Starter/Generator Assembly - Club Car Carryall 500 2019 Maintenance And Service Manual

19
Starter/Generator
2. Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 19-4, Page 19-3).
Using a spring scale, test brush spring tension. If any spring has a tension less than 24 ozf (0.68 kgf), replace all
four springs (Figure 19-6, Page 19-4). See following CAUTION.
CAUTION
• When checking brush spring tension, do not push springs beyond the point they would normally be if
there were new brushes installed. Exerting excessive force or pushing brush springs beyond their
normal maximum extension point will damage springs.
490

STARTER/GENERATOR ASSEMBLY

1. Install the brushes (27) into the holders. Install the terminal hardware (25) (Figure 19-4, Page 19-3).
2. To prevent contact between the brushes and commutator as the commutator is installed, and possible damage
to the brushes, lift the brush springs 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 19-7, Page 19-5).
3. Install the commutator end cover (23) onto the armature shaft. Align the locating pin with the pin hole in the cover.
Install two M6 x 180 mm bolts (20) and tighten to 100 in·lb (11.3 N·m) (Figure 19-3, Page 19-3).
4. Push the brushes down into the holders. Position springs on the end of 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 19-4, Page 19-3).
Page 19-4 2019 Carryall 500 and 700 Maintenance and Service Manual
Figure 19-6 Brush Spring Tension Test
ELECTRICAL COMPONENTS: GASOLINE
VEHICLES