Club Car CARRYALL 252 2007, Maintenance And Service Manual

Page: 212 / 536

13
Starter/Generator
ELECTRICAL COMPONENTS: KEY-START WITH
NEUTRAL REV GAS VEHICLE
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.
CAUTION
• 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 13-11) .
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 finger- tight
(Figure 13-13, Page 13-11) .
4. Install the belt (3), then tighten the mounting bolts. See Belt Tension Adjustment on page 13-12.
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).
6. Install the white wire from the solenoid to the F2 terminal on the starter/generator. Install the black wire from the
frame to the A2 terminal on the starter/generator. Install a flat washer, lockwasher and nut onto each terminal,
and tighten the nut to 48 in-lb (5.4 N·m).
7. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.
Page 13-10 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual