Reconditioning The Motor; Motor Assembly - Club Car IQ Plus 2008 Maintenance And Service Manual Supplement

MOTOR (MODEL DA5-4006)

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 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.
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).
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)
0.014 ohms between
bars 1 and 15
0.55 ohms
2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement
Reconditioning the Motor
Page 16-11
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