Maintenance; Daily Brake Performance Test; Brake System Inspection; Master Cylinder - Cushman 632904 Service Manual

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

MAINTENANCE

B

Daily Brake Performance Test

To assure correct braking performance, all periodic mainte-
nance, inspections and procedures must be performed as indi-
cated in the Periodic Service Schedule in Section A of this
manual.
It is important that a Daily Brake Performance Test be per-
formed and the entire brake system be serviced in accordance
with the Periodic Service Schedule.
The brake system must be bled whenever any part of the brake
system has been replaced.
Depress brake pedal. The pedal should have some free
play and then become hard. A brake pedal that has no
free travel, excessive free travel or a spongy feel indi-
cates a brake inspection is required. A brake pedal that
falls after it is applied indicates a leak in the master or
wheel cylinders. Check brake fluid level. Adjust brakes if
required and inspect system for fluid leaks.

Brake System Inspection

Brake failure usually occurs as either a gradual
decrease in braking effect from the shoe material being
worn away, a loss of braking at one wheel or a sudden
and complete failure with no brakes working except the
parking brake.
Inspect front and rear brakes for signs of fluid leak-
age.Inspect rear brake shoes and front disc pads for
wear.
Care should be taken to prevent brake fluid from coming into
contact with the brake shoes. If the brake shoes should
become wet with hydraulic fluid, remove the brake drum and
wipe the brake shoes and drum until they are dry.
Complete brake failure usually indicates a loss of hydrau-
lic fluid pressure.
The hydraulic system may be checked for leaks by apply-
ing pressure to the pedal gradually and steadily. If the
pedal sinks very slowly to the floor, the system has a leak.
This is not to be confused with a springy or spongy feel
due to the compression of air within the lines.
Check for leaks along all lines and at brake assembly. If
no external leaks are apparent, the problem is inside the

master cylinder.

Page E-2
NOTICE
NOTICE
Repair and Service Manual
Do not allow brake fluid to contact painted surfaces.
Wipe off immediately.
After making any repairs to hydraulic lines, wheel cylin-
ders or master cylinder, the brakes must be bled to
remove any trapped air. A bleeder valve is located at
each wheel cylinder for this purpose.
To assure correct braking performance, all periodic
maintenance, inspections and procedures must be per-
formed as indicated in the Periodic Service Schedule in
Section 'A' of this manual. The brake system must be
bled whenever any part of the brake system has been
replaced.
MASTER CYLINDER
Just like any other brake part, the master cylinder will
eventually require replacement. The usual reason for a
master cylinder failure is the cylinder seals (cups) deteri-
orate. Fluid leaks past the cups and shows as an exter-
nal leak. A common symptom is a 'spongy' brake pedal
that goes all the way to the floor when all the other brake
components are in good condition. The rubber parts
wear with usage or deteriorate with age or fluid contami-
nation. Corrosion or deposits formed in the cylinder bore
due to moisture or dirt in the hydraulic system may result
in wear of the cylinder bore or related parts. Do not try to
remove corrosion or deposits with a cylinder hone. If
corrosion or deposits are present, discard master cylin-
der and replace with new one.

Brake Fluid

NOTICE
Hydraulic brake systems must be totally flushed if the fluid
becomes contaminated with water, dirt or other corrosive
chemicals. To flush, bleed the entire system until all brake fluid
has been replaced with fresh DOT 3 standard automotive
brake fluid.
It is important to maintain proper fluid levels in the mas-
ter cylinder. The fill cap for the cylinder is located under
the driver seat. To prevent contamination when checking
fluid, wipe off any dirt from fill cap before removing it.
Reservoir fluid level should be checked per 'PERIODIC
SERVICE SCHEDULE' in Section A. When required,
clean brake fluid should be added to maintain fluid level
1/4" (6 mm) from top of reservoir. Use fresh DOT 3 stan-
dard automotive brake fluid.