. solder old brushes and install the relay alternator Opel Vectra b new brushes, do not forget about the spring, bushing I left the old. My old brushes were already on edge and were touching the contacts just a little bit.

Do not forget to rivet or pinch the pill with small screws. Installing the three-level voltage regulator.

Since the alternator is disassembled and I have long wanted to make this regulator, why not. Quote Stitchy A man came in with a Vectra B who was annoyed by the constant noise from the engine.

At first I was going to blame the alternator belt tensioner, but after changing the belt tensioner the situation had not changed. Changed the alternator to another, after a complete rebuild, that is, with the replacement of all bearings and brushes, the noise still remained. And the noise came clearly from the generator.

And the one after the reassembly was twisted before putting it in and it did not make any strange noises. To remove the fuse, use tweezers to remove the fuse from the socket.

Take the fuse out of the tweezers. The wire inside the fuse is easily seen and will break if the fuse blows.

The brake pads, chains, bolts, and pinch points should be replaced with the same grade of fuse. Never replace the fuse more than once without determining the cause of the blown fuse.

Brushes for Metabo power tools (available from stock)

If there is no information about the electric brushes you can use the application form from the site. Our specialists will contact you after we receive your information. Go to

Presented brushes are original (not China) and come from official European manufacturer. These brushes are made of high-quality graphite, which implies a long lifetime Price is for 1 set. 1 set = 2 pcs. electric brushes

When it’s time to change the alternator brushes?

Main signs of failure of brushes on an alternator:

  • spontaneous disconnection of electric devices when the engine is running;
  • Decreased brightness or blinking of the control lights and regular lights;
  • The voltage drop in the on-board voltage during operation of the power unit;
  • appearance of extraneous sounds (rustling or squeaking) during alternator operation;
  • turn on the control indicator of the lack of charge (the lamp is in the instrument cluster);
  • rapid battery discharge when the car is in motion.

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