Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 535 / 544

Page 24-11
E
24
MOTOR ASSEMBLY
1. If the bearing has been removed, replace the bearing:
1.1. Press on a new bearing using an arbor press that exerts pressure on the inner race only. See
NOTE below.
ITEM SERVICE LIMIT
Commutator diameter (minimum) 2.265 inches (66.675 millimeters)
Commutator concentric with armature shaft within .001 inch (0.0508 millimeter)
Limit depth of cut when machining commutator .005 inch (0.127 millimeter)
Bar to bar run out should not exceed .0002 inch (.00508 millimeter)
If undercut of segment insulator is less than .016 inch (0.406 millimeter), it should be
undercut to
.031 inch (0.8 millimeter)
Machined face of Commutator 8-16 micro inches
Field coil resistance (V-Glide 36 Volt, 2.97 Hp.) .00711
Ω
Field coil resistance (V-Glide 36 Volt, 3.50 Hp.) .00514
Ω
Field coil resistance (PowerDrive System 48, 3.10 Hp.) 0.02040
Ω
Field coil resistance (PowerDrive System 48, 3.75 Hp.) (optional equipment) 0.00884
Ω
Field coil resistance (PowerDrive Plus 48 Volt, 3.20 Hp.) 1.32353
Ω
FIGURE 24-13
• MAKE SURE THAT THE BEARING RETAINER (16) (FIGURE 24-8, PAGE 24-7) IS POSITIONED ON
THE ARMATURE SHAFT BEFORE THE BEARING IS PRESSED ON.
• AN ARBOR WITH AN OUTSIDE DIAMETER OF LESS THAN 5/8 INCH (16MM) SHOULD BE USED
TO PRESS THE BEARING ON.
TRANSAXLE
INPUT SHAFT
GUIDE RING
(GLUED TO INPUT SHAFT)
GUIDE RING
WITH ADHESIVE
(TO BE INSTALLED)
ARMATURE
SHAFT
TO MAKE A GUIDE RING INSTALLATION TOOL, GLUE A
GUIDE RING (CLUB CAR PART NO. 1017891-01) ONTO
AN INPUT SHAFT (CLUB CAR PART NO. 1013764) AS
SHOWN AND ALLOW THE GLUE TO SET.
TO INSTALL A NEW GUIDE RING IN THE ARMATURE
SHAFT:
COAT THE ENTIRE OUTSIDE SURFACE OF THE NEW
GUIDE RING WITH A THIN FILM OF GUIDE RING
ADHESIVE (CLUB CAR PART NO. 1018132-01) AND THEN
SLIDE IT ONTO THE INPUT SHAFT NEXT TO THE GUIDE
RING THAT IS GLUED ON.
MATING THE SPLINES OF THE GUIDE RING
INSTALLATION TOOL WITH THE SPLINES IN THE
ARMATURE SHAFT, INSERT THE GUIDE RING
INSTALLATION TOOL INTO THE ARMATURE SHAFT
UNTIL THE NEW GUIDE RING IS SEATED AGAINST THE
END OF THE ARMATURE SPLINES.
REMOVE THE GUIDE RING INSTALLATION TOOL FROM
THE ARMATURE, MAKING SURE THAT THE GUIDE RING
REMAINS SEATED. ALLOW THE NEW GUIDE RING TO
SET FOR 24 HOURS BEFORE INSTALLING THE SNAP
RING AND INSTALLING MOTOR ONTO THE
TRANASAXLE.
NOTE