Cushman HAULER 800 2012 Technician's Repair And Service Manual page 105

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
On TCT motors, remove the magnet on the end of the
armature by carefully removing the snap rings and
attaching screw.
Remove bolts (14) that hold the commutator end cover
(11) to the motor housing (4).
Pull on commutator end cover to remove armature (3)
and cover (as an assembly) from the housing. A light tap
on the end cover may be necessary to loosen.
Bearing Replacement
Tool List
Heat gun or lamp......................................................... 1
Arbor press.................................................................. 1
Bearing driver set ........................................................ 1
Snap ring pliers ........................................................... 1
Do not use a torch to heat the commutator end cover.
Only a moderate amount of heat should be applied.
Excessive heat will damage the end cover and bearing.
Proper support must be given to the commutator end
cover during press operations. Inadequate and/or
uneven support will cause the end cover to fracture.
To aid disassembly, heat only the commutator end cover
before attempting removal of the armature.
Once heated, place the commutator end cover/armature
assembly in press, giving as much support to the end
cover as possible, and press the armature out of the
bearing.
Push back each brush until its spring (6) is resting
against the side of the brush. This keeps the brushes
out of the way during bearing replacement (Ref. Fig. 5
on Page G-4).
Remove internal snap ring (8) and heat the commutator
end cover again. Press bearing (9) out from commutator
end cover (11).
When installing bearing into end cover, apply pressure
against the bearing's outer race to avoid bearing dam-
age.
Press the new bearing into the commutator end cover
using heat again to aid installation.
Install the snap ring.
If brushes are to be replaced, proceed now to 'Brush Replace-
ment' before installing the armature.
For proper location, the armature has a positive stop
feature.
When installing armature into the bearing/end cover
Qty.
assembly, support the bearing's inner race to avoid
damage.
Press the armature into the new bearing using moderate
heat to aid installation.
Release brushes against commutator. Ensure the
springs are seated against the rear of the brushes and
are able to move freely.
Brush Replacement
Tool List
Wrench, 1/2" ................................................................1
Ratchet ........................................................................1
Socket, 5/16" ...............................................................1
Brushes should be measured as shown and replaced
when the minimum dimension of .62" (16 mm) is
reached (Ref. Fig. 4 on Page G-3).
Remove brush terminal hardware (13) at A1 and A2
(Ref. Fig. 3 on Page G-2).
Remove screws securing brush plate (5). Remove
brushes, rigging and brush plate.
Pull back each brush until each of the springs (6) rest
against the side of its brush (Ref. Fig. 5 on Page G-4).
1.30"
(33 mm)
Repair and Service Manual
MOTOR - HAULER 800
NOTICE
.62" Min
(16 mm)
New
Brush
Fig. 4 Brush Wear
B
B
Qty.
Worn
Brush
(Replace)
Page G-3