1
IMPORTANCE:
It is important that the brakes of the Big Country 4 X 2
Utility Vehicle be properly maintained in order for the
utility vehicle to operate safely and dependably. In
addition to the obvious safety concerns, there is an
electric interlock between the brakes and the gear
selector mechanism. If the brakes are out of adjust-
ment, the gear selector mechanism will not work as it
was designed to. The condition and adjustment of the
brake system should be checked in accordance with
the two-tiered service interval described under the
“Service Intervals” heading in “Description of the Brake
System”.
DESCRIPTION OF THE BRAKE SYSTEM:
• The brake pedal arm lifts up on the pull bolt that
transfers the force through a stack of bellville
washers to an equalizer bracket. The equalizer
bracket distributes the brake pedal force
between the cores of two cables. The bellville
washers are stacked in opposite directions to
provide a spring action, softening the brake
pedal feel.
• Each cable housing is mounted to a bracket on
the firewall using two large jam nuts. Each cable
actuates a drum brake at the end of each rear
axle.
•A parking brake latches the brake pedal in the
applied position when engaged.
• There are two electrical switches in the sys-
tem. A parking brake switch lights an indicator
bulb in the instrument panel to help prevent the
operator from trying to drive the Big Country 4 X
2 with the brakes engaged. A brake switch
works with the Electronic Shift Module to prevent
the operator from shifting gears without the
brake applied.
• Service intervals will vary with the type severity
of use. If the vehicle is operated on hills or with
heavy loads, it may be necessary to shorten the
maintenance intervals because of the increased
load on the brake system and the increased con-
sequences of brake system failure. A visual
inspection and operational test should be per-
formed every 50 hours. The brake drums
should be removed for a complete inspection
every 500 hours or 24 months, as the tran-
saxle gear lube is being changed.
1. VISUAL INSPECTION AND
OPERATIONAL TEST:
1.1. Open the hood of the Big country 4 X 2 and
examine the brake arm, parking brake latch, and
all of the associated hardware.
1.2. Check the condition of the brake cables and
their mounting hardware: See Figure 1.2.
• Jam nuts at the front should be secure.
• Locating clamps at the front of the engine com-
partment should be secure.
• Mounting clips and clevis pins at the back end of
the cable housing should be secure and in good
condition.
• Cable cores should not be frayed or corroded.
Rubber boots should be intact.
• Cable housings should not be kinked, chafed,
burned, crushed or otherwise damaged.
1.3. Any significant wear, damage, or binding should
be addressed prior to making an operational
test.
Figure 1.2
Left brake
Cable
Fuel tank
clamp
cable
Big Country 4 x 2
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