B
32
Repair and Service Manual
BRAKES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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FAULT TESTING AND INSPECTION
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. See the
Adjusting Brake Pedal Free Travel.
After this initial period, no
further adjustments should be required until routine main-
tenance is scheduled.
Fault Testing and Inspection Procedures
To fault test the mechanical brake system, inspect the
brake pedal and linkage to find worn or damaged parts
per the Fault Test Flowchart (Figure 5). Then, perform the
Periodic Brake Performance Test to evaluate system per-
formance. Based on the results of the inspection and
tests, refer to the Troubleshooting Table (Figure 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 under See the
Satisfactory brake performance
does not eliminate the need for rou-
tine brake testing and inspection as
shown in the SCEDULED MAINTENANCE CHART
section. Continued proper brake operation depends
on periodic maintenance.
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 (Figure 7). Replace or adjust
the pedal bumper if required. See the
Figure 7 Brake Pedal Bumper Inspection
Figure 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 (Figure 8). Replace pedal, spring, bush-
ings and bolt as required. See the
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 pressed enough to remove slack from the
compensator and cables. Too much pedal free travel
may indicate wheel brakes not adjusting, wear in the
cables and linkages or initial break-in of components.
1/4" - 3/8" (6 - 9.5 mm) Diameter
Drill or Bolt Must Pass
Through Gap
Adjust At Bumper If Needed
Pivot
Bolt
Brake
Pedal Bushing
Torsion Spring
Brake
Pedal
Arm
Part of
Frame
