Maintenance And Repairs - Cushman HAULER 800X 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
Heavy Shoe
Spring
Adjuster
Spring
Fig. 16 Orientation of Brake Shoe Springs
11. Repeat procedure at the opposite wheel brake.
12. Check/adjust brake pedal free travel.
Whenever the brake system is serviced or requires a
parts replacement, the brake pedal free travel must be
checked and adjusted. "Adjusting Brake Pedal Free
Travel" on Page M - 12 This includes all linkage and
wheel brake components.

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
Page M-12
Light
Shoe
Spring
Adjuster
Spring
Light
Shoe
Spring
Repair and Service Manual
Tool List
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
Qty.
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
essential to proper brake function. Too much pedal free
travel will limit braking capability. Too little pedal free
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 spheri-
cal nut (Ref. Fig. 17). Tighten the jam nut to 10 - 11 ft.
lbs. (14 - 15 Nm).
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