Citroën Berlingo Electrique/Service Manual/Brush Replacement

This page provides additional tips on how to change the Citroën Berlingo Electrique motor brushes.

The motor brushes are a key element of the Berlingo and failure of the units can cause significant damage to the motor and may also cause damage to the very expensive controller. It is therefore recommended that brushes are changed at regular intervals defined in the service manual.

Brush suppliers

It is recommended that only genuine Citroen brushes are used. These units are expensive but are; manufactured to tight tolerances, made with specially hard wearing carbon and finished (with serated bearing services) to provide quick bedding-in and therefore minimal impact on the commutator.

The genuine Citroen supplied brushes seem to be supplied by http://www.schunkgraphite.com

http://www.schunkgraphite.com/ supplied Marc Boden. Did not have groves for bedding in.

Required tools

The following tools are recommended:

8 and 10 mm socket.
10mm ring spanner
Miniature goose neck pen light taped as shown.

Remove old brushes

Follow instructions supplied with the brushes.

Inspect brush container

Once the old brush has been removed. Inspect the brush container for signs of spark erosion, between the brush container and the commutator. This may obstruct the movement of the brush and result in further sparking and possible motor/controller damage. If erosion is present it may be necessary to remove the (possibly very hard) material as follows:

make up a commutator protector using sheet metal (ideally steel) as shown on right (damaging the commutator is very costly problem to rectify).
insert the (long part of the ) protector between the brush holder and commutator
using a drill with a Dremel bit to very carefully remove any burrs or obstructions
continually check that the protector is still in place and performing its job

Check brush is inserted and seated correctly

Insert the brush with the slopping face aligned with the commutator. This can be checked after the brush has been inserted by checking the slope on the back of brush is opposite to the slope on commutator end.

Once the brush is inserted check that it moves freely and seats solidly on the commutator. Use the miniature goose neck pen light taped as shown to verify brush is seated correctly.

insert the goose neck behind the brush
lift the brush a little to see the light between the brush and commutator
release the brush and check that the light is obscured.

Finish off

Follow instructions supplied with the brushes.