Club Car Carryall 500, Maintenance And Service Manual

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MOTOR (MODEL DA5-4006): ELECTRIC
VEHICLES
Motor Component Testing and Inspection
16
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 16, Page 16-2.
2. Release the clasp and remove the headband from the motor.
3. Inspect the brushes (16) for damage or excessive wear (Figure 16-13, Page 16-10) . 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.
Terminal Insulator Inspection
1. Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-2.
2. Remove the terminal insulators by performing steps 1 through 11 of Motor Disassembly on page 16-4.
3. Inspect the insulators for cracks or other damage. Replace insulators as required.
Bearing Inspection
NOTE: Replacement of the end cap bearing is highly-recommended if the end cap is removed from the motor. The
following procedure is provided as a guideline for determining general bearing failure.
1. Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-2.
2. Remove the bearing by performing steps 1 through 13 of Motor Disassembly on page 16-4.
3. Use a clean cloth to wipe the carbon dust off of the bearing. Inspect the bearing by spinning it by hand and
checking for both axial (A) and radial (B) play
(Figure 16-12, Page 16-9) .
4. Replace the bearing if it is noisy, does not spin smoothly, or has excessive play. Check the bearing and replace if
rusted, worn, cracked, or if there is an abnormal color change in the metal of the bearing.
1
2
A
B
Figure 16-11 Brush Spring Tension Test Figure 16-12 Bearing Inspection
Speed Sensor Magnet Inspection
Inspect the speed sensor magnet (12) for rust, wear, and cracks (Figure 16-13, Page 16-10) . Replace the magnet
if necessary.
2017 Carryall 500 and 700 Maintenance and Service Manual Page 16-9