19
4
The brush wears out,
changes colors and breaks.
The motor vibrates; the clearance between the brush and its holder
is too big; the clearance between the brush and commutators is too
big; the mica between different commutators comes out; the brush is
made of wrong materials; the brush is wrong type.
5
Big sparks
The motor is over-loaded; the commutators are not clean, not round
or not smooth; mica or some commutator is coming out; the brush is
not ground properly; the brush is under a lot of pressure; wrong
brush type; the brush is jammed in the brush holder; the brush
holder is loose or vibrating; the polarity and sequence of magnetic
poles goes wrong.
6
The brush and its wires get
hot.
Big sparks from the brush; poor contact between brush and soft
wires; small section area of soft wires.
7
The brush is noisy
The surface of the commutator is not smooth.
Caution!
Only a Qualified Electrician Can Change and Adjust the Carbon Brush and Commutator.
Maintenance of the Traction AC Motor
If your vehicle is equipped with AC motor, then the motor is maintenance free!
5.4 Maintenance of the Speed Controller:
Caution!
Only a qualified electrician is allowed to do the maintenance for the controller.
WARNING!
There are no spare parts available inside the controller. No attempt should be made to open, repair, or
otherwise modify the controller. Doing so may damage the controller and will void the warranty.
Cleaning
It is recommended that the controller be kept clean and dry and that its fault history file be checked and
cleared periodically.
Periodically cleaning the controller exterior will help protect it against corrosion and possible electrical
control problems created by the dirt, grime, and chemicals that are part of the operating environment and
that normally exist in battery powered systems.
Please use the following cleaning procedure for routine maintenance:
1) Turn the power key to OFF position.
2) Remove power by disconnecting the battery.
3) Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn)
across the controller’s B+ and B- terminals.
4) Remove any dirt or corrosion from the connector areas. The controller should be wiped clean with a
moist rag. Dry it before reconnecting the battery. The controller should not be subjected to pressured
water flow from either a standard hose or a power washer.
5) Make sure the connections are tight, but do not over tighten them.
Faulty History File
The handheld programmer (ordered separately) can be used to access the controller’s fault history file. The
programmer will read out all the faults the controller has experienced since the last time the history file was
cleared. Faults such as contactor faults may be the result of loose wires; contactor wiring should be
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