Replace brushes on Advanced DC motor

sebagomike

Looking for help changing the brushes and leads in my Advanced DC (AY4-4001) motor. I have removed as much as i can to access the brushes but cant remove them because the end cap doesn't have enough play. How can I remove the end cap and where can I find the correct replacement brushes and leads with the studs?
Thanks for the help in advance.

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yurtle

Check the stickies.

madoc1

what is the motor type? series or sepex? if it has the wires in the rear, you have to pull out the magnet they are attached to to access a small retaining screw.

simple man

Now mind you, I've never had my motor apart, but I believe you have to take out the whole brush holder assembly to change them.

sebagomike

Thanks for the info.
Not sure on the motor. Its a DCS, 10 pin connector, tow / maintenance switch, F+R at the right knee, regenerative braking. motor wire is small wound many times around, no wire coming from the rear just a removable cap cover. I can move the retaining clip to access the brushes but cant pull them all the way out because they hit the cap. If I have to pound the cap off will I be able to re-install it the same way?

yurtle

That's what I did. The service and parts manual have instructios and exploded diagrams. I used a heat gun, found a socket that fit, and beat it out carefully. I used a hard faced plastic mallet, but a dead-blow hammer would have also worked. I placed the cap in my work mate and had my wife catch it so it didn't fall. Reassemble is just the reverse.