Reconditioning The Motor; Motor Assembly - Club Car DS Villager 4 Maintenance And Service Manual Supplement

16B
MOTOR (MODELS EJ4-4001 AND EJ8-4001A)

RECONDITIONING THE MOTOR

See General Warning, Section 10, Page 10-1.
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 follow-
ing table.
ITEM
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 Warning, Section 10, Page 10-1.
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 16b-11, Page 16b-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 16b-16, Page 16b-13).
2.2. Insert the two terminal posts through insulators (4) in the end cap (11) wall at the A1 and A2 posi-
tions (Figure 16b-15, Page 16b-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 tight-
ening the nuts (Figure 16b-15, Page 16b-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 16b-10, Page 16b-7).
Page 16b-12 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
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
Reconditioning the Motor