Cushman Shuttle 4 - Mechanical Brakes

TABLE OF CONTENTS FOR SECTION ‘K’
SECTION TITLE PAGE NO.
Page K-i
Repair and Service Manual
MECHANICAL BRAKES
BRAKE SYSTEM OVERVIEW..................................................................................K - 1
General Description ......................................................................................... K - 1
How the Service Brake Works..........................................................................K - 1
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 Flowchart 1............................................................................ K - 4
Troubleshooting Flowchart 2............................................................................ K - 5
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 and Adjuster Replacement ......................................................... K - 17
Brake Cable and Equalizer Assembly Removal and Installation .................... K - 18
Compensator Assembly Removal and Installation ......................................... K - 19
Brake Pedal Removal and Installation............................................................ K - 19
Parking Brake Catch Bracket Removal and Installation ................................. K - 20
Parking Brake Pedal Removal and Installation............................................... K - 20
Pedal Bumper Adjustment.............................................................................. K - 20
Parking Brake Release Linkage Removal and Installation ............................. K - 20
Parking Brake Kick-Off Cam Removal and Installation................................... K - 20
LIST OF ILLUSTRATIONS
Fig. 1 Mechanical Brake System ...........................................................................K - 1
Fig. 2 Wheel Brake Adjustment .............................................................................K - 2
Fig. 3 Parking Brake and Kick-Off Mechanism.......................................................K - 3
Fig. 4 Compensator Assembly...............................................................................K - 3
Fig. 5 Troubleshooting Table .................................................................................K - 6
Fig. 6 Brake Pedal Bumper Inspection...................................................................K - 8
Fig. 7 Brake Pedal Inspections ..............................................................................K - 8
Fig. 8 Checking for Excessive Free Travel.............................................................K - 9
Fig. 9 Equalizer and Compensator.........................................................................K - 9
Fig. 10 Parking Brake Pedal Hinge Inspection .....................................................K - 10
Fig. 11 Kick-Off Cam Inspections ........................................................................K - 10
Fig. 12 Periodic Brake Performance Test ............................................................K - 11
Fig. 13 Equally Load Vehicle ...............................................................................K - 12
Fig. 14 Adjuster Mechanism ................................................................................K - 13