EASYchange® Removable Brush Holders

Reliability Starts with a Better Brush Holder

Cutsforth Brush Holders Keep Generators Running Longer

The Cutsforth EASYchange® Removable Carbon Brush Holder transforms generator maintenance by enabling safer, faster brush changes—even while the unit remains online. Its removable design reduces ring-fire or flashover risk, improves personnel safety, extends collector ring life, and lowers maintenance costs by eliminating common brush holder issues with OEM and other aftermarket holders. We have never had a failure as a result of our brush holder. With more than 20 years in the market in 50,000 installations across 1,700+ units worldwide, EASYchange has become the trusted standard for efficient, reliable generator brush maintenance.

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Brush Holder Highlights

Directly replaces most OEM or aftermarket holders with minimal modification
Uses the same grade of carbon brush already in your system
Allows the safest online brush changes by racking out a brush under no current, reducing time around energized, rotating equipment.
Reduces carbon deposit buildup within brush holder assemblies, and reduces risk of photographing
High-quality materials and design minimize common brush and ring issues
Typical retrofits completed in 1–2 days
Installed on GE, Toshiba, Mitsubishi, Brush, Doosan, Siemens, Westinghouse, and other OEM brands
Fully integrates with Cutsforth EASYchange Brush Condition Monitoring for continuous visibility into brush performance

How it Works

Installation

EASYchange holders install quickly with minimal modification to existing rigging, allowing most retrofits to be completed in just 1–2 days.

Replacing a Brush

Brushes can be safely removed, inspected, and replaced in seconds without shutting down or exposing personnel to energized components. Watch video.

Positioning the Brush Leads

The ergonomic “pistol-grip” design makes routing and securing brush leads simple, consistent, and free from strain or interference. Watch video.

EASYchange Height Setter Tutorial

The included Height Setter tool ensures precise brush seating and optimal contact pressure for consistent performance and longer ring life. Watch video.

EASYchange vs OEM Holders

Compared to traditional OEM holders, EASYchange offers safer online brush changes, reduced maintenance issues, and significantly longer collector ring service life. Watch video.

Removable Carbon Brush Holder FAQs

What types of generators benefit from Cutsforth EASYchange carbon brush holders?

Our carbon brush holders are currently installed on gas and steam turbines, hydroelectric equipment, and at nuclear power plants. Other retrofits include chemical plants, paper mills, and oil and gas refineries. From the smallest power producers to some of the nation’s largest power companies, Cutsforth brush holders are quickly becoming the BEST choice for an in-service removable brush holder. In addition to the United States, Cutforth brush holders have been installed overseas in several countries.

What brands of generators are Cutsforth EASYchange carbon brush holders installed on?

General Electric, Westinghouse, Allis Chalmers, Electric Machinery, Alstom, ABB, ASEA, GM, Siemens, and Hitachi.

Why should I consider a retrofit with Cutsforth EASYchange carbon brush holders?

Our brush holder will bring increased personnel safety, increased collector ring and brush rigging reliability, and decreased maintenance costs to your plant.

What problems will Cutsforth EASYchange carbon brush holders address on my generator?

Arcing, brush binding, poor terminal connections, poor spring pressure, and photographing.

Our brush holders can reduce collector ring wear and improve and protect the critical brush-to-ring connection.

How long does a Cutsforth EASYchange carbon brush holder retrofit take?

Entire retrofits can usually be completed in one business day. The Cutsforth team works with your company and/or outage coordinators to get our brush holders installed during your outage.

How long have Cutsforth EASYchange holders been operating in generators?

Our holders have been in service and operating for about 20 years. There are currently over 40,000 Cutsforth EASYchange brush holders in operation worldwide.

How reliable has Cutsforth carbon brush holder been?

We are proud to proclaim that we have never had a failure to date from our brush holder.

Have Cutsforth carbon brush holders ever been installed on DC motors?

Yes, on larger critical applications. We have installed our brush holders on larger DC motors such as MG sets.

Can Cutsforth EASYchange carbon brush holders be installed on commutators, pilot exciters and Alterrex ring sets?

Yes, the installation will be dependent on what the existing brush size is and the ring or commutator size (width), and the type of existing brush rigging setup currently installed.

How can we clean the brushes and collector rings?

Denatured alcohol combined with clean, lint-free rags is the best way to clean the brush holders and collector rings.

How can I see a demonstration or receive more information?

We regularly schedule online demonstrations, which consist of a web-based meeting and conference call for plant personnel. Please schedule a demo by filling out this form.

Benefits of EASYchange® Removable Brush Holders

Cutsforth EASYchange® Removable Brush Holders are designed to improve generator safety, simplify maintenance procedures, and increase the reliability of brush rigging systems. By replacing traditional brush holder designs with a removable holder system, facilities can reduce maintenance risks while improving generator performance.

Key benefits of EASYchange removable brush holders include:

Safer Brush Maintenance. Traditional brush replacement often requires technicians to work near energized and rotating equipment. EASYchange holders allow brushes to be removed and replaced under no current, significantly reducing exposure to hazardous conditions.
Faster Brush Replacement. The removable holder design allows maintenance teams to quickly rack brushes out and replace them in seconds. This reduces the time required for inspections and routine maintenance tasks.
Improved Generator Reliability. Consistent brush alignment and proper contact pressure help maintain stable electrical contact between the brush and collector ring. This reduces common problems such as brush chatter, uneven wear, and electrical arcing.
Reduced Risk of Electrical Flashover. Improved brush performance helps prevent conditions that can lead to collector ring damage, ring fires, or electrical flashover events.
Extended Collector Ring Life. Proper brush seating and consistent contact pressure reduce excessive wear on collector rings, helping extend the lifespan of critical generator components.
Lower Maintenance Costs. Simplified brush replacement procedures and improved equipment reliability help reduce maintenance labor, minimize unplanned outages, and lower overall operating costs.
Quick Retrofit Installation. EASYchange brush holders are designed to replace many OEM brush holders with minimal modifications, allowing retrofits to be completed quickly during planned maintenance outages.
Compatibility With Monitoring Systems. EASYchange brush holders can be integrated with Cutsforth Brush Condition Monitoring systems, providing real-time visibility into brush wear and enabling predictive maintenance strategies.

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Key capabilities of EASYchange removable brush holders include:

Safe brush replacement while generators remain online
Removable holder design that reduces maintenance risk
Minimal modification required for installation
Compatibility with most OEM and aftermarket brush holders
Improved brush-to-ring contact for better electrical performance
Reduced carbon buildup and common brush rigging problems

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Additional Resources

Complimentary Brush Rigging Inspection Worksheet

Tool: Brush Density Calculator

Webinar: Brush Failures and How to Solve Them

White Paper: Root Cause Analysis of Collector Ring Fires in Power Generators