Abstract: A motor and method of assembly of a motor having a stator core and at least a first end shield. The method includes selecting a bearing cap from one of a plurality of bearing caps. Each of the plurality of bearing caps has a different bearing cap length and is dimensioned for attachment to the first end shield. The bearing cap is selected from the plurality of bearing caps as a function of a width of the stator core. The invention is also a motor system that includes a stator core selected from a plurality of stator cores and a bearing cap selected from a plurality of bearing caps. Each of the plurality of stator cores has a different stator core width and each of the plurality of bearing caps has a different bearing cap length. The bearing cap is selected as a function of a width of the selected stator core.

Abstract: A motor and method of manufacturing a motor having a steel shaft with a carbon content greater than or equal to about 0.4 percent by weight and a powder metal bearing coupled about the shaft. The invention also includes a method of using a motor having a non-hardened steel shaft with a carbon content greater than or equal to about 0.4 percent by weight and a powder metal bearing coupled about the non-secondary hardened shaft. The method includes applying a radial load to the bearing greater than about 25,000 pound-feet per square-inch minute.

Abstract: A lubricant retention assembly is employed with an electric motor to prevent the loss of lubricant from a self contained lubricant reservoir of the motor. The lubricant retention assembly includes a thrust collar mounted on the motor shaft and a bearing cap surrounding the thrust collar, where the thrust collar has an annular flange that throws lubricant leaking along the shaft radially outwardly toward the bearing cap. The bearing cap has an angled interior surface that deflects the lubricant thrown from the annular flange of the thrust collar back into the motor interior and toward the lubricant reservoir. A thrust washer is also provided on the shaft adjacent the thrust collar and prevents lubricant leakage along the shaft between the interface of the shaft and the thrust collar. The thrust washer and thrust collar have complementary configurations that maintain the thrust washer in position on the shaft adjacent the thrust collar.

Abstract: A motor shaft bearing assembly restricts the pivoting or swiveling movement of a self-aligning bearing supporting a motor shaft in a bearing seat. The bearing assembly provides projections adjacent the bearing seat that engage with an exterior surface of the bearing to restrict the movement of the bearing relative to the bearing seat. As an alternative or in addition to the projection adjacent to the bearing seat, a bearing retainer holding the bearing against the bearing seat is provided with a projection that engages into the exterior surface of the bearing to restrict the movement of the bearing relative to the bearing seat.