Club Car Carryall 500, Maintenance And Service Manual

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MOTOR (MODEL DA5-4006): ELECTRIC
VEHICLES
Reconditioning the Motor
16
RECONDITIONING THE MOTOR
See General Warnings on page 1-1.
Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures
is absolutely essential for successful motor reconditioning.
MOTOR SPECIFICATIONS
Any rework must be performed by a qualified technician. Motor service specifications are listed in the following table.
_
ITEM SERVICE LIMIT
Commutator diameter (minimum) 2.80 in. (71.10 mm)
Commutator concentric with armature shaft within 0.003 in. (0.08 mm)
Bar to bar runout should not exceed 0.005 in. (0.013 mm)
Undercut of segment insulator after machining commutator 0.040 in. (1.0 mm)
Armature resistance at 75 °F (24 °C) 0.014 ohms between bars 1 and 15
Field resistance at 75 °F (24 °C) 0.55 ohms
MOTOR ASSEMBLY
See General Warnings on page 1-1.
1. Replace the bearing.
1.1. Use an arbor press to install a new bearing into the end cap. To help avoid damaging the bearing, apply
pressure only to the outer race when installing the bearing.
1.2. Install the retaining ring to secure the bearing.
2. Install the brushes and brush rigging. 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.
When replacing brushes, replace all eight brushes.
Install the brushes in the same rigging 180° apart from each other.
2.1. Insert the brushes into the brush rigging as shown.
2.2. Insert the two terminal posts through insulators in the end cap (20) wall at the A1 and A2 positions
(Figure 16-13, Page 16-10) .
2.3. Place external insulators and washers on each terminal post, and secure terminal with nuts. Tighten nuts to
100 in·lb (11.3 N·m). Ensure that the terminal posts do not rotate when tightening the nuts.
2.4. Secure the brush rigging to the end cap with four bolts. Tighten the bolts to 25 in·lb (2.8 N·m).
2.5. One at a time, push the brushes back until they are completely retracted into their mounting slots (Figure
16-14, Page 16-12) .
2017 Carryall 500 and 700 Maintenance and Service Manual Page 16-11