Voltage Test For Battery; Starter/Generator Disassembly; Starter/Generator Repair And Replacement; Starter/Generator Brush Removal - Cushman HAULER 1200 Repair Manual

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ELECTRICAL

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

STARTER/GENERATOR

Starter/Generator Removal

See ENGINE section.

Disassembly

Tool List

DVOM.......................................................................... 1

Wrench, 24 mm ........................................................... 1

Wrench, 10 mm ........................................................... 1

Wrench, 6 mm ............................................................. 1

Wrench, 5 mm ............................................................. 1

Socket, 10 mm............................................................. 1

Phillips Screwdriver ..................................................... 1

Two Jaw Puller ............................................................ 1

Straight Blade Screwdriver .......................................... 1

Ratchet ........................................................................ 1

Torque Wrench, ft. lbs.................................................. 1

Torque Wrench, in. lbs................................................. 1

Clean Cloth.................................................................. 1

NOTICE: In general, starter/generator service is best

performed by trained motor technicians who have

the knowledge and equipment to overhaul the unit.

Some checks and repairs however, can be accom-

plished by a skilled mechanic. Make your own evalu-

ation of the equipment and skills available before

starting disassembly.

Hold the pulley (1) and remove the pulley nut (2). Remove

the pulley, screws (4) and front cover (3) (Ref. Fig. 5).

Remove the brush covers (6) by prying out with a screw-

driver. Pull up on the brush springs and move to the side

of brushes, slide the brushes out approximately 1/4" (6

mm) (Ref. Fig. 5). Remove the through bolts (7) and the

rear cover (8). Remove the frame and field coils (9).

Remove the 5mm screws from the brush holder and 6

mm nuts from A1 and A2 terminals. Remove the brush

holder. If the bearing needs to be replaced, use an auto-

motive style two jaw puller to remove the bearing from

armature (Ref. Fig. 6).

Brush

Spring Position

for Installed Brushes

Fig. 6 Starter/Generator Brush Removal

138

Brush

Spring

Brush

Spring Position for

Removing/Replacing

Brushes

Qty.

Repair and Replacement

Clean commutator with a soft, clean cloth.

Replace any damaged or cracked brush holders or

brushes worn to less than 11/16" (17mm) in length or

to the line marked on the brush.

Test the insulation between the core and the commu-

tator segments and shaft with a circuit tester. If conti-

nuity is indicated, the insulation is defective and the

armature must be replaced.

With the brushes removed, using a DVOM, check

the field coils for continuity between F1 and F2 and

DF and F1. If an open circuit exists, replace the field

coils. Check for continuity between all four terminals

and the frame (outer shell). If continuity is indicated,

the field coils are grounded against the frame and

the field coils must be replaced.

Clean all parts to be reinstalled. Installation is

reverse order of removal. Tighten bolts and nuts to

the following values:

•

4 mm - torque to 15 - 21 in. lbs. (1.6 - 2.3 Nm)

•

5 mm - torque to 30 - 43 in. lbs. (3.3 - 4.8 Nm)

•

6 mm - torque to 52 - 74 in. lbs. (6.7 - 8.3 Nm)

•

14 mm - torque to 33 - 40 in. lbs. (3.7 - 4.5 Nm)

Tighten terminal nuts to the following torques:

•

F1 - F2 - torque to 43 - 52 in. lbs. (4.8 - 6.7 Nm)

•

DF - torque to 26 - 35 in. lbs. (2.9 - 3.9 Nm)