Hello everyone,

Has anyone replaced the carbon brushes in the chargecooler pump before? Mine have worn very low, so low in fact that they are making a rattling noise as they are able to move about slightly in the brush guide when the pump is on. I discovered this recently when I replaced the pump bearings.
Using google cache I found some links on gt4oc.net to a pump refurbishment guide someone produced supposedly detailing part numbers of new/replacement brushes but cannot access it as I am not a member.

The closest I have found so far is this company:

http://www.anglocarbon.com/acatalog/automotive.htm

Who say they will be able to make up a custom set if I send them a sample, however there is a minimum order amount of £25 so won't be worthwhile unless it is part of some sort of group buy.
For reference my brushes have approximately 15mm of meat left on them.

I'm sure some off the shelf bushes available for something will fit - has anyone had any luck?

I tried to find some off the shelf and failed. I ended up getting some made up.

The main problem is that you don't have a new one to measure - obviously they wear down so you have to guess the size.

IMHO 15mm of "meat" is enough (snigger) and I doubt they start with more than 30-40mm.

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JP
GT4DC Treasurer

Grey St185 RC
Silver BMW E46 M3
Multicolour yawn Honda VFR400
Silver Honda Civic Type-R

How many sets would £25 buy?

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GT4DC Events Co-ordinator
1996 ST205 UK

Oh - found this place as well HTTP://WWW.CARBONBRUSH.CO.UK

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GT4DC Events Co-ordinator
1996 ST205 UK

Thread bump... My chargecooler pump has now failed & thrown code 54.
I tried bridging the INTR CLR relay, the pump just refuses to run. I'm yet to confirm but i'm fairly sure the brushes have worn so low they are now only making intermittent contact with the commutator. I just hope the commutator is ok otherwise it's new pump time

Does anyone have a set lying about which they could measure for me? I'm going to try and find some which fit & can be filed to a roughly correct length. I only need the cross sectional dimensions. IIRC it's roughly 6x5mm.

When you undo the cap, the top plate of the brush will spring out by as many mm as you have meat left.
You can tell if the brush has been struggling to make contact as the end will be badly pitted from the sparking. I'll try and get some piccies up tomorrow for reference. This is usually caused by the brush being worn out and too short, or by it sticking in it's holder. They should be a little loose to prevent this.

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If at first you don't suck seed, try drier grain.

IMO - Just get a refurbed pump from here: http://www.gt4-play.co.uk/catalog/product_info.php/cPath/24_25_67_72/products_id/32

Highly recommended.

_________________
GT4DC Events Co-ordinator
1996 ST205 UK

Since it would appear the brushes are short, thats a bill of £300 when it probably just needs brushes.

TBH 15mm is probably less than half worn and I very much doubt it's that. More likely a wiring / relay fault IMO but worth checking the easy stuff first.

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If at first you don't suck seed, try drier grain.

For reference, a 'good' brush next to a worn out brush that has been arcing. (These are not charge cooler brushes by the way, but our 24V electric vehicles)



And both brushes from the side to show the remaining length New ones are about 25mm.

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If at first you don't suck seed, try drier grain.

^^ Interesting, I didn't notice the supplement. That is quite a bit more than I paid for mine.

_________________
GT4DC Events Co-ordinator
1996 ST205 UK

Found the time to take a look today:



You can see the arcing (or the embedded copper wire, hard to tell) on the smallest bush here,4.7mm meat left:



Nice to know my assumption was correct I suppose.

Dimension of cross section measured as 5.96 x 6.97 mm so 6x8mm. Just need to find some now. I guess I could find some oversize ones and carefully sand them down to the correct dimension?

Found some here:

http://m.ebay.co.uk/itm/121506670278

May have to solder the gt4 bit onto the end, but going to give them a go!

I believe it was these guys I used:-
http://www.engineeringcarbonproducts.com/order_form.php

I still have some sets that are erghh the wrong size! I can send you a set to trim I think if I remember where they are!

My memory suggests I got the spring & wire too long for the brush length I spcified but you may get away with it by sanding down the actual briush face.

After all that work I found my shaft was bent as well so the the pump was useless.

_________________
JP
GT4DC Treasurer

Grey St185 RC
Silver BMW E46 M3
Multicolour yawn Honda VFR400
Silver Honda Civic Type-R

Be careful as the ebay brushes look like they're intended for mains power tools which are probably lower current than the chargecooler pump. They are probably pure carbon, wheras lower voltage ones normally have some copper content.

They are easy to file down though. File is better than sandpaper as it's straight.

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If at first you don't suck seed, try drier grain.

Forgot to update this. Those ebay brushes worked fine. I went with the 20mm long ones, and accidentally bought 6x8 instead of 6x7mm so had to file them down. I also reused the OEM copper tail & spring.

I'll keep an eye on them nibbles. Couldn't see much in the way of copper flecks in the Toyota brushes.