Brakes - Cushman HAULER 800 2012 Technician's Repair And Service Manual

TABLE OF CONTENTS FOR SECTION 'K'
SECTION TITLE
MECHANICAL BRAKES
BRAKE SYSTEM OVERVIEW ..............................................................................................................K - 1
General Description ....................................................................................................................K - 1
How the Service Brake Works ....................................................................................................K - 2
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 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 Removal ................................................................................................................K - 17
Brake Shoe Installation..............................................................................................................K - 18
Brake Cable and Equalizer Assembly Removal and Installation ..............................................K - 19
Compensator Assembly, Removal and Installation ..................................................................K - 20
Brake Pedal Removal and Installation ......................................................................................K - 20
Parking Brake Catch Bracket Removal and Installation ...........................................................K - 20
Parking Brake Pedal Removal and Installation .........................................................................K - 21
Pedal Bumper Adjustment ........................................................................................................K - 21
Parking Brake Release Linkage Removal and Replacement ...................................................K - 21
Parking Brake Kick-Off Cam Removal, Replacement and Installation. ....................................K - 22
LIST OF ILLUSTRATIONS
Fig. 1 Mechanical Brake System ...........................................................................................................K - 1
Fig. 2 Parking Brake and Kick-Off Mechanism .....................................................................................K - 2
Fig. 3 Compensator Assembly ..............................................................................................................K - 3
Fig. 4 Troubleshooting Flowchart ...........................................................................................................K - 4
Fig. 5 Troubleshooting Flowchart ..........................................................................................................K - 5
Fig. 6 Troubleshooting Table ................................................................................................................K - 6
Fig. 7 Brake Pedal Bumper Inspection ..................................................................................................K - 8
Fig. 8 Brake Pedal Inspection ...............................................................................................................K - 8
Fig. 9 Check for Excessive Free Travel ................................................................................................K - 9
Repair and Service Manual

BRAKES

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