Club Car Carryall 300 2018 Maintenance And Service Manual page 342

20
Starter/Generator
2. 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.
3. Install the drive end cover (36) onto the armature. Secure the bearing retainer ring (32) (Figure 20-6, Page 20-5).
4. Slide the housing with field coils over the armature. Use the tapped mounting holes to align housing to the
cover, rotate and orient as shown.
NOTE: The terminal insulators should be on the commutator end of the housing.
5. 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).
6. Install the commutator end cover (23) onto the armature shaft. Use the tapped mounting holes to align housing
to the cover, rotate and orient as shown. Install the two M6 x 180 mm bolts (20), and tighten to 60 in·lb (6.8
N·m) (Figure 20-1, Page 20-2).
7. 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).
8. Install the belt pulley (39) onto the shaft, and install the lock washer (40) and M14 nut (41). Tighten the nut to 30
ft·lb (40.7 N·m) (Figure 20-6, Page 20-5).
9. Install the A1 to F1 terminal jumper wire on the starter/generator.
9.1. Loosely attach wire, flat washers, lock washers and nuts onto each terminal.
9.2. Orient wire at A1 to be 1 inch (25.4 mm) away from A2 terminal as shown and tighten nut to 44 in·lb (5 N·m)
(Figure 20-12, Page 20-11). See following NOTE.
NOTE: Secure bottom nut of terminal with wrench before tightening top nut.
9.3. Form wire against starter housing as shown and allow terminal at F1 to self-orient. Tighten nut to 44
in·lb (5 N·m). See preceding NOTE.
Page 20-10 2018 Carryall 300 Maintenance and Service Manual
ELECTRICAL COMPONENTS: PEDAL-START
GAS VEHICLE