Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 166 / 544

Page 12-30
12
G
Assembly of the Starter/Generator, Continued:
3. 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) and tighten to 95-104 in.lbs. (10.6/11.6
N-m) (Figure 12-39, Page 12-28).
4. 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).
Disassembly of the Starter/Generator to Service the Armature/Commutator
1. Remove two bolts (20) and washers (21 and 22), and pull commutator end cover (23) free of the starter
housing (24) (Figure 12-39, Page 12-28).
• 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.
• IF THE BRUSHES ARE NOT REMOVED, CONTACT BETWEEN THE BRUSHES AND COMMUTA-
TOR AS THE COMMUTATOR END COVER IS BEING REMOVED OR INSTALLED COULD POSSI-
BLY DAMAGE 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).
FIGURE 12-43
WARNING
NOTE
BRUSH BEING HELD
BY BRUSH SPRING