Carbon brush: information and how to replace

This guide focuses on the motor section and the specific steps for replacing the carbon brushes.

 

The procedure is identical for all AVA Go, Smart, and Easy models.

 

Want to learn more about carbon brushes, lifespan, and troubleshooting? Scroll down for tips, safety info, and common symptoms.

 

To open and reassemble, please follow the step-by-step motor replacement guide for your machine.

Once the motor and pump assembly has been removed from the chassis, continue with the steps below to replace the brushes.

 

Here are the links to the full motor replacement guides for each model:

• AVA Go – Motor Replacement Guide
• AVA Smart – Motor Replacement Guide
• AVA Easy – Motor Replacement Guide

 

Always prioritize safety first: Safety instructions – AVA of Norway

 

 

 

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B. Inspect and clean

• Use compressed air or a soft brush to remove any carbon dust or debris from inside the motor.
• Inspect the commutator (the copper-coloured ring the brushes contact): it should be smooth, clean, and free from deep scoring, burn marks, or broken solder joints.
• The motor shaft should turn smoothly by hand with no resistance or scraping.

 

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C. Remove worn carbon brushes

• Gently press the small locking tab (a) to release the brush.
• Carefully pull it out (b) of the holder. If it’s stuck, use tweezers or a small screwdriver.
  • Take note of how the brushes were installed and how the wire connectors are positioned for correct reassembly.

 

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D. Install new carbon brushes

Insert the new brushes one at a time. Make sure:

• The spring tension is strong and presses the brush into place.
• The brush moves freely inside the holder.
• The flat surface of the brush is in full contact with the commutator.

E. Visual check before reassembly

• Double-check that both brushes are seated properly and move freely.
  • If any brush sticks or doesn’t sit flush, remove and reinstall.

F. Refit the motor cover

• Slide the motor cover back into position.
  • It will click into place when the locking tabs engage.

Now return to the main guide for motor/pump disassembly and reassembly to complete the remaining steps correctly.

 

 

 

Additional information:

Carbon brushes on universal motors

The AVA Easy, Go and Smart models use compact universal motors. These motors are designed for high-speed operation and are ideal for pressure washers due to their size-to-power ratio.

Normal Wear and Lifetime

Carbon brushes are wear parts and must be replaced when they are worn down. Under normal home use, a set of brushes typically lasts:

• Approx. 100 hours of use, depending on load, cooling, and water conditions.
• Frequent short sessions (start/stop cycles) and high back-pressure may reduce lifespan.

Brush length guide:

• New brush: typically 22 mm.
• Worn-out brush: below 12 mm or when spring no longer maintains pressure.

Moisture and brush dust

Moisture inside the motor (from storage or leaks) can mix with brush dust and form conductive sludge, which may cause:

• Electrical tracking and arcing.
• Shortened brush life.
• Premature commutator wear.

Always clean the motor area thoroughly when changing brushes:

• Use compressed air or a soft brush.
• Never blow directly into the motor with high-pressure air – keep distance.
• Vacuum loose particles if possible.
• Avoid using water or any liquid cleaner.

Smell and smoke during first use

A faint burning smell or light smoke may occur during the first few minutes of use after brush replacement. This is expected while the new brushes are bedding in (forming contact with the commutator).

This is normal if:

• It stops after a few minutes.
• It doesn’t worsen with continued use.
• There’s no visible sparking from inside the housing.

Stop immediately if:

• The smell intensifies or turns sharp/pungent.
• There’s visible black smoke or constant sparking.
• The motor becomes hot to the touch within 1–2 minutes.

Not just the brushes?

If the machine doesn’t run properly after replacing the brushes, check:

• That the commutator (the copper contact surface) is smooth and clean.
• That the motor shaft spins freely.
• That both brushes have firm spring tension and are seated properly.

Warranty and use classification

Replacing carbon brushes does not void AVA’s warranty. However:

• Carbon brushes are classified as consumables and are not covered by warranty.
• Needing new brushes may indicate heavier use than typical home usage, and the machine may be considered commercially used if wear is excessive.

Learn more about our warranty: AVA Warranty Terms & Conditions

Two Funfacts about universal motors

• Extremely powerful for their size
  • Universal motors deliver high RPM and torque in a very compact format – that's why they’re found in power tools, vacuums, and pressure washers.
• Runs on both AC and DC
  • As the name implies, universal motors can run on either alternating or direct current, making them incredibly versatile (though AVA products use AC only).