Brush Wear; Field Coil Replacement; Securing Brushes; Motor Assembly - Cushman Shuttle 2 Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
NOTICE
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
assembly, support the bearing's inner race to avoid dam-
age.
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.

Field Coil Replacement

Tool List
Wrench, 1/2"................................................................ 1
Ratchet, 3/8" drive....................................................... 1
Socket, 1/2", 3/8" drive ................................................ 1
To replace field coil (8), remove field coil terminal hard-
ware (9) at S1 and S2 (Ref. Fig. 3).
Remove bolts (10) that secure field coil retainers (11) to
motor housing (4). Remove the field coils.
Replacement field coils are installed in reverse order of
disassembly.
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).
1.30"
(33 mm)
Remove brush terminal hardware (12) at A1 and A2
(Ref. Fig. 3).
Remove screws (13) securing brush plate (14). Remove
brushes, rigging and brush plate.
Pull back each brush until each of the springs (15) rest
Qty.
against the side of its brush (Ref. Fig. 5). Remove
brushes and replace with new brush replacement kit.
Locate springs against the side of each brush.
Qty.
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 commu-
tator. 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
Repair and Service Manual
.62" Min
(16 mm)
New Brush
Fig. 4 Brush Wear
Brush
Spring
Brush
Spring Position
for Installed Brushes
Fig. 5 Securing Brushes
MOTOR
B
B
Worn Brush
(Replace)
Brush
Spring Position for
Removing/Replacing
Brushes
Qty.
Page K-3