Removable Carbon Brush Holders

Cutsforth Condition Monitoring

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.

Landing Page Form

Talk to an Expert

"*" indicates required fields

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. A wide range of purpose-built adapters bolt directly to your existing yoke, so most units require little to no structural change. Cutsforth has retrofitted thousands of brush riggings across gas and steam turbines, hydro units, and nuclear plants since EASYchange came to market in 2002.

Replacing a Brush

Replacing a brush takes seconds, with no shutdown required and no need to reach into energized, rotating equipment. The holder lifts free of its mount so inspection, cleaning, and brush replacement happen safely away from the collector ring. The included Height Setter tool ensures every brush is seated at the right height and pressure, protecting brush life and ring condition on every change.

Positioning the Leads

The ergonomic “pistol-grip” design makes routing and securing brush leads simple, consistent, and free from strain or interference. The shape guides the holder into place the same way every time, preventing incorrect installation and keeping shunts clear of adjacent hardware. Consistent lead positioning means less strain on the shunt connection and fewer of the wear issues that shorten brush life.

EASYchange Height Setter Tutorial

The included Height Setter tool ensures precise brush seating and optimal contact pressure for consistent performance and longer ring life. Setting each brush to the same height keeps current shared evenly across the rigging instead of overloading individual brushes. The result is more predictable wear, fewer arcing and hot-spot issues, and a collector ring that stays in service longer.

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. High-quality materials and design reduce carbon deposit buildup, photographing, and the brush box restrictions that drive arcing and uneven wear. With more than 5,000 power generation units retrofitted, the design has a long field record of lowering maintenance costs and limiting the risk of ring fires and forced outages.

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 pilot exciters and Alterrex ring sets?

Yes, assuming your application utilizing a steel ring with a helical groove. We can likely and have likely installed on similar units. The installation will be dependent on what the existing brush size is, ring size (width and diameter) 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.

Talk to an Expert

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

Talk to an Expert

EASYChange Brush Holders Reduce Maintenance Costs

These brush holders are designed to directly replace many existing OEM holders, allowing retrofits to be completed quickly-often in one to two days depending on the generator configuration.

The system also includes specialized tools such as the EASYchange height setter to ensure proper brush seating and consistent contact pressure, which helps extend collector ring life and improve overall generator performance.

EASYchange brush holders can also integrate with Cutsforth Brush Condition Monitoring, providing real-time visibility into brush wear and performance so maintenance teams can optimize brush replacement schedules and prevent unexpected failures.

By improving both safety and reliability, EASYchange removable brush holders help power plants and industrial facilities reduce maintenance costs while keeping generators operating efficiently.

Installed Across Many Industries

Because of these advantages, EASYchange brush holders have been installed on thousands of generators across industries such as:

power generation
hydroelectric facilities
nuclear plants
chemical plants
pulp and paper mills
oil and gas refineries

Talk to an Expert