Maintenance And Repairs; Parts Replacement Vs. Repair; Adjusting Brake Pedal Free Travel - Cushman HAULER 800 2012 Technician's Repair And Service Manual

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

MAINTENANCE AND REPAIRS

Tool List
Hydraulic floor jack ...................................................... 1
Scale............................................................................ 1
Jack stands.................................................................. 4
Wheel chocks .............................................................. 4
Socket, 1/2" ................................................................. 1
Socket, 3/4" ................................................................. 1
Socket, 11/16".............................................................. 1
Socket, 15/16" ............................................................. 1
Socket, 1 1/8" .............................................................. 1
Socket, 1/4" ................................................................. 1
Torque wrench, ft. lbs. ................................................. 1
Torque wrench, in. lbs................................................. 1
Extension, 6", ............................................................. 1
Ratchet ........................................................................ 1
Open end wrench, 1/4" ................................................ 1
Open end wrench, 1/2" ................................................ 1
Open end wrench, 5/8" ................................................ 1
Straight blade screwdriver ........................................... 1
Straight blade screwdriver, narrow .............................. 1
Pliers............................................................................ 1
Vernier/Dial calipers..................................................... 1
Plastic tipped hammer ................................................. 1
Puller (P/N 15947-G1) ................................................. 1
Pry bar ......................................................................... 1
Dust mask.................................................................... 1
Emery cloth.................................................................. 1

Parts Replacement vs. Repair

Some maintenance or repair tasks can take consider-
able labor to do correctly. Assessment of the condition of
worn components is critical to the operation of the brake
system. In some cases, component replacement may be
more cost effective than the removal, cleaning, inspec-
tion and reassembly of the component(s).

Adjusting Brake Pedal Free Travel

Brake pedal free travel MUST be checked and adjusted
any time that the brake system is serviced or when parts
are replaced.
Brake pedal free travel is the distance the pedal travels
from rest to the point at which the brake cables start to
move the brake levers. This should not be confused with
the light resistance that is felt as the brake pedal is
depressed enough to remove slack from the compensa-
tor and cables. Correct adjustment of free travel is
Page K-14
essential to proper brake function. Too much pedal free
travel will limit braking capability. Too little pedal free
Qty.
travel may cause the brakes to drag (not fully released).
Either condition can prevent the brakes from adjusting
properly.
This procedure is intended to adjust the brakes
and seat brake system components. The brake
system may not be effective for the first few
applications of the brake pedal.
Pre-adjust service brake pedal free travel to the correct
setting by loosening the jam nut and adjusting the spher-
ical nut (Ref. Fig. 18 on Page K-14). Tighten the jam nut
to 10 - 11 ft. lbs. (14 - 15 Nm).
The correct brake pedal free travel should be set to
7/8" - 1 1/8" (2.2 - 2.9 cm).
Press the brake pedal aggressively 4 - 6 times to estab-
lish known free travel.
All brake tests must be done in a safe location
with regard for the safety of all personnel.
In a safe location free from people and vehicles, drive
the vehicle at reduced speed and apply the brakes
aggressively. As the brakes adjust and stop the vehicle
effectively, start driving at maximum speed and brake
aggressively 10 times.
At the spherical nut, adjust the free travel as noted
above.
Drive again and brake aggressively 10 times.
Repair and Service Manual
7/8" - 1 1/8" (2.2 - 2.9 cm)
Spherical Nut
Fig. 18 Free Travel Adjustment
Jam Nut