Series motor rebuild?

agpfl

So I purchased a dirt cheap project 2006 Series with no batteries. I finally got a set of old batteries to test with. The end game is converting from Series to PDS, but in the mean time I decided to just put the batteries in and test the motor and controller to make sure they work properly before I sell them. I go to put the batteries in and can't budge the cart out of its spot to install them. Turns out when I washed off the 2 inches of mud, I flooded the motor and the brushes rusted to the com bars. I tore down the motor and freed up each brush.

This brings up a few questions.
Do I just reassemble the motor and test it?
Are the com bars on the armature too scored?
Should I replace the bearing and brushes?




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BGW

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BobBoyce

That was not rusted. That was welded from the heat of excessive brush arcing. Likely reasons are the brushes worn down so much that the brush springs could not maintain proper pressure, or they were not able to move freely by rust or corrosion of the brush holders. It looks like the formvar insulation on the windings near the bonds has been mostly burned away. If the formvar were not damaged, I would turn the commutator in a lathe to restore usable surface and install new brushes/brush holdars. But that armature looks pretty cooked to me. There are fairly deep grooves burned into the commutator surface.

yurtle

Since it's paid for, you have nothing to lose. The manual in the stickies tells the length tolerance of the brushes. You can clean up the commutators with a Scothbrite, or given the looks of them, fine emery cloth. I wouldn't hold your breath, given how bad it looks. You can smooth out the brushes fairly easily, since it's soft.

crash test dummy

time for new motor

Raystar57

I would think that after that commutator was turned, mica undercut and new brushes it might work maybe.
That service would have a moderate cost and new brushes. Plus there may be more issues with it.
I don't have much experience with motors and repair costs.
I would try to find a used motor if you need to get it running before PDS conversion.
That just looks bad...

agpfl

Already have my PDS core off to PQ. I would like to sell this motor if it's worth anything, otherwise it goes into the trash. I did reassemble it and ran about 7mph. I am sure if I put money and time into it I could improve it, but I just want to either sell it or throw into trash.

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Seaquell

cgtech

Want some bad karma? Sell that motor to someone. It's junk. The grooves are so deep, if it were cut enough to get rid of them, it would no longer meet minimum diameter specs.

agpfl

What if I include the pictures and full disclosure? Is it something that would be useful for someone to purchase? I do believe you are right.

sfracer

hey everybody i’m new at forum, hope to learn more and if i’m able
to help, count with that…

in the meantime, yesterday i pulled out series and dc armature motor, before that i check continuity at armature bolts including brushes and then continuity at body, finally complete the job, re assembly and test it… works great

i have been doing research about those engines and how rebuild it and it is easy, needs a lot of patience, but it
works