Ezgo WorkHorse ST 480, Руководство по ремонту и обслуживанию техника

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BRAKES
Page D-9
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
WHEEL BRAKE ASSEMBLY
REPLACEMENT
Tool List Qty. Required
Socket, 3/4", 1/2" drive................................................ 1
Ratchet, 1/2" drive....................................................... 1
Wheel chocks.............................................................. 4
Hydraulic floor jack...................................................... 1
Jack stands ................................................................. 2
Socket, 1/4" hex bit, 3/8" drive .................................... 1
Ratchet, 3/8" drive....................................................... 1
Socket, 1/2", 3/8" drive................................................ 1
Socket, 9/16", 3/8" drive.............................................. 1
Needle nose pliers ...................................................... 1
Torque wrench, 3/8" drive, in. lbs. ............................... 1
Torque wrench, 3/8" drive, ft. lbs. ................................ 1
If one wheel brake
assembly requires
r e p l a c e m e n t , t h e
second must also be replaced.
Wear a dust mask and eye protection when-
ever working on wheel brakes. Do not use
pressurized air to blow dust from brake
assemblies.
Be sure that the parking brake is released.
Loosen rear wheel lug nuts and lift rear of vehicle per
Section B.
Remove wheel and drum. See ‘BRAKE DRUM
REMOVAL AND INSTALLATION’ on page D-5.
Loosen the four allen head bolts and lock nuts securing
the wheel brake backing plate to the flange on the axle
tube (Ref Fig. 5 on page D-6). Remove banjo bolt to
detach brake line from wheel cylinder. Remove the four
allen head bolts and lock nuts and discard.
Remove the clevis pin securing the park brake cable to
the wheel brake lever.
Installation is the reverse of removal. Connect the brake
cable to the wheel brake lever with the clevis pin installed
from the top down and a new cotter pin. Loosely install
wheel brake assembly to axle tube flange using new
hardware. Attach brake line to wheel cylinder using new
copper gaskets and tighten banjo bolt to 124 - 177 in. lbs.
(14 - 20 Nm) torque. Tighten allen head bolts and lock
nuts to 23 - 27 ft. lbs. (31 - 37 Nm) torque.
BLEEDING AND FLUSHING
Tool List Qty. Required
Shop towels............................................................. A/R
Hose ........................................................................ A/R
Clean container ........................................................... 1
Brake fluid, DOT 3................................................... A/R
Wrench, 1/4" box end .................................................. 1
Crowfoot wrench, 1/4", 3/8" drive ................................ 1
Torque wrench, 3/8" drive, in. lbs. ............................... 1
Bleeding
The brake hydraulic system must be free of air to func-
tion properly. Any air in the system is compressed when
pressure is applied, and the result is a springy, spongy
brake pedal.
Air may enter the system if any of the hydraulic parts are
disconnected or if the brakes are operated with the mas-
ter cylinder fluid very low.
The process of removing any air that may be trapped in
the hydraulic system is known as bleeding the brakes.
Bleeding requires the use of the brake pedal and master
cylinder as a hydraulic pump to expel air and brake fluid
from the system when a bleeder screw is opened.
Bleed the complete hydraulic system at both wheels if …
•
Primary brake line was disconnected from the
flexible brake hose
•
Air was introduced into the system through low
fluid level in master cylinder reservoir.
If a line or hose was disconnected at any fitting located
between the master cylinder and the wheel cylinders,
then all wheel cylinders served by the disconnected line
or hose must be bled.
Bleeding Sequence
Bleed at each wheel cylinder in succession, beginning
with the passenger side wheel, which is farthest from the
master cylinder, and then the driver side wheel.
N e v e r r e u s e a n y
e x c e s s f l u i d o r
return to the original
container. Dispose of brake fluid properly.
An assistant will be necessary to perform this
procedure.
Use a clean cloth to wipe off the master cylinder reservoir
and wheel cylinder bleeder valves (Ref Fig. 7 on page D-
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