Cushman HAULER 1200, Руководство по ремонту, Страница: 82 / 176

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64
Repair and Service Manual
FRONT HYDRAULIC 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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from the master cylinder (1) and allow brake fluid to drain
into a container. Discard fluid. Do not reuse old brake
fluid.
Remove the hardware (3) securing the master cylinder to
the master cylinder housing bracket (2).
Install Master Cylinder
Install the new master cylinder (1), bolt (3) as shown in
(Figure 1). Tighten nuts (4) to torque value specified
below.
Install the brake line to the new master cylinder and
tighten to 60 - 80 in. lbs. (6.8 - 9 Nm) torque.
Latch the parking brake pedal.
Rotate and hold the upper actuator pivot (9). Adjust the
master cylinder clevis (28) until the clevis pin (16) can be
installed.
Tighten the jam nut against the master cylinder clevis.
Install a new cotter pin (25). Bleed the hydraulic system.
Add clean, fresh DOT 3 brake fluid into reservoir. Bleed
system as instructed in See the BLEEDING BRAKES on
page 65 .
MASTER CYLINDER FLUID
NOTICE: Hydraulic brake systems must be totally
flushed if the fluid becomes contaminated with
water, dirt or other corrosive chemicals.
Flush Hydraulic Brake System
Bleed the entire system until all brake fluid is removed.
Replace with fresh DOT 3 standard automotive brake
fluid.
Check Brake Fluid
The brake fluid must be checked at regular intervals (as
specified in the Periodic Service Schedule) or immedi-
ately when fluid leaks are found.
Clean the cap with a shop rag and remove the cap from
the master cylinder. Use a mechanics mirror and a flash-
light to check the fluid level. Add fluid if level is below 1/4”
(6.5 mm) from the top of the reservoir. Inspect for visible
fluid leaks.
ROUTINE MAINTENANCE
Tool List Quantity
Shop Rag ..................................................................AR
Mechanics Mirror .........................................................1
Flashlight......................................................................1
Transmission Fluid Funnel...........................................1
Torque Wrench, ft. lbs ..................................................1
Torque Wrench, in. lbs. ................................................1
Crows Foot 9/16”, 3/8” drive ........................................1
Open End Wrench, 3/8" ...............................................1
Open End Wrench, 1/2” ...............................................1
Open End Wrench, 5/8” ...............................................1
Open End Wrench, 9/16” .............................................1
Needle Nose Pliers ......................................................1
Ratchet.........................................................................1
Sockets, 3/8"................................................................1
Sockets, 1/2"................................................................1
Sockets, 5/8"................................................................1
Sockets, 9/16"..............................................................1
Micrometer/Vernier Caliper ..........................................1
2" C Clamp...................................................................1
Floor Jack ....................................................................1
Jack Stands .................................................................1
Ball Joint Separator......................................................1
Lug Wrench, 3/4" .........................................................1
Jack..............................................................................1
Jack Stands .................................................................4
Brake Adjusting Tool ....................................................1
Plastic Faced Hammer.................................................1
Never work on a vehicle that is sup-
ported by a jack alone. To decrease
the risk of personal injury, the vehi-
cle must be supported on jack stands during proce-
dures that require lifting.
REPLACEMENT OF WEAR ITEMS
Wear a dust mask and eye protec-
tion when working on wheel brakes.
Do not use pressurized air to blow dust from brake
assemblies.
Brake Pad Replacement
NOTICE: Unless fluid is lost or a brake line is dis-
connected, there is no need to bleed the system to
replace brake pads.
The brake pads must always be replaced as a full
set of four pads.
Remove old brake pads:
Raise the vehicle per the SAFETY section.
Loosen both of the bolts securing the caliper to the spin-
Item Torque Specification
4 12 - 15 ft. lbs. (16 - 20 Nm)
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