Replacing Brushes

[manan]

Looking for tips or advice on how to replace brushes in a 36v CC DS motor. motor data is: CLUB CAR : 102237701: GE : 5BC58JBS6362. Lug broke off while changing wiring. Seems to have a lot of corrosion.

[Muddog]

Motor Assembly, Continued:
2. Install the brushes. See NOTE below.
3. Position the brush rigging (12) on the mounting tabs in the housing with winding assembly (2) and
secure with screws (11). Tighten the screws to 15-25 in.lbs. (1.6/2.8 N-m) (Figure 24-8, Page 24-7)
(See Figure 24-14).
4. One at a time, pull the brush spring extensions back from the brushes and slide the brushes back until
they are completely retracted into their mounting slots. Then position the brush springs against the
sides of the brushes so that spring pressure will hold them in the retracted position.
5. Slide the armature, bearing end first, into the housing with winding assembly. Make sure the brushes
are held back while positioning the armature for proper commutator/brush contact. Release the
brushes and place the springs outside of the brushes so that the brushes are being held against the
commutator. See CAUTION below.
6. Attach the bearing retainer (16) to the end shield (10) by aligning the screw holes in the bearing
retainer with the two mating screw holes in the end shield and installing the screws (9) (Figure 24-15).
Tighten the screws to 14-20 in.lbs. (1.6/2.2 N-m). See NOTE below.
7. Align the matching marks on the end shield and the housing with winding assembly, then install the four
screws ( (Figure 24-8, Page 24-7). Tighten the screws to 80-100 in.lbs. (9/11.3 N-m).
8. Make sure that the armature turns freely. If it doesn’t turn freely, disassemble the motor again to find
the problem. Make sure the bearing is properly seated in the end shield when assembling the motor.
• WHEN INSTALLING NEW BRUSHES, BRUSH SETS CAN BE REMOVED AND REPLACED ONE
AT A TIME. THIS METHOD ASSURES THAT THE TERMINALS AND BRUSHES WILL BE PROPERLY
POSITIONED IN THE RIGGING.
• WHEN REPLACING BRUSHES, ALWAYS REPLACE ALL FOUR BRUSHES. NEVER REPLACE
ONLY TWO.
• INSTALL THE BRUSHES 180° APART FROM THE OTHER BRUSH IN THE SAME RIGGING.
• IF THE MOTOR IS BEING ASSEMBLED WITH THE ARMATURE STANDING ON END AS THE
COMMUTATOR IS POSITIONED, MAKE SURE THE BRUSHES ARE HELD BACK. DO NOT
ALLOW THE BRUSHES TO SUPPORT THE WEIGHT OF THE HOUSING WITH WINDING
ASSEMBLY. THE BRUSHES CAN BE EASILY DAMAGED BY THIS WEIGHT.
• USE A LONG SCREW WITH THE SAME THREAD SPECIFICATIONS AS THE MOUNTING
SCREWS TO MAINTAIN HOLE ALIGNMENT WHILE STARTING THE FIRST MOUNTING SCREW.
SEE FIGURE 24-15.
• POWERDRIVE PLUS VEHICLES ONLY: MAKE SURE ON THAT THE MOTOR SPEED SENSOR
LEAD THAT IS ON THE END SHIELD IS LINED UP WITH THE F2 AND A2 TERMINALS ON THE

[manan]

Thanks Muddog for the info. It seems the first part of the procedure is missing. It starts with the installation of new brushes. Is there much difficulty in the disassembly process?