Club Car Carryall 1, Maintenance And Service Manual Supplement, Page: 147 / 176

MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Assembly
2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 16b-13
16B
2.5. One at a time, push the brushes back until they are completely retracted into their mounting slots
and the spring pressure holds them in the retracted position as shown (Figure 16b-17,
Page 16b-13) .
3. With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing
(Figure 16b-18, Page 16b-13) . See following CAUTION.
CAUTION
• Make sure the brushes are held back. Do not allow the brushes to support the weight of the
commutator. The brushes can be easily damaged by this weight.
4. Gently press each brush with a small screwdriver until the spring rests on the end of each brush as shown
(Figure 16b-19, Page 16b-13) .
5. Align the match marks on the end cap and the motor frame (1) and secure with two bolts (16)
(Figure 16b-15, Page 16b-11) . Tighten bolts to 130 in-lb (14.7 N·m).
6. Install the speed sensor magnet (24) with screw (23). Tighten to 65 in-lb (7.3 N·m).
7. Install the speed sensor (10) with screws (25). Tighten to 20 in-lb (2.3 N·m).
8. Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem.
Figure 16b-16 Brush Rigging Figure 16b-17 Retracted Brushes
Figure 16b-18 Armature Installation Figure 16b-19 Brush Setting