Mechanical Brakes - Ezgo EXPRESS L4 Technician's Repair And Service Manual

TABLE OF CONTENTS FOR SECTION 'M'
SECTION TITLE
BRAKE SYSTEM OVERVIEW ..................................................................................M - 1
General Description .........................................................................................M - 1
How the Service Brake Works..........................................................................M - 1
Equalizer Link ..................................................................................................M - 2
Automatic Adjuster Mechanism ........................................................................M - 2
How the Parking Brake Works .........................................................................M - 2
Compensator Assembly ...................................................................................M - 3
Kick-Off Actuating Linkage ...............................................................................M - 3
TROUBLESHOOTING TABLE .................................................................................M - 4
TROUBLESHOOTING AND INSPECTION ...............................................................M - 6
New Vehicles ...................................................................................................M - 6
Troubleshooting and Inspection Procedures ....................................................M - 6
Brake Pedal and Linkage Inspection ................................................................M - 6
Periodic Brake Performance Test (PBPT) ........................................................M - 8
Aggressive Stop Test .......................................................................................M - 9
Wheel Brake Inspection .................................................................................M - 10
MAINTENANCE AND REPAIRS.............................................................................M - 12
Parts Replacement vs. Repair........................................................................M - 12
Adjusting Brake Pedal Free Travel.................................................................M - 12
Brake Drum Removal and Installation ............................................................M - 13
Wheel Brake Service......................................................................................M - 14
Backing Plate/Entire Wheel Brake Assembly Removal and Installation .........M - 15
Brake Shoe and Adjuster Replacement..........................................................M - 15
Brake Cable and Equalizer Assembly Removal and Installation ....................M - 16
Compensator Assembly Removal and Installation .........................................M - 17
Brake Pedal Removal and Installation............................................................M - 17
Parking Brake Catch Bracket Removal and Installation .................................M - 18
Parking Brake Pedal Removal and Installation...............................................M - 18
Pedal Bumper Adjustment..............................................................................M - 18
Parking Brake Release Linkage Removal and Replacement .........................M - 18
Parking Brake Kick-Off Cam Removal and Installation...................................M - 18
LIST OF ILLUSTRATIONS
Fig. 1 Mechanical Brake System ........................................................................... M - 1
Fig. 2 Wheel Brake Adjustment............................................................................. M - 2
Fig. 3 Parking Brake and Kick-Off Mechanism ...................................................... M - 3
Fig. 4 Compensator Assembly .............................................................................. M - 3
Fig. 5 Troubleshooting Table ................................................................................ M - 4
Fig. 6 Brake Pedal Bumper Inspection .................................................................. M - 6
Fig. 7 Brake Pedal Inspections ............................................................................. M - 6
Fig. 8 Checking for Excessive Free Travel ............................................................ M - 7
Fig. 9 Equalizer and Compensator........................................................................ M - 7
Fig. 10 Parking Brake Pedal Hinge Inspection ...................................................... M - 8
Fig. 11 Kick-Off Cam Inspections.......................................................................... M - 8
Fig. 12 Periodic Brake Performance Test.............................................................. M - 9
Fig. 13 Equally Load Vehicle .............................................................................. M - 10
Fig. 14 Adjuster Mechanism ............................................................................... M - 11
Fig. 15 Brake Shoe Wear.................................................................................... M - 11
Fig. 16 Orientation of Brake Shoe Springs .......................................................... M - 12
Fig. 17 Free Travel Adjustment ........................................................................... M - 13
Fig. 18 Check Clevis Pins ................................................................................... M - 13
Repair and Service Manual

MECHANICAL BRAKES

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