Club Car IQ PLUS 2008, Maintenance And Service Manual Supplement

Page: 125 / 164

MOTOR (MODEL DA5-4006) Motor
2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement Page 16-5
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housing when removing bolts.
6. Remove the end cap and armature from the motor frame (Figure 16-5, Page 16-4) .
7. Inspect the brush springs for proper tension. See Motor Brush, Spring, and Terminal Insulator
Inspection on page 16-7.
8. Remove the armature from the end cap bearing. See following CAUTION and NOTE.
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CAUTION
• Removing the armature from the end cap requires two people: one to operate the press, and
another to hold the armature. Failure to heed this CAUTION could result in personal injury
and/or damage to the armature resulting from an unsupported armature falling after it
becomes disengaged from the end cap bearing.
NOTE: Replacement of the end cap bearing is recommended if the armature is removed.
8.1. Position the brush springs to reduce tension during removal of the armature. (Figure 16-6,
Page 16-4).
8.2. Place the end cap in a press with the armature facing down.
8.3. Place a bearing press tool with an outer diameter smaller than that of the armature shaft between
the press ram and the armature shaft (Figure 16-7, Page 16-4) .
8.4. Have an assistant support the armature while the press is activated.
9. Inspect the armature for wear and damage. See Armature Inspection and Testing on page 16-6.
10. Inspect the motor frame and field windings. See Motor Frame and Field Windings Inspection on
page 16-7.
11. Remove the brush rigging.
11.1. Mark the brush terminal posts (A1 and A2).
11.2. Remove the two nuts securing the brush terminals (A1 and A2) to the end cap .
11.3. Remove the four bolts and the brush rigging from the end cap
(Figure 16-8, Page 16-6) .
12. Inspect the terminal insulators. See Terminal Insulator Inspection on page 16-9.
13. Remove the bearing from the end cap.
13.1. Remove the retaining ring that secures the bearing in the end cap (Figure 16-9, Page 16-6) .
13.2. Use an arbor press to remove the bearing from the end cap.
14. Inspect the bearing for wear and damage. See Bearing Inspection on page 16-9.