Reconditioning The Motor; Motor Specifications; Motor Assembly - Club Car 2009-20011 Electric Precedent Maintenance And Service Manual

20

Reconditioning the Motor

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.
Commutator diameter (minimum)
Commutator concentric with armature shaft within
Bar to bar runout should not exceed
Undercut of segment insulator after machining commutator
Armature resistance at 75 °F (24 °C)
Field coil resistance at 75 °F (24 °C)

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 (Figure 20-11, Page 20-7).
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 four brushes. Never replace only two.
Install the brushes in the same rigging 180° apart from each other.
2.1. Insert the brushes into the brush rigging as shown (Figure 20-16, Page 20-13).
2.2. Insert the two terminal posts through insulators (4) in the end cap (11) wall at the A1 and A2 positions
(Figure 20-15, Page 20-11).
2.3. Place external insulators (5) and washers (6) on each terminal post, and secure terminal with nuts (7).
Tighten nuts (7) to 100 in-lb (11.3 N·m). Ensure that the terminal posts do not rotate when tightening
the nuts (Figure 20-15, Page 20-11).
2.4. Secure the brush rigging to the end cap with two screws. Tighten the screws to 25 in-lb (2.8 N·m) (Figure
20-10, Page 20-7).
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 20-17, Page 20-13).
Page 20-12 2009-2011 Electric Precedent Maintenance and Service Manual
ITEM
MOTOR (MODEL EJ4-4001 AND EJ8-4001A)
SERVICE LIMIT
2.80 in. (71.10 mm)
0.003 in. (0.08 mm)
0.005 in. (0.013 mm)
0.040 in. (1.0 mm)
0.012 ohms between bar 1 and bar 15
1.75 ohms