Cushman HAULER 800 2012 Technician's Repair And Service Manual page 106

MOTOR - HAULER 800
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
Remove brushes and replace with new brush replace-
ment kit. Locate springs against the side of each brush.
Spring Position
for Installed Brushes
Fig. 5 Securing Brushes
Install terminals and brush plate using reverse order of
removal. Install armature (commutator end) through
brush plate and press into new bearing using moderate
heat to aid installation. Position brushes against com-
mutator. Ensure the springs are seated against the rear
of the brushes and are able to move freely.
Motor Assembly
Tool List
Socket, 3/8"................................................................. 1
Torque wrench, in. lbs ............................................... ..1
Align the commutator end cover with the holes in the
motor housing and assemble (Ref. Fig. 3 on Page G-2).
Secure the commutator end cover to the motor housing
with bolts (14) and tighten to 90 in. lbs. (10 Nm) torque.
For TCT vehicles, attach ring magnet to armature shaft
with screw. Insert speed sensor and secure with the
snap ring (Ref. Fig. 3 on Page G-2).
Page G-4
Brush
Brush
Spring
Brush
Spring Position for
Removing/Replacing
Brushes
Repair and Service Manual
Motor Tests
The armature and motor housing are not available as
individual parts. No testing is recommended to deter-
mine the specific area of failure. When a test of the
power wiring system indicates that the system is operat-
ing correctly and the vehicle either does not run or runs
poorly, the motor is the only remaining component and
must be replaced.
Motor Installation
Tool List
Socket, 7/16" ............................................................... 1
Torque wrench, in. lbs. ................................................ 1
Be sure that a bumper spline is installed between the
motor input pinion shaft and splines. Apply a small
quantity of molybdenum grease to the male portion of
the spline. Carefully mate the motor spline with the
input shaft of the rear axle. Align the orientation marks
and install the mounting hardware. Tighten to 168 in.
lbs. (19 Nm) torque (Ref. Fig. 2 on Page G-1).
Attach the four motor wires to motor (Ref. Fig. 6 on
Page G-4). Tighten the nuts to 66 in. lbs. (7 Nm) torque.
For TCT motors, install speed sensor to end cover.
Qty.
Motor
Terminal
F1
F2
A1
A2
MOTOR WIRING
Wire
Marker From
F1 Controller "F1"
F2 Controller "F2"
A1 Controller "A1"
A2 Solenoid
Fig. 6 Motor Wiring
Qty.