Club Car FE350 2005 Maintenance Service Supplement page 79

ELECTRICAL COMPONENTS
Visual Inspection of Field Coils
If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable.
Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or
grounded or shorted coil windings. Be sure the insulators are tight in the housing.
Starter/Generator Rework
Any rework must be performed by a qualified technician. Starter/Generator service specifications are listed in
the following table.
ITEM
Commutator diameter (minimum)
Concentric with armature shaft
within
Limit depth of cut when
machining commutator
If undercut of segment insulator
is less than 0.016 inch
(0.406 mm), then it should be
undercut to:
Dielectric strength
Armature insulation resistance
Starter field coil resistance
Generator field coil resistance
Starter/Generator Assembly
1. Place the field coil into the housing. The two insulators that look alike fit into the slots next to the F1 and
F2 markings on the outside of the housing. The insulator that looks different slides into the slot next to
the DF marking.
2. After the insulators are seated in the slots, install the threaded terminals through the wire connectors and
then through the insulators. Install a flat washer, lock washer and nut onto each threaded terminal on the
outside of the housing. Tighten nuts to 47.5 in-lb (5.4 N·m) (Figure 12-10, Page 12-7).
ý
CAUTION
• Route the field terminal wires so that they will not contact the armature.
3. Install the four pole pieces into the housing. Use the four screws to secure pole pieces to the inside of
the housing to retain the field wires. Tighten screws to 9 ft-lb (12.2 N·m) (Figure 12-10, Page 12-7).
4. Slide the bearing retainer onto the output end of the armature shaft (33) so that it will hold the outside of
the bearing (35) only.
5. Press a new ball bearing (35) onto the output end of the armature (Figure 12-7, Page 12-5). Press a new
ball bearing onto the commutator end of the armature shaft. See following CAUTION.
SERVICE LIMIT
1.535 in. (39 mm)
0.002 in. (0.051 mm)
0.007 in. (0.2 mm)
0.031 in. (0.8 mm)
500 VAC for one minute
0.2M ohms at 500 VDC
0.006-0.01 ohms
4.5-5.5 ohms
2005 FE350 Gasoline Vehicle Maintenance and Service Supplement
12
Starter/Generator
Page 12-9