Ezgo 605586 Repair And Service Manual page 124

ELECTRICAL
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
TESTING CHARGING CIRCUIT
Tool List
DVOM.......................................................................... 1
To prevent the possibility of injury resulting
from vehicle inadvertently starting, the drive
belt must be removed or both rear wheels
raised (see procedure in Section "B").
The charging circuit consists of a starter/generator, volt-
age regulator and battery (Ref. Fig. 1 on Page L-2). The
solenoid must be functional in order to start the vehicle,
but is not considered part of the charging circuit.
1. If the battery charge is inadequate (less than 11 VDC),
proceed as follows:
a) Check the battery voltage and inspect for loose or
corroded terminal posts and connections. Check
electrolyte level.
b) Check charging circuit component terminals for
proper, clean, tight connections.
c) Check for charging voltage as follows:
1) Raise the vehicle (see procedure in Section
B) so that both rear wheels are free to rotate.
2) With the engine off, measure the voltage at
the battery's terminals by placing the nega-
tive (-) probe on the negative (-) post and the
positive (+) probe on the positive (+) post of
the battery. Note the reading.
3) Attach the DC voltmeter across the regula-
tor's red and black leads.
4) Start the engine and accelerate to governed
speed.
5) The meter should read higher than before
starting the engine. In a reasonable amount
of time, the reading should settle between 14
and 15 volts, indicating the regulator is func-
tioning properly.
6) If no increase over battery voltage is
observed, there is a malfunction in the charg-
ing circuit.
7) If the reading is above 15 volts, check to
assure the wiring harness and generator field
winding (green lead) is not grounded. If it is
not, replace the regulator.
8) If the reading is below 14 volts, disconnect
the regulator's green field wire from the sys-
tem harness. Temporarily connect the green
Page L-6
Qty. Required
STARTER/GENERATOR
Starter/Generator Removal
See ENGINE section.
Starter/Generator Disassembly
Tool List
DVOM ..........................................................................1
Wrench, 24 mm............................................................1
Wrench, 10 mm............................................................1
Wrench, 6 mm..............................................................1
Wrench, 5 mm..............................................................1
Socket, 10 mm, 3/8" drive............................................1
Phillips screwdriver, 3/8" drive .....................................1
Two jaw puller .............................................................1
Straight blade screwdriver, ..........................................1
Ratchet, 3/8" drive .......................................................1
In general, starter/generator service is best performed by
trained motor technicians who have the knowledge and equip-
ment to overhaul the unit. Some checks and repairs however,
can be accomplished by a skilled mechanic. Make your own
evaluation of the equipment and skills available before starting
disassembly.
Hold the pulley (1) and remove the pulley nut (2).
Remove the pulley, screws (4) and front cover (3) (Ref.
Fig. 5 on Page L-7).
Remove the brush covers (6) by prying out with a screw-
driver. Pull up on the brush springs and move to the side
of brushes, slide the brushes out approximately 1/4" (6
mm) (Ref. Fig. 6 on Page L-7). Remove the through
bolts (7) and the rear cover (8). Remove the frame and
field coils (9). Remove the 5 mm screws from the brush
holder and 6 mm nuts from A1 and A2 terminals.
Remove the brush holder. If the bearing needs to be
replaced, use an automotive style two jaw puller to
remove the bearing from armature (Ref. Fig. 7 on Page
L-7).
Repair and Service Manual
field wire to ground. If the voltage rises above
its prior reading, replace the regulator.
9) If the above procedures do not correct the
problem, check for faults in the vehicles wir-
ing harness and/or generator.
Qty. Required