Cushman HAULER 800 2012 Technician's Repair And Service Manual page 103

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
GENERAL
Do not hold vehicle on hill by using accelerator and
motor. Leaving the motor in a stalled condition for more
than 3-4 seconds will raise the commutator bars
resulting in unacceptable noise and accelerated brush
wear and cause permanent damage to motor.
Disassembly of the motor is not recommended except to
replace a worn or noisy bearing. If the motor is disas-
sembled, it should be cleaned of any dirt buildup and the
brush length checked. Replace brushes if required.
Neither the motor housing nor armature is available as
service items, therefore in the unlikely event of a failure
in either of these components, the entire motor must be
replaced.
Motor Removal
Before any electrical service is performed on TCT model
vehicles, the Run-Tow/Maintenance switch must be
placed in the 'Tow/Maintenance' position.
If a power wire (battery, motor or controller) is discon-
nected for any reason on the TCT model vehicle, the
Run-Tow/Maintenance switch must be left in the 'Tow/
Maintenance' position for at least 30 seconds after the
circuit is restored.
Disconnect the negative (BL-) battery cable
with an insulated wrench before attempting to
remove wires from the motor (see safety
p r o c e d u r e s i n S A F E T Y s e c t i o n o f t h i s
manual). The shorting of motor wires could
cause an explosion.
Tool List
Insulated wrench, 9/16"............................................... 1
Chalk or paint pen ....................................................... 1
Socket, 7/16" ............................................................... 1
Ratchet ........................................................................ 1
Internal snap ring pliers ............................................... 1
Using an insulated wrench, disconnect the negative (-)
battery cable from the battery (Ref. Fig. 1 on Page G-1).
Remove all wires from motor.
For Hauler 800 Only
Mark both the axle and motor housings to permit
realignment during reassembly of motor to rear axle
(Ref. Fig. 2 on Page G-1).
On TCT motors, remove the snap ring and remove the
speed sensor from the motor end cover.
Take care not to damage the splines when removing
and reassembling the motor to the rear axle housing.
Remove the three bolts that secure the motor to the axle
housing and carefully slide the motor straight out from
Qty.
the axle splines.
Motor Disassembly
Tool List
Straight blade screwdriver ...........................................1
Ratchet ........................................................................1
Socket, 3/8" .................................................................1
Plastic faced hammer ..................................................1
Repair and Service Manual
MOTOR - HAULER 800
Front of Vehicle
Fig. 1 Disconnect Battery Cable
Fig. 2 Mark Axle and Motor
Remove BL-
Qty.
Page G-1