Mechanical Brakes - E-Z-GO TXT FLEET Technician's Repair And Service Manual

Gasoline powered personnel carriers

Table of Contents

TABLE OF CONTENTS FOR SECTION 'M'

SECTION TITLE

BRAKE SYSTEM OVERVIEW ...................................................................................................................................M - 1

General Description .......................................................................................................................................M - 1

How the Service Brake Works .......................................................................................................................M - 2

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 FLOWCHART ........................................................................................................................M - 4

TROUBLESHOOTING TABLE ...................................................................................................................................M - 6

TROUBLESHOOTING AND INSPECTION ................................................................................................................M - 8

New Vehicles .................................................................................................................................................M - 8

Troubleshooting and Inspection Procedures .................................................................................................M - 8

Brake Pedal and Linkage Inspection .............................................................................................................M - 8

Periodic Brake Performance Test (PBPT) ...................................................................................................M - 10

Aggressive Stop Test ...................................................................................................................................M - 11

Wheel Brake Inspection ...............................................................................................................................M - 12

MAINTENANCE AND REPAIRS ..............................................................................................................................M - 14

Parts Replacement vs. Repair .....................................................................................................................M - 14

Adjusting Brake Pedal Free Travel ..............................................................................................................M - 14

Brake Drum Removal and Installation .........................................................................................................M - 15

Wheel Brake Service ...................................................................................................................................M - 16

Backing Plate/Entire Wheel Brake Assembly Removal and Installation ......................................................M - 17

Brake Shoe Removal ...................................................................................................................................M - 17

Brake Shoe Installation.................................................................................................................................M - 17

Brake Cable and Equalizer Assembly Removal and Installation .................................................................M - 18

Compensator Assembly, Removal and Installation .....................................................................................M - 19

Brake Pedal Removal and Installation .........................................................................................................M - 19

Parking Brake Catch Bracket Removal and Installation ..............................................................................M - 20

Parking Brake Pedal Removal and Installation ............................................................................................M - 20

Pedal Bumper Adjustment ...........................................................................................................................M - 20

Parking Brake Release Linkage Removal and Replacement ......................................................................M - 21

Parking Brake Kick-Off Cam Removal, Replacement and Installation. .......................................................M - 21

LIST OF ILLUSTRATIONS

Fig. 1 Mechanical Brake System ............................................................................................................................... M - 1

Fig. 2 Parking Brake and Kick-Off Mechanism .......................................................................................................... M - 2

Fig. 3 Compensator Assembly .................................................................................................................................. M - 3

Fig. 4 Troubleshooting Flowchart .............................................................................................................................. M - 4

Fig. 5 Troubleshooting Flowchart ............................................................................................................................... M - 5

Fig. 6 Troubleshooting Table ..................................................................................................................................... M - 6

Fig. 7 Brake Pedal Bumper Inspection ...................................................................................................................... M - 8

Fig. 8 Brake Pedal Inspection .................................................................................................................................... M - 8

Fig. 9 Check for Excessive Free Travel ..................................................................................................................... M - 9

Fig. 10 Equaliser and Compensator .......................................................................................................................... M - 9

Fig. 11 Parking Brake Pedal Hinge Inspection ........................................................................................................ M - 10

Fig. 12 Kick-Off Cam Inspection .............................................................................................................................. M - 10

Fig. 13 Periodic Brake Performance Test ................................................................................................................ M - 11

Fig. 14 Equally Loaded Vehicle ............................................................................................................................... M - 12

Repair and Service Manual