Visual Inspection Of Field Coils; Starter/Generator Rework; Starter/Generator Assembly - Club Car Turf 252 2007 Maintenance And Service Manual

ELECTRICAL COMPONENTS: PEDAL-START GAS
VEHICLE

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 14-10, Page 14-7).
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 14-10, Page 14-7).
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 14-7, Page 14-5). Press a new ball
bearing onto the commutator end of the armature shaft. See following CAUTION.
CAUTION
• To prevent damage to the retainer, use care while pressing new bearing onto the output end of the
shaft.
• Press against the inner race of the new bearing until it is fully seated.
2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual
Starter/Generator
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
Page 14-9
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