Club Car 2007 XRT 800, Maintenance Service Manual, Page: 480 / 516

MOTOR (MODEL EJ4-4001) Motor Component Testing and Inspection
Page 27-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
27
2. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 27-4.
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, Section 27, Page 27-2.
2. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 27-4.
3. Inspect the brush springs (14) (Figure 27-15, Page 27-10) . 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 27-13, Page 27-9) .
4.3. Gently pull the scale to obtain the spring tension reading. See following CAUTION.
CAUT ION
• 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 oz. (990 grams) (Figure 27-13, Page 27-9) .
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 for brush
installation.
See Motor Assembly on page 27-11.
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, Section 27, Page 27-2.
2. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 27-4.
3. Inspect the brushes (13) for damage or excessive wear (Figure 27-15, Page 27-10) . 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.