Club Car Carryall 300 2021, Maintenance And Service Manual

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16
Motor Component Testing and Inspection ELECTRIC VEHICLE - MOTOR
MOTOR FRAME AND FIELD WINDINGS INSPECTION
1. Remove the motor from the vehicle. See Motor Removal on page 16-4.
2. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-6.
3. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or
grounded or shorted coil windings. If the insulation on the field windings is scorched, replace the motor or
the stator shell assembly.
MOTOR BRUSH, SPRING, AND TERMINAL INSULATOR INSPECTION
Brush Spring Tension Test
1. Remove the motor from the vehicle. See Motor Removal on page 16-4.
2. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-6.
3. Inspect the brush springs (14) (Figure 16-15, Page 16-12) . Replace springs that are discolored from heat
(light gold or blue tinted).
4. Test the brush springs for proper tension.
4.1. Place a C-shaped steel plate on a scale.
4.2. Place the end of the C-shaped plate so that it is between the spring and the brush as shown (Figure
16-13, Page 16-11) .
4.3. Gently pull the scale to obtain the spring tension reading. See following CAUTION.
CAUTION
• When checking brush spring tension, do not over-extend the spring. Using excessive force will
damage the spring.
4.4. Replace springs which require a force of less than 35 ozf (0.99 kgf) (Figure 16-13, Page 16-11) . See
following NOTE.
NOTE: When installing new brushes, remove and replace brushes one at a time. This method ensures the terminals
and brushes will be properly positioned in the rigging. Refer to Motor Assembly on page 16-13 for brush
installation.
When replacing brushes, replace all four brushes. Never replace only two.
Install the brushes in the same rigging 180° apart from each other.
Brush Inspection
1. Remove the motor from the vehicle. See Motor Removal on page 16-4.
2. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-6.
3. Inspect the brushes (13) for damage or excessive wear (Figure 16-15, Page 16-12) . Replace brushes if required.
See preceding NOTE.
4. Use dial calipers or a micrometer to measure the brush length. The minimum-allowable brush length is 0.62
inches (16 mm). Replace the set of brushes as required.
See preceding NOTE.
Terminal Insulator Inspection
1. Remove the motor from the vehicle. See Motor Removal on page 16-4.
2. Remove the terminal insulators by performing steps 1 through 12 of Motor Disassembly on page 16-6.
3. Inspect the insulators (4 and 6) for cracks or other damage (Figure 16-15, Page 16-12) . Replace insulators
as required.
Page 16-10 2021 Carryall 300 Maintenance and Service Manual