Compensator Assembly, Removal And Installation; Brake Pedal Removal And Installation; Parking Brake Catch Bracket Removal And Installation - 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
Compensator Assembly, Removal and
Installation
Disconnect the compensator assembly from the brake
pedal by removing the cotter pin and clevis pin (Ref. Fig.
27 on Page K-19).
Loosen and remove the jam nut and the spherical nut
connecting the compensator rod to the equalizer link.
Remove the compensator assembly.
Installation is the reverse of removal. Use new cotter
pins in the clevis pin.
Adjust the brake pedal free travel. "Adjusting Brake Pedal
Free Travel" on page 14

Brake Pedal Removal and Installation

Disconnect the compensator assembly (1) from the
brake pedal by removing the cotter pin (2) and the clevis
pin (3). Unplug the wiring harness on models equipped
with brake lights. Unhook the torsion spring (4) by insert-
ing a thin blade screwdriver between the small hook and
the bracket. Move the hook back and to the side to
release the torsion spring (Ref. Fig. 28 on Page K-20).
Remove the lock nut (5), the shoulder bolt (6) and
remove the brake pedal.
Inspect the shoulder bolt for corrosion that could cause
binding. This bolt and both bushings (7) must be
replaced with new ones if corrosion or wear is found.
Brake pedal installation is in the reverse order of disas-
sembly. Tighten the nut (5) to 25 - 29 ft. lbs. (34 - 39 Nm)
torque and use a new cotter pin when installing the com-
pensator assembly. Connect brake light wiring harness,
if equipped.
Adjust the brake pedal free travel. "Adjusting Brake Pedal
Free Travel" on page 14
Check for proper brake light operation if equipped.
Page K-20
9
Fig. 28 Brake Pedal Removal and Installation
Parking Brake Catch Bracket Removal and
Installation
Remove the driver side front wheel to gain access to the
brake pedal release mechanism.
To prevent serious injury death resulting from
the use of worn parking brake components, to
not attempt to re-new worn components. The
catch bracket is a hardened part. Do not grind
or file it as doing so will cause the part to lose
its hardness characteristics. A new part must
be used.
Repair and Service Manual
6
7
8
Pedal
Latch
5
4
7
2
1
3
Older
Models
9
2001
and
10
Later
8