Ezgo EXPRESS L6 2012 User Manual

TABLE OF CONTENTS FOR SECTION ‘K’
SECTION TITLE PAGE NO.
Page K-i
Repair and Service Manual
BRAKES
MECHANICAL
BRAKE SYSTEM OVERVIEW .................................................................................. K - 1
General Description ......................................................................................... K - 1
How the Service Brake Works.......................................................................... K - 1
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 Flowchart 1 ............................................................................ K - 4
Troubleshooting Flowchart 2 ............................................................................ K - 5
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 - 19
Brake Pedal Removal and Installation............................................................ K - 19
Parking Brake Catch Bracket Removal and Installation ................................. K - 20
Parking Brake Pedal Removal and Installation............................................... K - 20
Pedal Bumper Adjustment.............................................................................. K - 20
Parking Brake Release Linkage Removal and Installation ............................. K - 20
Parking Brake Kick-Off Cam Removal and Installation................................... K - 20
HYDRAUALIC DISC
SYSTEM DESCRIPTION.............................................................................................K - 22
MASTER CYLINDER REPLACEMENT ......................................................................K - 22
BRAKE MASTER CYLINDER FLUID .........................................................................K - 22
Check Brake Fluid .............................................................................................. K - 22
ROUTINE MAINTENANCE .........................................................................................K - 23
REPLACEMENT OF WEAR ITEMS............................................................................K - 23
Brake Pad Replacement.....................................................................................K - 23
Rotor Replacement............................................................................................. K - 23

Ezgo EXPRESS L6 2012 Specifications

General

Brand	Ezgo
Model	EXPRESS L6 2012
Category	Utility Vehicle
Language	English