Club Car Carryall 500 2016 Maintenance And Service Manual page 249

MOTOR (MODEL DA5-4006): ELECTRIC
VEHICLES
5. Remove the four end cap bolts. The weight of the motor housing will cause it to drop when the bolts are removed.
See following CAUTION.
CAUTION
• The motor housing will drop when the bolts are removed. Do not put fingers under the motor 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 16-8.
8. Remove the armature from the end cap bearing. See following CAUTION and NOTE.
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 16-7.
10. Inspect the motor frame and field windings. See Motor Frame and Field Windings Inspection on page 16-8.
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.
2016 Carryall 500 and 700 Maintenance and Service Manual
16
Motor Disassembly
Page 16-5