MECHANICAL BRAKES
Read section A and B completely prior to operation or repair of golf car
F-1
TABLE OF CONTENTS
BRAKE SYSTEM OVERVIEW-------------------------------------------------------------------------------------------- F-3
GENERAL DESCRIPTION---------------------------------------------------------------------------------------------F-3
HOW THE SERVICE BRAKE WORKS-----------------------------------------------------------------------------------F-4
EQUALIZER LINK-----------------------------------------------------------------------------------------------------------F-4
AUTOMATIC ADJUSTER MECHANISM-------------------------------------------------------------------------------F-4
HOW THE PARKING BRAKE WORKS---------------------------------------------------------------------------------F-5
COMPENSATOR ASSEMBLY----------------------------------------------------------------------------------------------F-6
KICK-OFF ACTUATING LINKAGE---------------------------------------------------------------------------------------F-7
TROUBLESHOOTING FLOWCHART----------------------------------------------------------------------------------F-10
TROUBLESHOOTING TABLE--------------------------------------------------------------------- -----------------------F-10
NEW VEHICLE TROUBLESHOOTING AND INSPECTION------------------------------------------------------- F-11
TROUBLESHOOTING AND INSPECTION PROCEDURES------------------------------------------------------ F-11
TROUBLESHOOTING TABLE--------------------------------------------------------------------------------------------F-11
BRAKE PEDAL AND LINKAGE INSPECTION------------------------------------------------------------------------F-12
PERIODIC BRAKE PERFORMANCE TEST (PBPT) ---------------------------------------------F-16
AGGRESSIVE STOP TEST-----------------------------------------------------------------------------F-19
WHEEL BRAKE INSPECTION -------------------------------------------------------------------------------------------F-19
MAINTENANCE AND REPAIRS ----------------------------------------------------------------------------------------F-23
PARTS REPLACEMENT VS. REPAIR----------------------------------------------------------------------------------F-23
ADJUSTING BRAKE PEDAL FREE TRAVEL-------------------------------------------------------------------------F-24
BRAKE DRUM REMOVAL AND INSTALLATION--------------------------------------------------------------------F-25
WHEEL BRAKE SERVICE-------------------------------------------------------------------------------------------------F-27
BACKING PLATE/ENTIRE WHEEL BRAKE ASSEMBLY REMOVAL AND INSTALLATION--------------F-29
BRAKE SHOE AND ADJUSTER REPLACEMENT------------------------------------------------------------------F-29
BRAKE CABLE AND EQUALIZER ASSEMBLY REMOVAL AND INSTALLATION--------------------------F-31
COMPENSATOR ASSEMBLY, REMOVAL AND INSTALLATION------------------------------------------------F-31
BRAKE PEDAL REMOVAL AND INSTALLATION ----------------------------------------------------------------F-32
PARKING BRAKE CATCH BRACKET REMOVAL AND INSTALLATION--------------------------------------F-32
PARKING BRAKE PEDAL,REMOVAL AND INSTALLATION-----------------------------------------------------F-33
PEDAL BUMPER ADJUSTERMENT------------------------------------------------------------------------------------F-34
PARKING BRAKE RELEASE LINKAGE REMOVAL AND REPLACEMENT----------------------------------F-34
PARKING BRAKE RELEASE LINKAGE AND KICK-OFF CAM, REMOVAL AND INSTALLATION -----F-35
LIST OF ILLUSTRATIONS
Fig. F1: Mechanical Brake System-------------------------------------------------------------------------------------- F-3
Fig. F2 Wheel Brake Adjustment----------------------------------------------------------------------------------------- F-4
Fig. F3: Parking Brake Kick-Off Mechanism------------------------------------------------------------------------- F-6
Fig. F4: Compensator Assembly --------------------------------------------------------------------------------------- F-6
Fig. F5: Troubleshooting Flowchart------------------------------------------------------------------------------------ F-8
Fig. F6: Troubleshooting Flowchart (Continued) --------------------------------------------------------------------- F-9
Fig. F7 Troubleshooting Table---------------------------------------------------------------------------------------------F-10