2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 6-1
6
SECTION 6 – HYDRAULIC AND PARK BRAKE
SYSTEMS
∆ WARNING
• Only trained technicians should repair or service the vehicle. Anyone doing even simple
repairs or service should have knowledge and experience in electrical and mechanical repair.
• Follow all procedures exactly as stated in this manual, and heed all DANGER, WARNING, and
CAUTION statements in this manual as well as those affixed to the vehicle.
• Wear safety glasses or approved eye protection while servicing vehicle. Wear a full face shield
and rubber gloves when working with batteries.
• Some brake shoes contain asbestos fiber, and asbestos dust is created when these brake
mechanisms are handled. Wear approved eye and respiratory protection when disassembling
and cleaning brake mechanisms. Inhalation of asbestos could result in severe personal injury
or death. Do not use compressed air or aerosol sprays to clean the brake mechanism. Clean
brake mechanisms using the negative pressure enclosure/HEPA vacuum system or low
pressure/wet cleaning method per OSHA/29 CFR -1910.1001.
• Turn key switch OFF, place Forward/Reverse handle in the NEUTRAL position and remove key
prior to servicing.
• Do not wear loose clothing. Remove jewelry such as rings, watches, chains, etc. before
servicing vehicle.
• Moving parts! Do not attempt to service the vehicle while it is running.
• Use insulated tools when working near batteries or electrical connections. Use extreme
caution to avoid shorting of components or wiring.
• To avoid unintentionally starting the vehicle:
- Disconnect battery cables, negative cable (–) first.
- Disconnect the spark plug wire from the spark plug.
• Frame ground – Do not allow tools or other metal objects to contact frame when
disconnecting battery cables or other electric wiring. Never allow a positive wire to touch the
vehicle frame, engine or any other metal component.
• Lift only one end of the vehicle at a time. Before lifting, set the park brake when lifting the front
of the vehicle, unload the cargo bed and chock the wheels that remain on the floor. Use a
suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum
lifting capacity. Do not use lifting device to hold vehicle in raised position. Use approved jack
stands of proper weight capacity to support the vehicle.
GENERAL INFORMATION
The Pioneer 1200 vehicle is equipped with two types of shoe drum braking systems: a hydraulic, four-wheel
braking system for normal stopping, and a hand-activated mechanical rear-wheel park brake system for
retaining the vehicle when it is stationary.
The hydraulic brake system consists of a hydraulic brake cluster on each wheel and a master cylinder. Each
cluster utilizes a hydraulic cylinder and two brake shoes. The wheel cylinders’ dual-piston design ensures an
even distribution of force on each pair of brake shoes. Each brake cluster utilizes a leading-trailing design.
The rear-wheel, mechanical park brake system of the Pioneer 1200 vehicle utilizes a hand-activated park
brake handle between the driver and passenger seats, a brake cable equalizer and two park brake cables.
The brake clusters used on the rear wheels are identical to those used on the two front wheels with the addi-
tion of a lever and strut.
