Club Car Gasoline Service Manual page 172

Starter/Generator Assembly, Continued:
12
5. Slide the housing with field coils over the armature. Use the locating pin to align housing to the cover.
G
NOTE
• THE TERMINAL INSULATORS SHOULD BE ON THE COMMUTATOR END OF THE HOUSING.
6. 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 12-43, Page 12-
30).
7. 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 180mm screws (20) (for vehicles prior to serial number 9533-452031, the
generators have lockwashers and flat washers with the screws) tighten to 95-104 in.lbs. (10.6/11.6 N-
m) (Figure 12-39, Page 12-28).
8. Install the brushes 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 12-41, Page 12-28).
9. Slide the spacer (37) onto the end of the shaft. Insert the shaft key (34) (if your generator has one) into
the shaft. Install the belt pulley (38 or 39) onto the shaft, install the flat washer (42) (if your generator
has one) and slide on the lockwasher (40) and M14 nut (41). Tighten the nut to 25-30 ft. lbs. (34/41 N-
m) of torque (Figure 12-44, Page 12-31).
Installing the Starter/Generator (Figure 12-50)
WARNING
• WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS:
- WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
- REMOVE THE KEY.
- PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL.
- DISCONNECT THE BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2).
• FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED.
• SEE THE SAFETY WARNINGS ON PAGE 12-1.
1. Install the two 3/8 hex head pivot screws (5) into the mounting bracket with the heads of the screws fac-
ing towards the passenger's side of the vehicle. Position the starter/generator in the mounting bracket
so that the screws will go through the bracket before going through the starter/generator. Install a lock-
washer (6) and 3/8 nut (7) onto each screw. Tighten the screws and nuts to finger tight (Figure 12-50,
Page 12-37).
2. Install the adjustment screw (11) through the adjusting bracket (4) and then through the starter/genera-
tor. Install a lockwasher (9) and 5/16 nut (12) onto the end of the adjustment screw (11). Tighten to fin-
ger tight (Figure 12-50, Page 12-37).
3. Install the belt (3) then tighten the mounting screws (See Belt Adjustments on Next Page).
4. Connect the yellow wire from the voltage regulator to the DF terminal on the starter/generator (Figure
12-2, Page 12-3). Install a flat washer, lockwasher, and nut onto the terminal. Torque the nut to 26-35
in.lbs. (3.0/4.0 N-m).
5. Install the white wire from the solenoid to the F2 terminal on the starter/generator. Install the black wire
from the frame to the A1 terminal on the starter/generator. Install the black wire from the F1 to the A2
terminal on the starter/generator (Figure 12-2, Page 12-3). Install a flat washer, lockwasher, and nut
onto each terminal. Torque the nut to 43-52 in.lbs. (4.8/5.9 N-m).
Page 12-36