Mechanical Brakes - Cushman Shuttle 2 Service Manual

TABLE OF CONTENTS FOR SECTION 'K'
SECTION TITLE
BRAKE SYSTEM OVERVIEW .................................................................................. K - 1
General Description ......................................................................................... K - 1
How the Service Brake Works.......................................................................... K - 1
Equalizer Link .................................................................................................. K - 2
Automatic Adjuster Mechanism ........................................................................ K - 2
How the Parking Brake Works ......................................................................... K - 2
Compensator Assembly ................................................................................... K - 3
Kick-Off Actuating Linkage ............................................................................... K - 3
TROUBLESHOOTING FLOWCHART ...................................................................... K - 4
Troubleshooting Flowchart 1 ............................................................................ K - 4
Troubleshooting Flowchart 2 ............................................................................ K - 5
TROUBLESHOOTING TABLE ................................................................................. K - 6
TROUBLESHOOTING AND INSPECTION ............................................................... K - 8
New Vehicles ................................................................................................... K - 8
Troubleshooting and Inspection Procedures .................................................... K - 8
Brake Pedal and Linkage Inspection ................................................................ K - 8
Periodic Brake Performance Test (PBPT) ...................................................... K - 10
Aggressive Stop Test ..................................................................................... K - 11
Wheel Brake Inspection ................................................................................. K - 12
MAINTENANCE AND REPAIRS............................................................................. K - 14
Parts Replacement vs. Repair........................................................................ K - 14
Adjusting Brake Pedal Free Travel................................................................. K - 14
Brake Drum Removal and Installation ............................................................ K - 15
Wheel Brake Service...................................................................................... K - 16
Backing Plate/Entire Wheel Brake Assembly Removal and Installation ......... K - 17
Brake Shoe and Adjuster Replacement ......................................................... K - 17
Brake Cable and Equalizer Assembly Removal and Installation .................... K - 18
Compensator Assembly Removal and Installation ......................................... K - 19
Brake Pedal Removal and Installation............................................................ K - 19
Parking Brake Catch Bracket Removal and Installation ................................. K - 20
Parking Brake Pedal Removal and Installation............................................... K - 20
Pedal Bumper Adjustment.............................................................................. K - 20
Parking Brake Release Linkage Removal and Installation ............................. K - 20
Parking Brake Kick-Off Cam Removal and Installation................................... K - 20
LIST OF ILLUSTRATIONS
Fig. 1 Mechanical Brake System ........................................................................... K - 1
Fig. 2 Wheel Brake Adjustment ............................................................................. K - 2
Fig. 3 Parking Brake and Kick-Off Mechanism ....................................................... K - 3
Fig. 4 Compensator Assembly ............................................................................... K - 3
Fig. 5 Troubleshooting Table ................................................................................. K - 6
Fig. 6 Brake Pedal Bumper Inspection ................................................................... K - 8
Fig. 7 Brake Pedal Inspections .............................................................................. K - 8
Fig. 8 Checking for Excessive Free Travel............................................................. K - 9
Fig. 9 Equalizer and Compensator......................................................................... K - 9
Fig. 10 Parking Brake Pedal Hinge Inspection ..................................................... K - 10
Fig. 11 Kick-Off Cam Inspections ........................................................................ K - 10
Fig. 12 Periodic Brake Performance Test ............................................................ K - 11
Fig. 13 Equally Load Vehicle ............................................................................... K - 12
Fig. 14 Adjuster Mechanism ................................................................................ K - 13
Repair and Service Manual

MECHANICAL BRAKES

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