Fault Testing Table - Cushman HAULER 1200 Repair Manual

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

FAULT TESTING TABLE

Refer to the following fault diagnosis table only after the
Condition
Fails Brake Performance Test by stop-
ping in a longer distance than normal
In excess of 1-1/8" (2.9 cm) free pedal
travel (Soft Pedal)
Less than 7/8" (2.2 cm) free pedal trav-
el (Hard Pedal)
Neither wheel locks when parking
brake is latched. (Note: At full speed
the wheels may not lock, but should
brake aggressively).
Unequal braking (one wheel locks
while other rotates)
Neither wheel locks
653045
thorough visual inspection, Daily Brake Performance Test
has been performed (Figure 6).
Possible Cause
Wheel brake failure due to severely worn
or damaged components
Brake pedal not returning
Brake not adjusting
Brake shoes wet
Brake cables damaged or sticky
Brake shoes severely worn
Brake shoes glazed
System not adjusted properly
End of brake cable loose from anchor
brackets
Cracked brake drum
Low pedal force at parking brake latch
Brake cables damaged
Brake return bumper out of adjustment Adjust per manual
End of brake cable loose from anchor
brackets
Wheel brake failure due to severely worn
or damaged components
System not adjusted properly
High pedal force at parking brake latch Adjust per manual
Brake cables damaged or sticky
System not adjusted properly
Wheel brake failure due to severely worn
or damaged components
Incorrect compensator spring adjustmentReturn to factory specification
Excessive brake pedal free travel
Wheel not locking is not adjusting
Sticky/dragging cable
Cracked brake drum
Brake shoes wet or glazed
Rusted or sticky brake pivot hardware
Brake system requires complete
adjustment
Brake pedal not returning
Figure 6 Fault Testing Table
Repair and Service Manual
BRAKES
Correction
Replace all severely worn or damaged com-
ponents
Check for binding of brake pedal
Check brake pedal free travel
Check brake cables
Check brake adjusters
Check pedal pivot
Check again when shoes are dry
Check brake cable and replace if sticky or
damaged
Replace
Sand shoes with emery cloth provided that
shoes have .06" (1.5 mm) min. material
Check and adjust per manual
Check and repair
Replace
Adjust per manual
Replace
Check and repair
Replace all severely worn or damaged com-
ponents
Adjust per manual
Check brake cable and replace if sticky or
damaged
Check and adjust per manual
Replace all severely worn or damaged com-
ponents
Adjust per manual
Check brake operation of wheel that is
not locking
Check for brake lever return
Check that brake levers return at equal
rate - (Indication of dragging cable)
Replace
Check again when shoes are dry
Replace
Adjust entire system
Check for binding of brake pedal
Check brake pedal free travel
B
45