Cushman HAULER 800 2012 Technician's Repair And Service Manual page 165

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
actuator pivot and the linkage rod (See Actuator linkage
bushings).
The clevis pin joining the brake cylinder clevis and the
upper actuator pivot must be removed by removing the
cotter pin and discarding. Remove clevis pin.
Remove Locknut from shoulder bolt and remove shoul-
der bolt. Pivot components may now be removed and
bushing removed and replaced with new ones. Be sure
to replace the nylon bushing with the flange oriented up.
Reassemble using new cotter pins. and tighten lock nut
to 5 - 10 (7 - 13 Nm) ft. lbs torque.
BLEEDING BRAKES
Tool List
Hose........................................................................ A/R
Clean container ........................................................... 1
Brake fluid, DOT 3................................................... A/R
Wrench, 1/4" box end.................................................. 1
The hydraulic brake system must be free of air to oper-
ate properly. Air can enter the system when hydraulic
parts are disconnected for servicing or replacement, or
when the fluid level in the master cylinder reservoir is
very low. Air in the system will give the brake pedal a
spongy feeling upon application.
NOTICE
An assistant will be necessary to perform this procedure.
Use a clean cloth to wipe off the master cylinder reser-
voir and wheel cylinder bleeder valves (Ref. Fig. 33 on
Page K-27). Clean each fitting before opening to pre-
vent contaminating the system. Open the master cylin-
der reservoir and top off with standard automotive DOT
3 brake fluid.
Never reuse any excess fluid or return to the
original container. Dispose of brake fluid prop-
erly.
Brake fluid should never be returned to the original con-
tainer and reused due to the possibility of contamination
by dirt, grease, moisture or used brake fluid which could
cause failure of the braking system. Dispose of in
accordance with Federal, state and local codes.
Attach a short length of clear hose to the caliper bleed
valve and insert the other end into a suitable clean con-
tainer containing fresh, clean brake fluid (Ref. Fig. 33
on Page K-27). Check the fluid level in the master cylin-
der frequently during this operation to prevent air from
entering the lines.
Bleeder
Hose
Qty.
Starting with the passenger side rear brake and going to
the driver side rear brake, bleed the brakes using the
following procedure:
The bleeder valve at the caliper must be closed at the end of
each stroke and before the brake pedal is released to insure
that air cannot enter the system. It is also important that the
brake pedal be returned to full 'up' position.
Open the bleeder valve and have an assistant depress
brake pedal gently until fluid flows into container. Close
the bleeder valve and have the assistant slowly release
the brake pedal. Repeat the process until no bubbles
can be seen leaving the bleeder valve. Close the valve
and repeat at other side. After bleeding, check fluid
level using a mechanics mirror and a flashlight. Add
fluid if the level has fallen below 1/4" (6.5 mm) from the
top of the reservoir and inspect for visible fluid leaks.
Repair and Service Manual
BRAKES - FRONT DISC
Bleeder
Bleeder
Valve Hose
Fig. 33 Bleeding Brakes
NOTICE
B
B
Page K-27