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Old 08-22-2019, 01:53 PM   #1
Golfdog
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Default CC Series 48v no go with new brushes

I have replaced the brush set on a 99 Series cart and tested it with one wheel jacked up and it went fine. Removed jack and tried to drive away- nothing other than solenoid activating. Checked all the wires and terminals and changed the solenoid, same result, goes on the jack not on the ground. Pulled the motor to check it out and noticed that the brushes have flat bases and the marks on each show that they are only making contact with one segment each of the commutator. Could this be the issue of not enough to create torque.?
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Old 08-22-2019, 02:01 PM   #2
Fairtax4me
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Default Re: CC Series 48v no go with new brushes

If it runs with it in the air, try running it at 1/4 - 1/2 throttle with BOTH rear wheels off the ground for 15-20 minutes to help the brushes break in.
Back in my days of rebuilding and racing (for fun) 540 sized RC brushed motors, I used to stick the motor in a small cup of water and run it at about 1/4 speed for 20 minutes to break in new brushes. Made one heck of a difference in the power output without potentially burning the armature trying to break it in. Of course, those were quite a bit smaller PM motors with only a 3 pole armature.

If you still have the motor out, make sure your brush springs are not hung up and the brushes move freely in the holders.
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Old 08-22-2019, 03:15 PM   #3
Golfdog
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Default Re: CC Series 48v no go with new brushes

Motor is still out and all looks quite normal. I had a look at a couple of u-tube videos and the new brushes used there all seem to have flat bases when new, so I maybe barking up the wrong tree.
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Old 08-22-2019, 03:21 PM   #4
Sergio
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Default Re: CC Series 48v no go with new brushes

When You have the cart on the ground, Does the voltage on the controller side of the solenoid big posts goes down when You press the pedal?

You may have a high resistance path on circuit.
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Old 08-26-2019, 03:00 PM   #5
Golfdog
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Default Re: CC Series 48v no go with new brushes

Tks Sergio, It transpired that the lever fwd/rev unit was the cause of the issue, bad contact. Now working great
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