Troubleshooting And Inspection; New Vehicles; Troubleshooting And Inspection Procedures; Brake Pedal And Linkage Inspection - Cushman HAULER 800 2012 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
TROUBLESHOOTING AND INSPEC-
TION

New Vehicles

A new vehicle will undergo an initial break-in of compo-
nents including brake cables and brake shoes. In this
break-in period, it is not uncommon for the brake pedal
free travel (and the effort required to latch the parking
brake) to change. The timing of this change varies with
terrain and the driving habits of the operator(s). When
this occurs, the brake linkage should be adjusted.
"Adjusting Brake Pedal Free Travel" on page 14 After this ini-
tial period, no further adjustments should be required
until routine maintenance is scheduled.

Troubleshooting and Inspection Procedures

To troubleshoot the mechanical brake system, inspect
the brake pedal and linkage to find worn or damaged
parts per the Troubleshooting Flowchart (Ref. Fig. 5 on
Page K-5). Then, perform the Periodic Brake Perfor-
mance Test to evaluate system performance. Based on
the results of the inspection and tests, refer to the Trou-
bleshooting Table (Ref. Fig. 6 on Page K-6) to evaluate
symptoms and repairs. If required, disassemble the
wheel brake to locate and correct internal faults.
Instructions for removal or replacement of parts and
adjustments referred to in this section of the manual are
described in detail
REPAIRS" on page 14 .
Satisfactory brake performance does not eliminate the
need for routine brake testing and inspection as shown on
the Periodic Service Schedule in Section A. Continued
proper brake operation depends on periodic mainte-
nance.

Brake Pedal and Linkage Inspection

1. Inspect brake pedal return bumper.
Be sure that the brake pedal is contacting the pedal
return bumper when released, that the bumper is in
good condition and that a 1/4 - 3/8" (6 - 9.5 mm) gap
exists between the brake pedal arm and the setscrew
heads of the kick-off cam (Ref. Fig. 7 on Page K-8).
Replace or adjust the pedal bumper if required. "Pedal
Bumper Adjustment" on page 21.
Page K-8
under "MAINTENANCE
Repair and Service Manual
1/4" - 3/8" (6 - 9.5 mm) Diameter
Drill or Bolt Must Pass
Through Gap
Fig. 7 Brake Pedal Bumper Inspection
Brake
Pedal
Arm
AND
Fig. 8 Brake Pedal Inspection
2. Check brake pedal return.
Apply the brake pedal and release. Check that the
brake pedal arm rests against the pedal bumper when
released. Check that the torsion spring is hooked
around both the pedal and the frame and is in good
condition. If the pedal does not return fully or is slug-
gish, the brake pedal bushings and pivot bolt should
be inspected (Ref. Fig. 8 on Page K-8). Replace
pedal, spring, bushings and bolt as required. "Brake
Pedal Removal and Installation" on page 20
3. Check the brake pedal free travel.
Brake pedal free travel is the distance the pedal
moves from rest to the point at which the brake shoes
first contact the brake drums. This should not be con-
fused with the light resistance that is felt as the brake
pedal is depressed enough to remove slack from the
compensator and cables. Too much pedal free travel
may indicate wheel brakes not adjusting, wear in the
Adjust At Bumper If Needed
Part of
Frame
Pivot
Bolt
Brake
Pedal Bushing
Torsion Spring