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Unread 10-30-2010, 01:20 AM   #1
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Default Need help getting to brushes (36v motor)

I just bought a '93 36volt project cart with new but half charged batteries from a freind and have been trying to get it running for two days now. He put the batteries in but never got it running. I tried hooking batteries straight to the motor using directions found here and on the motor with no results. I found that the motor lug (S1) with the brown wire attached to it was bent and damaged with the outer nut welded stuck at half way screwed on. I think that someone twisted it and broke the wire to the brush off on the inside of it and I want to fix it. BUT, I am afraid of damaging the motor trying to remove it. I also thought of the possibility that the brushes fall in and when I do fix it I have no way top make the brushes stay sprung in while I slide the rear of the motor back on. So far I have diagnosed and repaired the wiper microswitch so not the solenoid does click but of course no motor joy. Testing shows 36v to all 3 leads of the motor the motor anytime the pedal is pressed a little or a lot, (besides the one to negative of course). The next logical step is to check the brushes but I fear that removal of a motor = a ruined motor and many hours of hassle.

Please give any advice you have.

Thanks,

John
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Unread 10-30-2010, 01:25 AM   #2
nimda
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Default Re: Need help getting to brushes (36v motor)

It's not as bad as you think. You HAVE to pull the motor off though. Once you get it off you'll see how it comes aparts.
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Unread 10-30-2010, 01:45 AM   #3
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Default Re: Need help getting to brushes (36v motor)

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Originally Posted by roady89 View Post
It's not as bad as you think. You HAVE to pull the motor off though. Once you get it off you'll see how it comes aparts.
How? I removed the three bolts holding it to the transaxle and the one bolt to the bracket on the transaxle. It spins but won't slide off. I all the posts I read are of people ruining the shaft motor after hours of trying to pull it off.
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Unread 10-30-2010, 01:48 AM   #4
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Default Re: Need help getting to brushes (36v motor)

Well...it's gotta come off one way or the other. Use WD-40 and let it set a bit, then wiggle it up down back and forth. Hopefully it'll come off.
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Unread 10-30-2010, 10:42 AM   #5
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Default Re: Need help getting to brushes (36v motor)

After you get done with motor repairs and before replacing motor do yourself a favor and replace the Guide Ring part #101789101 and Retaining Ring part #101822801 that are inside the motor shaft where it goes into differential input shaft. If guide is worn you will get noise as shaft is centered by guide as there is no bearing to support shaft in correct place.
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Unread 10-30-2010, 11:09 AM   #6
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Default Re: Need help getting to brushes (36v motor)

I had one literally FALL OFF after trying for days to get it off. The motor housing was unbolted and I needed to move the cart so I pushed it....the motor was spinning while pushing and fell out on the ground. I guess the rapid up and down unbalanced motion of the motor loosened it up.

It will come off, it has to. Once you get it off there will be 2 bolts on the can end. Take those out, set the motor on the can end and slip the outer case off OVER the armature. Leave the armature there. You'll then see the brushes and holder assembly. If you pull the armature out you'll have to hold the brushes when you go back. You have to reinstall the armature back first then the outer case. Don't even try to reinstall the outer case first. I pull the brush back enough in its holder and cock it one way and it wedges itself. The brush spring is applying sideways pressure at that point. Then you can slip the armature back in, then let brush slip back in.
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Unread 10-30-2010, 12:33 PM   #7
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Default Re: Need help getting to brushes (36v motor)

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?
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Unread 10-30-2010, 01:13 PM   #8
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Default Re: Need help getting to brushes (36v motor)

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Originally Posted by roady89 View Post
I had one literally FALL OFF after trying for days to get it off. The motor housing was unbolted and I needed to move the cart so I pushed it....the motor was spinning while pushing and fell out on the ground. I guess the rapid up and down unbalanced motion of the motor loosened it up.

It will come off, it has to. Once you get it off there will be 2 bolts on the can end. Take those out, set the motor on the can end and slip the outer case off OVER the armature. Leave the armature there. You'll then see the brushes and holder assembly. If you pull the armature out you'll have to hold the brushes when you go back. You have to reinstall the armature back first then the outer case. Don't even try to reinstall the outer case first. I pull the brush back enough in its holder and cock it one way and it wedges itself. The brush spring is applying sideways pressure at that point. Then you can slip the armature back in, then let brush slip back in.
I got it off. I had to drop the suspension from the frame to give me room to get the motor case off but I did it. I found what I already suspected was wrong. Someone turned the motor stud and broke one the of the coil wires off. I have since cleaned out the motor and weaved a bunch of strands of copper around the two peices and soldered it back together. It came out good and will likely work well. The only hurdle now is how to hold back the brushes to slide the case back on. I read your advice above. Do you mean to pull the brushes out all the way back so they snag on the rear of the holder? I have been looking at it for 15 minutes and came back to the computer for just this advice. I am not replacing any bearings though. I want this thing running for halloween and the motor is HEAVILY worn on the armature anyway. I will get this running then look for an upgrade. I have no complex electronics in this thing so I am sure I can even go up to 48 volts and not break anything. I may need a ressitor to drop coil voltage on the solenoid though.

John
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Unread 10-30-2010, 05:00 PM   #9
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Default Re: Need help getting to brushes (36v motor)

Rememebr to use ( 2 ) wrenches when installing motor wiring so problem wont be back ( twisting wiring off inside ) If your going to upgrade later get the 36 volt motor up in good shape or replace with a rebuilt one as its ideal for 48 volts input. 36 volt motors give a real jump of performance similiar to a higher HP when used with 48 volts without any problems. Note go with 48 volt solenoid and use a electronic resistor kit in your existing V Glide unit ands add a solid state controller to replace your resistor bank you now will have great performing cart.
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Unread 10-30-2010, 05:12 PM   #10
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Default Re: Need help getting to brushes (36v motor)

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Originally Posted by jonequest View Post
I got it off. I had to drop the suspension from the frame to give me room to get the motor case off but I did it. I found what I already suspected was wrong. Someone turned the motor stud and broke one the of the coil wires off. I have since cleaned out the motor and weaved a bunch of strands of copper around the two peices and soldered it back together. It came out good and will likely work well. The only hurdle now is how to hold back the brushes to slide the case back on. I read your advice above. Do you mean to pull the brushes out all the way back so they snag on the rear of the holder? I have been looking at it for 15 minutes and came back to the computer for just this advice. I am not replacing any bearings though. I want this thing running for halloween and the motor is HEAVILY worn on the armature anyway. I will get this running then look for an upgrade. I have no complex electronics in this thing so I am sure I can even go up to 48 volts and not break anything. I may need a ressitor to drop coil voltage on the solenoid though.

John

Yes, pull the brushes back just enough so one side can hang on the holder and let the spring hold it there. In other words your going to basically pull the brush out and let one corner of the brush set on the outer part of the holder and let the brush spring hold it there while you put the armature back in. Once you get the armature back in you can set the brushes back.
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