It sounds like you need new brushes at a minimum.
I have the same motor and have taken some photos of my brushes
(installed) earlier this year. They are mounted in pairs (each brush has
two pigtails).
You can see the photos here:
https://www.summet.com/blog/2017/10/31/fb1-4001a-motor-brush-photos/
My motor is working correctly, so I assume these photos represent a
"good" or at least "ok" brush setup. (I don't know how far they are
supposed to stick up when new, so I don't know how worn my brushes
are....if anybody has a photo of the same setup with new brushes I'd
love to compare...)
Jay
On 10/31/2017 03:01 AM, EVDL Administrator via EV wrote:
Your brush problem report is puzzling.
I don't understand "the left side on both brushes was mostly shot." I've
never thought of brushes having a left or right side.
If by "shot" you mean brush wear, that much is not normal. IIRC, GE once
estimated that their DC motor brushes were good for at least 250,000 miles
of EV use.
According to the evalbum entry, you have a Honda with reverse motor
rotation. Are you sure the brush timing is set correctly for that? Maybe
your brushes were eroded by excessive arcing.
When you say "On one brush, the copper braids were completely gone. On the
second brush, the copper braids were nearly gone," do you mean that the
brush pigtails were burnt? That seems like a different issue to me.
I'd lay pigtail burnout to gross overload at low speeds or stall. I did
that to the brushes in my Comuta-car motor when starting on hills. But you
just don't see that kind of overload with a controller limiting the current,
and ADC 9" motors are a lot more durable than my C-car's feeble little 6hp
GE. So this seems odd too. But maybe I'm misinterpreting what you wrote.
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