1. Overview of the Features of Starter Carbon Brushes 

Starter electrical brushes, also known as carbon brushes, are mainly manufactured from electrolytic copper powder and graphite. The combination of copper powder and graphite allows this type of carbon brushes to have the conductive and lubricating properties. Therefore, the carbon brushes are widely applied on low-voltage motors. Carbon brushes applicable on the starters include J164, J204, J210, J438, etc. With high copper content, small electrical resistivity and large current density, the carbon brushes move flexibly on the brush holders. The carbon brushes installed on the same generator or starter must be consistent. In order to improve the maintenance quality and save labor, it is best to select the braded carbon brushes.

2. How to Deal with the Starter Brush Faults 

Broken carbon brushes, loose wires, undue wear, or inferior quality of brushes, each of them will cause malfunction of starters, for instance, the solenoid switch does not work, or abnormal noise or sparks occur when it is working. 

Causes of Carbon Brushes Faults 

1). Bad contact of carbon brushes and commutator causes some copper particles on the brush surface; 

2). Sparks cause the copper material to fall off and gather on the brush surface; 

3). Brush lead comes loose; 

4). Uneven pressure of brush springs; 

5). Brushes of inferior quality; 

6). Inconsistent brush models; 

7). Convex of commutator segments; 

8). Overloaded Motor;

9). High vibration 

Fault Processing Measures: 

1). Adjust the pressure of brush springs; 

2). Replace the poor quality brushes with high quality brushes; 

3). Ensure that same brushes are installed on the same motor or generator; 

4). Clean the carbon brushes, etc.