Motor Frame And Field Windings Inspection; Motor Brush, Spring, And Terminal Insulator Inspection - Club Car Carryall 550 2019 Maintenance And Service Manual

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Motor Component Testing and Inspection
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Figure 16-10 Armature Test

MOTOR FRAME AND FIELD WINDINGS INSPECTION

1. Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-2.
2. Remove the end cap and armature by performing steps 1 through 6 of Motor Disassembly on page 16-4.
3. 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 BRUSH, SPRING, AND TERMINAL INSULATOR INSPECTION

Brush Spring Tension Test
1. Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-2.
2. Release the clasp and remove the headband from the motor.
3. Inspect the brush springs (18) (Figure 16-13, Page 16-10). Replace springs that are discolored from heat
(light gold or blue tinted).
4. Test the brush springs for proper tension.
4.1. Place a C-shaped steel plate (1) on a scale (2).
4.2. Place the end of the C-shaped plate (1) so that it is between the spring and the brush.
4.3. Gently pull the scale (2) to obtain the spring tension reading. See following CAUTION.
CAUTION
• When checking brush spring tension, do not over-extend the spring. Using excessive force will
damage the spring.
4.4. Replace springs which require a force of less than 35 ozf. (990 gf.) (Figure 16-11, Page 16-9). See
following NOTE.
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 on page 16-11 for brush
installation.
When replacing brushes, replace all four brushes. Never replace only two.
Page 16-8 2019 Carryall 550 Maintenance and Service Manual
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ELECTRIC VEHICLE - MOTOR