Club Car Carryall 500 2016 Maintenance And Service Manual page 342

20
Starter/Generator
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 20-9, Page 20-7).
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 20-9, Page 20-7).
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 20-6, Page 20-5). 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.
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 20-6, Page 20-5).
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 20-5, Page 20-4).
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 20-1, Page 20-2).
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 20-2, Page 20-2).
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
20-6, Page 20-5).
Page 20-10 2016 Carryall 500 and 700 Maintenance and Service Manual
ELECTRICAL COMPONENTS: PEDAL-START
GAS VEHICLE