Club Car CARRYALL 272, Maintenance And Service Manual

Page: 183 / 312

ELECTRICAL COMPONENTS: FE400, KEY-START ENGINE Starter/Generator (Model 114-01-4005)
2006-2010 Turf/Carryall 272/472 and XRT 1200/1200 SE Maintenance and Service Manual Page 12-13
12
2. Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 12-17,
Page 12-12) . Insert the brush wiring terminal studs through the commutator end cover (23) and assem-
ble using the terminal hardware (31). Route the brush wiring between the brush holder assembly (26)
and the inside of the commutator end cover cover (23) and assemble using the screws and lock washers
(25). Using a spring scale, test brush spring tension. If any spring has a tension less than 14.8 ounces
(4.1 N), replace all four springs
(Figure 12-19, Page 12-13) . See following CAUTION .
ý
CAUTION
• When checking brush spring tension, do not push springs beyond the point they would
normally be if there were new brushes installed. Exerting excessive force or pushing brush
springs beyond their normal maximum extension point will damage springs.
Starter/Generator Assembly
1. To prevent contact between the brushes and commutator as the commutator is installed, and possible
damage to the brushes, pull back each brush spring 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 slid-
ing towards the center of the cover
(Figure 12-20, Page 12-14) .
2. Install the commutator end cover (23) onto the armature shaft. Orient the commutator end cover with the
field coil housing as shown. Install two M5 x 20 mm bolts (20) and tighten to 60 in-lb (6.8 N·m)
(Figure 12-16, Page 12-12) .
3. Push the brushes down into the holders. Position springs so that brushes are being held against the com-
mutator. Install the brush cover (30) that has the drain hole in it next to the A2 terminal. Install the remain-
ing three brush covers (29) in the openings in the commutator end cover (23)
(Figure 12-17,
Page 12-12) .
Figure 12-19 Brush Spring Tension Test
0
5
10
15
20
25
30
35
40
45
50