Cushman HAULER 800 2012 Technician's Repair And Service Manual page 109

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.
The motor housing is not available as a service item,
therefore in the unlikely event of a failure in this compo-
nent, the entire motor must be replaced.
Motor Removal
Disconnect the negative (BL-) battery cable
with an insulated wrench before attempting to
remove wires from the motor (see safety pro-
cedures in SAFETY section of this 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). Remove all
wires from motor.
Mark both the axle and motor housings to permit realign-
ment during reassembly of motor to rear axle
(Ref. Fig. 2).
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
the axle splines.
For HAULER 1000 Only
Qty.
Motor Disassembly
Tool List
Straight blade screwdriver ...........................................1
Ratchet ........................................................................1
Socket..........................................................................1
Plastic faced hammer ..................................................1
Remove bearing cap (1) (Ref. Fig. 3). Remove the mag-
net on the end of the armature by carefully removing the
attaching screw.
Remove bolts (2) that hold the commutator end cover
(3) to the motor housing (4).
Pull on commutator end cover to remove armature (5)
and cover (as an assembly) from the housing. A light tap
on the end cover may be necessary to loosen.
Repair and Service Manual
MOTOR - HAULER 1000
Remove battery cable
from (-) battery terminal
Fig. 7 Disconnect Battery Cable
Fig. 8 Mark Axle and Motor
B
B
Qty.
Page G-7