brushes break-in

rdnktrkr · 10-11-2010, 05:58 PM

I have a marathon that has been converted to 48v with a 480 amp controller, one of the studs to the cable ends to the brushes burnt out and when I was trying to remove the nut the stud broke, I replaced the brushes with HD brushes from a wellknown supplier and they looked very good, but now it has no power. Batteries were not completely charged but was at about 49v. Is there a break-in period for the new brushes? Could I have reinstalled something wrong? Thanks

THUNDERBASES · 10-12-2010, 06:26 AM

Your first problem is the broken stud. As for the break in period, I do not know if there is a way to access the motor commutator? If there is a way to access the commutator, put the cart on jack stands, have someone operate the motor, take a commutator stone and scuff the commutator up with that stone, that will help seat the brushes. I do not know how much experience you have with dc motors and doing this sort of stuff? Be careful. This is what we do to Overhead Crane Motors on our cranes out where I work.

scottyb · 10-12-2010, 08:27 AM

The brushes should 'work' right out of the box..... check your connections and of course check the diagram to make certain everything is hooked up correctly..... you didn't let any of those motor studs spin did you? they have two nuts on them for 2 wrenches. if they spin they can break the connection inside the motor.... you can test for this problem with a continuity test on your multimeter.
Tag & disconnect the motor leads, you should have continuity between the 2 A terminals and between the 2 S (or F) terminals BUT NOT between any A and S terminal. That would indicate a short.

rdnktrkr · 10-13-2010, 10:43 AM

AN update on new brushes. I charged battery pack and drove it around a little, after setting overnight now today I'm back to full power. I wonder if one of the new brushes was sticking in the holder? It sure is nice to have cart back up and running again. I ordered HD brush kit from EMP along with new insulator washers, Product looked very well made and lady on the phone was very nice. I would do business with them again.

THUNDERBASES · 10-13-2010, 01:52 PM

Glad to hear you got it running.

10-11-2010, 05:58 PM	#1
rdnktrkr Getting Wild Join Date: Sep 2007 Location: douglasville, Ga Posts: 125	brushes break-in I have a marathon that has been converted to 48v with a 480 amp controller, one of the studs to the cable ends to the brushes burnt out and when I was trying to remove the nut the stud broke, I replaced the brushes with HD brushes from a wellknown supplier and they looked very good, but now it has no power. Batteries were not completely charged but was at about 49v. Is there a break-in period for the new brushes? Could I have reinstalled something wrong? Thanks

10-12-2010, 06:26 AM	#2
THUNDERBASES Getting Wild Join Date: Aug 2008 Location: B'HAM, Alabama Posts: 137	Re: brushes break-in Your first problem is the broken stud. As for the break in period, I do not know if there is a way to access the motor commutator? If there is a way to access the commutator, put the cart on jack stands, have someone operate the motor, take a commutator stone and scuff the commutator up with that stone, that will help seat the brushes. I do not know how much experience you have with dc motors and doing this sort of stuff? Be careful. This is what we do to Overhead Crane Motors on our cranes out where I work.

10-12-2010, 08:27 AM	#3
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: brushes break-in The brushes should 'work' right out of the box..... check your connections and of course check the diagram to make certain everything is hooked up correctly..... you didn't let any of those motor studs spin did you? they have two nuts on them for 2 wrenches. if they spin they can break the connection inside the motor.... you can test for this problem with a continuity test on your multimeter. Tag & disconnect the motor leads, you should have continuity between the 2 A terminals and between the 2 S (or F) terminals BUT NOT between any A and S terminal. That would indicate a short.

10-13-2010, 10:43 AM	#4
rdnktrkr Getting Wild Join Date: Sep 2007 Location: douglasville, Ga Posts: 125	Re: brushes break-in AN update on new brushes. I charged battery pack and drove it around a little, after setting overnight now today I'm back to full power. I wonder if one of the new brushes was sticking in the holder? It sure is nice to have cart back up and running again. I ordered HD brush kit from EMP along with new insulator washers, Product looked very well made and lady on the phone was very nice. I would do business with them again.

10-13-2010, 01:52 PM	#5
THUNDERBASES Getting Wild Join Date: Aug 2008 Location: B'HAM, Alabama Posts: 137	Re: brushes break-in Glad to hear you got it running.

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