EASYchange® Removable Brush Holders

Reliability Starts with a Better Brush Holder

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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.

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.

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Positioning the Brush Leads

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

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EASYchange Height Setter Tutorial

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

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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.

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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

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.

What Are Removable Brush Holders?

EASYchange Removable Brush Holders are advanced generator retrofit components designed to make carbon brush maintenance safer, faster, and more reliable. These patented brush holders allow maintenance teams to remove and replace generator brushes quickly—without exposing personnel to energized components or requiring the generator to be taken offline.

Traditional brush holders can make brush replacement difficult and time-consuming, often requiring maintenance staff to work near energized and rotating equipment. The EASYchange removable design eliminates many of these risks by allowing brushes to be safely racked out under no current, reducing exposure to hazardous operating conditions.

EASYchange brush holders are installed on thousands of generators worldwide and have become a trusted retrofit solution for improving generator reliability and simplifying maintenance procedures.

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

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.

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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Why Industrial Facilities Choose EASYchange Brush Holders

Carbon brush maintenance is a critical part of generator reliability. Traditional brush holder designs can introduce several operational challenges that increase maintenance risks and lead to equipment problems if not properly managed.

Cutsforth EASYchange brush holders address these challenges by improving both maintenance procedures and the overall performance of the brush rigging system.

These problems can increase maintenance costs and lead to forced outages if not addressed.

EASYchange removable brush holders improve generator reliability by enabling maintenance teams to safely inspect and replace brushes more efficiently.

Common Generator Brush Issues

Facilities implement EASYchange brush holders to solve common generator issues such as:

  • Brush binding within the holder assembly
  • Poor electrical terminal connections
  • Inconsistent spring pressure on brushes
  • Carbon buildup inside brush rigging assemblies
  • Electrical arcing or “photographing” events
  • Excessive collector ring wear

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

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