E-Z-GO MPT 800 Technician's Repair And Service Manual

TABLE OF CONTENTS FOR SECTION ‘K’
SECTION TITLE PAGE NO.
Page K-i
Repair and Service Manual
K
BRAKES
BRAKES - REAR MECHANICAL
BRAKE SYSTEM OVERVIEW.........................................................................................................K - 1
General Description...............................................................................................................K - 1
How the Service Brake Works...............................................................................................K - 2
Equalizer Link........................................................................................................................K - 2
Automatic Adjuster Mechanism.............................................................................................K - 2
How the Parking Brake Works...............................................................................................K - 2
Compensator Assembly ........................................................................................................K - 3
Kick-Off Actuating Linkage....................................................................................................K - 3
TROUBLESHOOTING FLOWCHART ............................................................................................K - 4
TROUBLESHOOTING TABLE.........................................................................................................K - 6
TROUBLESHOOTING AND INSPECTION......................................................................................K - 8
New Vehicles.........................................................................................................................K - 8
Troubleshooting and Inspection Procedures.........................................................................K - 8
Brake Pedal and Linkage Inspection.....................................................................................K - 8
Periodic Brake Performance Test (PBPT)...........................................................................K - 10
Aggressive Stop Test ..........................................................................................................K - 11
Wheel Brake Inspection.......................................................................................................K - 12
MAINTENANCE AND REPAIRS....................................................................................................K - 14
Parts Replacement vs. Repair.............................................................................................K - 14
Adjusting Brake Pedal Free Travel......................................................................................K - 14
Brake Drum Removal and Installation.................................................................................K - 15
Wheel Brake Service...........................................................................................................K - 16
Backing Plate/Entire Wheel Brake Assembly Removal and Installation..............................K - 17
Brake Shoe and Adjuster Replacement ..............................................................................K - 17
Brake Cable and Equalizer Assembly Removal and Installation.........................................K - 18
Compensator Assembly, Removal and Installation.............................................................K - 18
Brake Pedal Removal and Installation.................................................................................K - 18
Parking Brake Catch Bracket Removal and Installation......................................................K - 19
Parking Brake Pedal Removal and Installation ...................................................................K - 19
Pedal Bumper Adjustment...................................................................................................K - 20
Parking Brake Release Linkage Removal and Replacement..............................................K - 20
Parking Brake Kick-Off Cam Removal, Replacement and Installation................................K - 20
LIST OF ILLUSTRATIONS
Fig. 1 Mechanical Brake System.....................................................................................................K - 1
Fig. 2 Wheel Brake Adjustment.......................................................................................................K - 2
Fig. 3 Parking Brake and Kick-Off Mechanism................................................................................K - 3
Fig. 4 Compensator Assembly ........................................................................................................K - 3
Fig. 5 Troubleshooting Flowchart....................................................................................................K - 4
Fig. 6 Troubleshooting Table...........................................................................................................K - 6
Fig. 7 Brake Pedal Bumper Inspection............................................................................................K - 8
Fig. 8 Brake Pedal Inspection .........................................................................................................K - 8
Fig. 9 Checking for Excessive Free Travel......................................................................................K - 9
Fig. 10 Equalizer and Compensator................................................................................................K - 9
Fig. 11 Parking Brake Pedal Hinge Inspection..............................................................................K - 10
Fig. 12 Kick-Off Cam Inspection....................................................................................................K - 10
Fig. 13 Periodic Brake Performance Test .....................................................................................K - 11
Fig. 14 Equally Load Vehicle.........................................................................................................K - 11
Fig. 15 Adjuster Mechanism..........................................................................................................K - 12
Fig. 16 Brake Shoe Wear..............................................................................................................K - 13
Fig. 17 Orientation of Brake Shoe Springs....................................................................................K - 13
Fig. 18 Free Travel Adjustment.....................................................................................................K - 14

E-Z-GO MPT 800 Specifications

General

Brand	E-Z-GO
Model	MPT 800
Category	Utility Vehicle
Language	English