Volvo

Elecktric

Mechanic Development Program

Brushes, checking and replacement

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Take into account the battery cables or the alternator, under no circumstances
whatsoever, should be disconnected while the engine running. Failure in following that
may lead to voltage high peaks which could cause personal injuries and short-circuits in the
electric system.
1

Break the circuit with the battery master switch. Remove first the condenser suppressor.
Short-circuit by connecting the tip of the cable to the condenser housing.

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If not in short-circuit, the condenser may wear out if carelessly handled. That may be
dangerous specially if get into contact with inflammable fluids.
2
Remove the voltage regulator. Test the brushes (if they have not been tested in previous diagnosis
solutions).
3

ADRO/PSPN/SUMARMAN

Volvo
Elecktric

Mechanic Development Program

Replace both brushes if one of them is damaged or too short. Measure the brush length from the
brush contact surface to the brush holder. The projected section should not measure less than 5
mm. Replace the brushes as follows: heat the cable and, at the same time, remove the brush with
pliers. Drill the rivet by its internal side with a 3.2 mm diameter drill. Remove the tin residues.
Specifications:
3.2 mm 5 mm
4

When installing the new brushes, insert the drilled rivet into the current conductor track. Rivet in
such a way so that the rivet wider section is projected outside.
5

ADRO/PSPN/SUMARMAN

Volvo
Elecktric

Mechanic Development Program

Install the new springs and brushes so that their ends face the regulator box. Tighten the brush
cable in the drilled rivet so as the brushes are projected 12 - 13 mm outside the brush holder.
Weld the cable.
Note: The welding tin should not trickle down along the brush handle. Cut the remainder section
from the cable.
Specifications:
12 - 13 mm

ADRO/PSPN/SUMARMAN