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Unread 10-30-2010, 05:15 PM   #11
nimda
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Default Re: Need help getting to brushes (36v motor)

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Originally Posted by OLD MEC View Post
ROADY89--Thats a new way to get a stuck motor off that I never thought of? Must put just enough spin on shaft to break it loose as you say?
Yea...beat all I ever seen. We tried for DAYS to get it off...then it just falls off. I guess its the same as jerking on it back and forth real fast....and with the weight of a 40lb motor it worked itself loose. The next time I get one thats stuck thats what I'm gonna do.
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Unread 10-31-2010, 12:44 AM   #12
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Default Re: Need help getting to brushes (36v motor)

OK I got it RUNNING!!! But it was not easy. First I had to replace some cvonnector ends of smaller wires that had rotted and were cracking off. Next I cleaned and remounted the solenoid connections. I diagnosed and replaced the microswitch in the vglide wiper unit. Radio Shack did not sell the right one but I was able to find one in an old peice of equipment I had. Next came the dreaded motor, as I suspected the coil wire was cracked off by someone turning the nut without a wrench or something worse. The whole stud was bent and deformed, then the inner insulator washer and square plastic insulator was craked in pieces as well. I was able to weave about 100 small copper wires around the coil and stud where they connect then solder them together. It looks ugly but is strong and solid. Then I made a new washer from a piece of plastic, and used some 2 part plastic repair epoxy to hold the square insulator in place and fill the gaps. I also rethreaded the crokked bolt enough to get the nuts on it and I am able to tighten the wire on there good. I just need washers due to many missing threads. Next I could not get the armature off the tranny so I found a way to hold the brushes in. I drilled the back of the motor housing then inserted wires to hold the springs back. Then slid the whole complete case back on the motor and wiggled it into place. After bolting it back onand spinning the wheels to verify there was no jams in the motor, I pulled the pins and the brushes sprang back onto the armature. Hooked up the wires and the cart drives. The batteries are new and never had a full charge yet so I drove about a block and back and put it on charge. The motor and all connections stayed cold so the connections I fixed should be good. I attached some photos I took.
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Unread 10-31-2010, 12:47 AM   #13
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Default Re: Need help getting to brushes (36v motor)

Close up of the repaired coil wire. Also take a look at how worn the armature is. This motor needs to be replaced rather than repaired. But I will run it for now.
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File Type: jpg 005.jpg (85.1 KB, 12 views)
File Type: jpg 006.jpg (121.6 KB, 10 views)
File Type: jpg 002.jpg (77.2 KB, 13 views)
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Unread 10-31-2010, 12:56 AM   #14
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Default Re: Need help getting to brushes (36v motor)

That was pretty slick. Thats how the do alternators.
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Unread 10-31-2010, 01:09 AM   #15
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Default Re: Need help getting to brushes (36v motor)

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That was pretty slick. Thats how the do alternators.
Thanks. I have had this thinbg 3 days now and learned a lot so far. One other question I have is that my charger is buzzing loud as hell and the ammeter gauge is sitting low on the scale. The bottom 1/8 of the scale is a green section to tell you when it is drawing low amps and therefore done right? My batteries are new never driven but only at 6.0 -6.2 volts max. I take it that means they are really low but the charger has been going for several hours and the batteries seem to have no more of a charge than before. The charger has gotten warm and if I loosen one of the battery terminals you can see some sparking indicating the charger is putting some power to the batteries. Is this normal? Is the first charge gonna take days? Also one more thkng. How much notice do you get whent he batteries are dying. If I am 3 blocks away and feel weakended power can I get home or do they fall off a cliff like LiPo drill batteries?
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Unread 10-31-2010, 01:10 AM   #16
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Default Re: Need help getting to brushes (36v motor)

Nicely done, Jonequest! I did the same thing on the starter/generator of my gas Yamaha a couple of years ago. That was before I found this site - now I know I can replace the complete brush assembly for under $50! I'm not sure if individual parts for the drive motors are available.

A lot of work, but didn't it feel great when that motor started turning?!

Let us know how your progress is going with the upgrade.
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Unread 10-31-2010, 01:17 AM   #17
nimda
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Default Re: Need help getting to brushes (36v motor)

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Originally Posted by jonequest View Post
thanks. I have had this thinbg 3 days now and learned a lot so far. One other question i have is that my charger is buzzing loud as hell and the ammeter gauge is sitting low on the scale. The bottom 1/8 of the scale is a green section to tell you when it is drawing low amps and therefore done right? My batteries are new never driven but only at 6.0 -6.2 volts max. I take it that means they are really low but the charger has been going for several hours and the batteries seem to have no more of a charge than before. The charger has gotten warm and if i loosen one of the battery terminals you can see some sparking indicating the charger is putting some power to the batteries. Is this normal? Is the first charge gonna take days? Also one more thkng. How much notice do you get whent he batteries are dying. If i am 3 blocks away and feel weakended power can i get home or do they fall off a cliff like lipo drill batteries?
check your total pack voltage. No, it shouldn't take days, only about 10 hours completely dead. Something isn't right.
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Unread 10-31-2010, 01:22 AM   #18
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Default Re: Need help getting to brushes (36v motor)

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check your total pack voltage. No, it shouldn't take days, only about 10 hours completely dead. Something isn't right.
Total pack is sitting at 37.0 volts. It has been charging for about 7 hours.
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Unread 10-31-2010, 01:23 AM   #19
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Default Re: Need help getting to brushes (36v motor)

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Originally Posted by SteveRand View Post
Nicely done, Jonequest! I did the same thing on the starter/generator of my gas Yamaha a couple of years ago. That was before I found this site - now I know I can replace the complete brush assembly for under $50! I'm not sure if individual parts for the drive motors are available.

A lot of work, but didn't it feel great when that motor started turning?!

Let us know how your progress is going with the upgrade.
It felt awesome considering the cart was basicly toast when I got it.
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Unread 10-31-2010, 01:31 AM   #20
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Default Re: Need help getting to brushes (36v motor)

What about the batteries do they die fast or give you some time to get home. I don't want to get stranded in the other side of the neighborhood.
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