Motor Installation - Club Car IQ Plus 2008 Maintenance And Service Manual Supplement

16
MOTOR (MODEL DA5-4006)
Figure 16-14 Retracted Brushes
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).
3. With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing
(Figure 16-15, Page 16-12). See following CAUTION.
CAUTION
• Make sure the brushes are held back. Do not allow the brushes to support the weight of the
commutator. The brushes can be easily damaged by this weight.
4. Move the springs back to their original position. Ensure that the spring rests on the end of each brush.
5. Align the match marks on the end cap (20) and the motor frame (14) and secure with four bolts
(Figure 16-13, Page 16-10). Tighten bolts to 130 in-lb (14.7 N·m).
6. Install the speed sensor magnet (12) with bolt (13). Tighten to 65 in-lb (7.3 N·m).
7. Install the speed sensor (10) with two screws (11). Tighten to 25 in-lb (2.8 N·m).
8. Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem.

MOTOR INSTALLATION

See General Warning, Section 10, Page 10-1.
1. Clean the transaxle input shaft.
1.1. Spray the input shaft thoroughly with CRC
1.2. Wipe input shaft with a clean cloth.
1.3. Inspect the grooves of the input shaft and remove any remaining debris.
1.4. Repeat steps 1.1 through 1.3 until input shaft is clean.
2. Lubricate the transaxle input shaft.
2.1. Squeeze approximately 1/2 inch (1.3 cm) of moly-teflon lubricant (CC P/N 102243403) from tube
onto a putty knife as shown (Figure 16-16, Page 16-13).
2.2. Rotate wheels to rotate input shaft.
2.3. Apply motor coupling grease evenly to the rotating input shaft starting at approximately 1/8 inch (3.1
mm) from the end of the shaft and working back toward the transaxle (away from the end of the
Page 16-12 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement
Figure 16-15 Armature Installation
®
Brakleen™ or equivalent brake cleaner degreaser.
Motor Installation