Starter/Generator Installation - Club Car Turf 252 2007 Maintenance And Service Manual

14
Starter/Generator
6. Install the output end cover (36) onto the armature. Secure the bearing retainer (32) to the cover and tighten the
screws (43) to 39 in-lb (4.4 N·m) (Figure 14-7, Page 14-5).
7. Slide the housing with field coils over the armature. Use the locating pin to align housing to the cover.
NOTE: The terminal insulators should be on the commutator end of the housing.
8. To prevent contact between the brushes and commutator as the commutator cover is installed, and possible
damage to the brushes, lift the brush springs out of the notches in the brushes and pull the brushes back from the
center of the commutator end cover. The springs will rest on the sides of the brushes and help prevent them
from sliding towards the center of the cover (Figure 14-6, Page 14-4).
9. Install the commutator end cover (23) onto the armature shaft. Align the locating pin with the pin hole in the cover.
Install the two M6 x 180 mm bolts (20), and tighten to 100 in-lb (11.3 N·m) (Figure 14-2, Page 14-2).
10. Push the brushes down into the holders. Place springs into the notches in the brushes. Install the brush cover
(30) that has the drain hole in it next to the A2 terminal. Install the remaining three brush covers (29) in the
openings in the commutator end cover (23) (Figure 14-3, Page 14-2).
11. Slide the spacer (37) onto the end of the shaft. Insert the shaft key (34) into the shaft. Install the belt pulley (39)
onto the shaft, and install the lock washer (40) and M14 nut (41). Tighten the nut to 28 ft-lb (38.0 N·m) (Figure
14-7, Page 14-5).

STARTER/GENERATOR INSTALLATION

1. Install the green wire from the F1 terminal to the A1 terminal on the starter/generator (Figure 14-1, Page 14-2).
Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 in-lb (5.4 N·m).
2. Install two 3/8-inch hex-head pivot bolts (5) into the mounting bracket with the heads of the bolts facing toward
the driver-side of the vehicle. Position the starter/generator in the mounting bracket so that the bolts will go
through the starter/generator before going through the bracket. Install a lock nut (7) onto each bolt. Tighten to
finger tight (Figure 14-13, Page 14-11).
3. Install the adjustment bolt (11) through the adjusting bracket (4) and then through the starter/generator. Install a
lock washer (9) and 5/16-inch nut (12) onto the end of the adjustment bolt (11). Tighten to finger tight (Figure
14-13, Page 14-11).
4. Install the belt (3), then tighten the mounting bolts. See Belt Tension Adjustment on page 14-12.
5. Connect the yellow wire from the voltage regulator to the DF terminal on the starter/generator. Install a flat
washer, lock washer, and nut onto the terminal. Tighten the nut to 31 in-lb (3.5 N·m).
6. Install the white wire from the solenoid to the F2 terminal on the starter/generator. Install the black wire from
the frame to the A2 terminal on the starter/generator. Install a flat washer, lock washer and nut onto each
terminal, and tighten the nut to 48 in-lb (5.4 N·m).
7. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.
Page 14-10 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual
ELECTRICAL COMPONENTS: PEDAL-
START GAS VEHICLE