Field Windings Inspection; Motor Components - Club Car DS Villager 4 Maintenance And Service Manual Supplement

16A
MOTOR (MODEL 5BC59JBS6390)
COMMUTATOR
Figure 16a-6 Armature Test

FIELD WINDINGS INSPECTION

Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or
grounded or shorted coil windings. If the insulation on the field windings is scorched, replace the motor or the
stator shell assembly.

MOTOR COMPONENTS

1. Inspect the insulators (4 and 7) for cracks or other damage (Figure 16a-9, Page 16a-8).
2. Inspect the brushes (13) for damage or excessive wear. Replace brushes if required. See following
NOTE.
3. Inspect the brush springs (14) (Figure 16a-9, Page 16a-8). Replace springs that are discolored from
heat (light gold or blue tinted). Replace springs which apply a force of less than 16 oz. (Figure 16a-7,
Page 16a-7). See following CAUTION and NOTE.
CAUT ION
• When checking brush spring tension, do not over-extend the spring. Using excessive force
will damage the spring.
NOTE: When installing new brushes, remove and replace brushes one at a time. This method ensures the
terminals and brushes will be properly positioned in the rigging. Refer to Motor Assembly for brush
installation. See Motor Assembly on page 16a-10.
When replacing brushes, replace all four brushes. Never replace only two.
Install the brushes in the same rigging 180° apart from each other.
Page 16a-6 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
ARMATURE CORE
Motor