Ezgo EXPRESS L4 Technician's Repair And Service Manual page 150

MECHANICAL BRAKES
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
TROUBLESHOOTING TABLE
Refer to the following troubleshooting table only after the thorough visual inspection, Periodic Brake Performance Test
(PBPT), and Aggressive Stop Test is performed (Ref. Fig. 5).
Condition
Fails Brake Performance Test by stop-
ping in a longer distance than normal
In excess of 1 1/8" (2.9 cm) free pedal
travel (Soft Pedal)
In Excess of 2 1/4" (5.4 cm) free peda
travel (Soft Pedal)
Less than 7/8" (2.2 cm) free pedal trav-
el (Hard Pedal)
Less than 2" (5 cm) free pedal travel
(Hard Pedal)
Neither wheel locks when park brake
is latched. (Note: At full speed the
wheels may not lock, but should brake
aggressively).
Page M-4
Possible Cause
Wheel brake failure due to severely
worn or damaged components
Brake pedal not returning
Brake not adjusting
Brake shoes wet
Brake cables damaged or sticky
Brake shoes severely worn
Brake shoes glazed
System not adjusted properly
End of brake cable loose from anchor
brackets
Cracked brake drum
Low pedal force at parking brake latch
Brake cables damaged
Brake return bumper out of adjustment Adjust per manual
End of brake cable loose from anchor
brackets
Wheel brake failure due to severely
worn or damaged components
System not adjusted properly
High pedal force at parking brake latch Adjust per Manual
Brake cables damaged or sticky
System not adjusted properly
Wheel brake failure due to severely
worn or damaged components
Incorrect compensator spring adjust-
ment.
Excessive brake pedal free travel
Fig. 5 Troubleshooting Table
Repair and Service Manual
Correction
Replace all severely worn or damaged
components
Check for binding of brake pedal
Check brake pedal free travel
Check brake cables
Check brake adjusters
Check pedal pivot
Check again when shoes are dry
Check brake cable and replace if sticky or
damaged
Replace
Sand shoes with emery cloth provided that
shoes have .06" (1.5 mm) min. material
Check and adjust per manual
Check and repair
Replace
Adjust per manual
Replace
Check and repair
Replace all severely worn or damaged
components
Adjust per Manual
Check brake cable and replace if sticky or
damaged
Check and adjust per manual
Replace all severely worn or damaged
components
Return to factory specification
Adjust per manual