Club Car 2007 XRT 800, Maintenance Service Manual

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ELECTRICAL COMPONENTS: 800 AND 810 GASOLINE VEHICLES Starter/Generator
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 13-9
13
CAUT ION
• Route the field terminal wires so that they will not contact the armature.
3. Install the four pole pieces into the housing. Use the four screws to secure pole pieces to the inside of
the housing to retain the field wires. Tighten screws to 9 ft-lb (12.2 N·m) (Figure 13-10, Page 13-6) .
4. Slide the bearing retainer onto the output end of the armature shaft (33) so that it will hold the outside of
the bearing (35) only (Figure 13-7, Page 13-5) .
5. Press a new ball bearing (35) onto the output end of the armature (Figure 13-7, Page 13-5) . Press a new
ball bearing onto the commutator end of the armature shaft. See following CAUTION.
CAUT ION
• Use care while pressing new bearing onto the output end of the shaft to prevent damage to
the retainer.
• Press against the inner race of the new bearing until it is fully seated.
6. Install the output end cover (36) onto the armature. Secure the bearing retainer (32) to the cover and
tighten the screws (43) to 39 in-lb (4.4 N·m) (Figure 13-7, Page 13-5) .
7. Slide the housing with field coils over the armature. Use the locating pin to align housing to the cover.
NOTE: The terminal insulators should be on the commutator end of the housing.
8. Install the commutator. Lift the brush springs out of the notches in the brushes and pull the brushes back
from the center of the commutator end cover to avoid interference. The springs will rest on the sides of
the brushes and help prevent them from sliding to the center of the cover
(Figure 13-6, Page 13-4) .
9. Install the commutator end cover (23) onto the armature shaft. Align the locating pin and hole in the cover.
Install the two M6 x 180 mm bolts (20) and tighten to 100 in-lb (11.3 N·m) (Figure 13-2, Page 13-2) .
10. 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) onto the openings in the commutator end cover (23)
(Figure 13-3, Page 13-2) .
11. Slide the spacer (37) onto the end of the shaft. Insert the shaft key (34) into the shaft. Install the belt pulley
(39) onto the shaft and install the lockwasher (40) and M14 nut (41) and tighten the nut to 28 ft-lb (38 N·m)
(Figure 13-7, Page 13-5) .
Starter/Generator Installation
1. Install the green wire from the F1 terminal to the A1 terminal on the starter/generator (Figure 13-1,
Page 13-2) . Install a flat washer, lockwasher, and nut onto each terminal and tighten to 48 in-lb (5.4 N·m).
2. Install two 3/8-inch hex-head pivot bolts (5) into the mounting bracket with the heads of the bolts facing
towards the driver side of the vehicle. Position the starter/generator in the mounting bracket so that the
bolts will go through the starter/generator before going through the bracket. Install a locknut (7) onto each
bolt and tighten to finger-tight
(Figure 13-13, Page 13-10) .
3. Install the adjustment bolt (11) through the adjusting bracket (4) and then through the starter/generator.
Install a lockwasher (9) and 5/16-inch nut (12) onto the end of the adjustment bolt (11) and tighten to fin-
ger- tight
(Figure 13-13, Page 13-10) .
4. Install the belt (3), then tighten the mounting bolts. See Belt Tension Adjustment on page 13-10.
5. Connect the yellow wire from the voltage regulator to the DF terminal on the starter/generator. Install a
flat washer, lockwasher and nut onto the terminal and tighten the nut to 31 in-lb (3.5 N·m).