Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 171 / 544

Page 12-35
G
12
Reworking the Starter/Generator
Any rework must be performed by a qualified technician. Starter/Generator service specifications are listed in
the table below.
Assembly of the Starter/Generator
1. Place the field coil into the inside of the housing. The two insulators that look the same 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. After the insulators are seated in the slots, install the threaded ter-
minals through the wire connectors and then through the insulators. Install a flat washer and a lock-
washer onto each threaded terminal (on the outside of the housing). Use a nut to secure the washers
and insulator to the housing. Tighten nuts to 43-52 in.lbs. (4.8/5.9 N-m) (Figure 12-47, Page 12-32).
2. Install the four pole pieces into the housing. Use the four screws to secure pole pieces to the inside of
the housing to maintain the field wires. Tighten screws to 9 ft.lbs. (12 N-m) (Figure 12-47, Page 12-32).
3. Slide the bearing retainer onto the output end of the armature shaft (31 or 33) so that it will hold the
outside of the bearing (35) only. Press a new ball bearing (35) onto the output end of the armature (Fig-
ure 12-44, Page 12-31). Press a new ball bearing onto the commutator end of the armature shaft
.
4. Install the output end cover (36) into the armature. Secure the bearing retainer (32) to the cover using
the three M5 x 18mm screws (43) (for vehicles prior to serial number 9533-452031, the generators use
washers and lockwashers with the bearing retaining screws). Tighten the screws to 35-43 in.lbs. (3.9/
4.8 N-m) (Figure 12-44, Page 12-31).
ITEM SERVICE LIMIT
Commutator diameter (minimum) 1.535 inches (39 millimeters)
Concentric with armature shaft within .002 inch (0.051 millimeter)
Limit depth of cut when machining commutator
(For Vehicles prior to Serial No. 9625-505061)
.005 inch (0.127 millimeter)
Limit depth of cut when machining commutator
(For Vehicles Serial No. 9625-505061 and later)
.007 inch (0.2 millimeter)
If under cut of segment insulator is less than .016 (0.406 millimeter), then it should be
undercut to
.031 inch (0.8 millimeter)
Dielectric strength 500 VAC for one minute
Armature insulation resistance 0.2M
Ω
at 500 VDC
Starter field coil resistance (For Vehicles prior to Serial No. 9625-505061) 0.1-0.3
Ω
Starter field coil resistance (For Vehicles Serial No. 9625-505061 and later) 0.006-0.01
Ω
Generator field coil resistance 4.5-5.5
Ω
• ROUTE THE FIELD TERMINAL WIRES SO THAT THEY WILL NOT CONTACT THE ARMATURE.
• TO PREVENT DAMAGE TO THE RETAINER USE CARE WHILE PRESSING NEW BEARING ON
TO THE OUTPUT END OF THE SHAFT.
• PRESS AGAINST THE INNER RACE OF THE NEW BEARING UNTIL IT IS FULLY SEATED.
CAUTION
CAUTION