20
MAINTENANCE SECTION
Disassembly of the Motor
1. Remove the Brush Caps (52) from the Rear End Plate
(50). Using a pick, catch the terminal of the Brush
Assembly (51) and pull it out of the Rear End Plate.
Do not damage the copper wires of the Brush
Assembly. Reinstall the Brushes as they were
removed unless they are replaced
2. Remove the insulation tape around the Motor.
3. Using a thin blade screwdriver, remove the Motor
Assembly Springs (44) by inserting the screwdriver
between the Springs and the Rear End Plate and prying
upward
4. Remove the Rear End Plate and the Front End Plate
(43) from the Field (46).
5. Pushing the Armature (48) toward the Fan side,
remove the Armature from the Field.
6. Do not damage the commutator or the windings of the
Armature. Hold the rotor, not the commutator.
7. Remove the Motor Pilot Rod from the Armature and
inspect it. If it is worn, replace it.
8. Remove the Front Armature Bearing (47) and the Rear
Armature Bearing (49) from the Armature and inspect
them. If they do not rotate smoothly, replace them.
9. Inspect the Armature, Field and End Plates. Use a
piece of fine cloth to wipe away contamination.
For excess build up, spray with contact cleaner and
brush if necessary.
10. To clean the commutator on the Armature, spray with
contact cleaner and brush if necessary.
11. Test the commutator. Replace the Armature if
necessary.
ASSEMBLY
Assembly of the Motor Housing
1.
Install the Front Armature Bearing (47) and the Rear
Armature Bearing (49) to the Armature shaft ends.
2.
Apply grease to both ends of the Motor Pilot Rod (42)
and insert it into the center hole of the Motor
Assembly.
3.
Insert the Armature through the notched end of the
Field (46).
Be careful not to damage the commutator or the
windings. Hold the rotor, not the commutator,
when assembling.
4.
Install the Rear End Plate (50) to the notched end of
Field and the Front End Plate (43) to the field.
5.
Snap the two Motor Assembly Springs (44) over the
notches of the Rear End Plate and the Front End Plate.
6.
Insert the Brush Assemblies (51) into the brush holders
of the Rear End Plate. Be sure the tab on the Brush
Assembly slides into the notch in the holder.
7.
Screw on the Brush Caps (52).
8.
Wrap one layer of 3M #56 insulation tape around the
Motor Assembly.
9.
For Throttle Lever Start Models, put two additional
strips of insulation tape, one upon the other, onto the
Brush Light Circuit Board (67) side of the Motor
Assembly. This insulates the area between the ground
wire and the Field.
Assembly of the Electrical Components
1.
Solder the red and blue wires to the Brush Light
Circuit Board.
2.
Solder the Reverse Switch (70) and the Resistor (72).
Using shrink tubing 5mm long as spacers, solder the
Capacitor (71) into place. Solder the red and blue
wires to the Reserve Switch Circuit Board (69).
3.
Solder the Start Switch (61) onto the Microswitch
Circuit Board (58).
4.
Insert the Switch Pilot Rod (56) into the hole in the
Switch Plate (59). (Refer to Dwg. TRD1819).
BRAKE SWITCH
SCREWS
BRAKE SWITCH
PURPLE
BROWN
GREEN
MICRO SWITCH
PCB ASSEMBLY
BRUSH LIGHT LED
LED PCB
INSULATING
FILM
SPACER FOR
LED PCB
START SWITCH
SCREWS
START SWITCH
SWITCH PLATE
PILOT ROD
ASSEMBLY
(Dwg. TPD1819)
