- brake characteristics and specifications - brake …

BRAKE

- BRAKE CHARACTERISTICS AND SPECIFICATIONS

- BRAKE CONTROL AND ADJUSTMENT

- BRAKE REMOVAL

- BRAKE REFIT

- SPECIFIC BRAKE TOOLING

40

(10/24/2013) 40-01-M166EN

40

BRAKE CHARACTERISTICS AND SPECIFICATIONS

pages

SERVICE BRAKE (MECHANICAL AND HYDROSTATIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PARKING BRAKE (MECHANICAL TRANSMISSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

PARKING BRAKE (HYDROSTATIC TRANSMISSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

(10/24/2013)40-01-M166EN

402


SERVICE BRAKE (MECHANICAL AND HYDROSTATIC)

Oil bath disc brake:

Number of discs per wheel 4

Braking area per disc face 146.85 cm2

Recommended operating pressure 70 to 80 bar

Disc diameter 201.5 mm

Disc thickness 4.75 - 4.85 mm

Wear compensation Auto

Friction material Paper N266

Action radius 88 mm

Number of slave cylinders 1

Track width 26.75 mm

MAX

76

250

LHMS brake fluid

Master cylinderØ 31,75 mmCyl.: 30.9 cm³

OilEpicycloidal step-

down gearR = 1/6

Towards rear drive axle(same as front drive axle)

MT 835 ST3B / MT 1135 ST3BMT 835 H ST3B / MT 1135 H ST3B / MT 1135 H A ST3B

(10/24/2013) 40-01-M166EN

40

3BRAKE CHARACTERISTICS

AND SPECIFICATIONS

PARKING BRAKE (MECHANICAL TRANSMISSION)

Disc brake on gearbox

Number of discs 1


Total braking area 93.6 cm2

Pressure of use 38 bar

Disc diameter 290 mm

Disc thickness 10 mm (9.5 to 12.7 mm)

Wear adjustment mechanical

Friction materials asbestos-free

Play (new: brake pad clearance = 0.5 mmrun-in: brake pad clearance = 0.25 mm)

BlockPower supply + Accumulator

MT 835 ST3B / MT 1135 ST3B

(10/24/2013)40-01-M166EN

404


PARKING BRAKE (HYDROSTATIC TRANSMISSION)

BlockPower supply +

Accumulator

Disc brake on gearbox

Number of discs 1


Total braking area 93.6 cm2

Pressure of use 38 bar

Disc diameter 290 mm

Disc thickness 10 mm (9.5 to 12.7 mm)

Wear adjustment mechanical

Friction materials asbestos-free

Play (new: brake pad clearance = 0.5 mmrun-in: brake pad clearance = 0.25 mm)

MT 835 H ST3BMT 1135 H ST3B / MT 1135 H A ST3B

(05/02/2016) 40-04-M166EN

40

BRAKE CONTROL AND ADJUSTMENT

pages

SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– MECHANICAL TRANSMISSION ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 2

– HYDROSTATIC TRANSMISSION ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 2

– ADJUSTMENT PROCEDURE (INCHING OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

– BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FREEWHEEL AND TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

– RELEASING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

– PUTTING THE REDUCTION GEARBOX IN NEUTRAL (HYDROSTATIC TRANSMISSION) . . 9

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

– ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

– BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

(05/02/2016)40-04-M166EN

402 BRAKE CONTROL AND ADJUSTMENT

120

103

Brake pedal position at rest

Brake pedal position under braking

1

2

3

1

4

5

SERVICE BRAKE

MECHANICAL TRANSMISSION ADJUSTMENT PROCEDURE

STOP ADJUSTMENT

Brake pedal (Item 1):

– Use the stop (Item 2) to set the brake pedal (Item 1) to a height of 120 mm above the cab floor (without floor mat).

– Tighten the locknut (Item 3). – Set the brake pedal clearance to 103 mm from the cab floor (without floor mat) undo the locknut

(Item 4) and turn the push rod (Item 5). – Tighten the locknut (Item 4).

HYDROSTATIC TRANSMISSION ADJUSTMENT PROCEDURE

Group 20 - "Transmission control and adjustment" PUMP / ENGINE CONTROL AND ADJUSTMENT 8 - BRAKE AND TH7 VALVE PEDAL ADJUSTMENT

(05/02/2016) 40-04-M166EN

40

3BRAKE CONTROL AND ADJUSTMENT

120

107

ADJUSTMENT PROCEDURE (INCHING OPTION)

1 - BRAKE PEDAL CONTROL AND ADJUSTMENT

– Use the stop (Item 2) to set the brake pedal (Item 1) to a height of 120 mm above the cab floor (without floor mat).

– Tighten the locknut (Item 3).

– Set the brake pedal clearance to 107 mm from the cab floor (without floor mat), undo the locknut (Item 4) and turn the push rod (Item 5).

– Tighten the locknut (Item 4).

1

2

3

1

4

5

: Brake pedal position at rest

: Brake pedal position under braking

(05/02/2016)40-04-M166EN


2 - POTENTIOMETER ADJUSTMENT

– Check that the potentiometer is plugged in to its electrical connector.

– View the voltage of the potentiometer on the Cluster screen (engine running).

To ascertain the method of displaying these values, please refer to the following chapter:

e Group 80 - Electrical troubleshooting - Input/output states.

Example of the value display on the Cluster.

Note: The potentiometer is managed by ECU "MP1" in "INANA".

– Position the potentiometer to obtain a minimum voltage of 0.5V with the brake pedal in rest position and a maximum voltage of 4.5V with the brake pedal depressed.

bWhen the brake pedal is fully depressed, the voltage of the potentiometer must not exceed 4.5V, otherwise calibration will fail.

0.5 V4.5 V

120

U mini = 0.5 V

U max = 4.5 V

3/5

ANA09 = 00,00 VANA10 = 00,51 VANA11 = 00,00 VANA12 = 00,00 V

– Progressively tighten the potentiometer, checking that the voltage value does not change.

: Brake pedal position at rest

: Position of the brake pedal when fully depressed

Maximum position

Without carpet

Total range of the potentiometer

(05/02/2016) 40-04-M166EN

40


3 - CALIBRATION OF BRAKE PEDAL (ENGINE RUNNING)

bThe appearance of the screen

SECUC a l i b r a t i o n

i n c o m p l e t e d

o r f a i l e d informs of non-adherence to an instruction or a cancellation request or an instruction outside of the time limit.

Release

the brake pedal

then press 1/3

BRAKE

Press completely

the brake pedal

then press 2/3

BRAKE

Calibration

incompleted

or failed

BRAKE

Press to Enter

Brake Pedal

Calibration Mode

RESET

>

>ADMIN CALIBERASESECUGAUGEM THRBRAKE

BRAKE

Press to

store new calibration 3/3

DIAG >INFO< CLOCK OPT

OK + right code

LCD

OK

RESET<

OK

Press OK to Enter Xpert Mode

ADMIN ERASE >

ENTERCUSTOMER CODE

BRAKE

Press OK to Enter BrakePedal Calibration Mode

XPERT

CALIB

or 5 min time out

or 5 min time out

Operating mode

Step 1Confirm to start brake pedal calibration.

Step 2Release brake pedal then confirm.

Step 3Press the brake pedal down fully then confirm.

Step 4Confirm to save new calibration.

Not OK

Not OK

Voltage ≥ 0.5 Vand Voltage ≤ 1.4 V

Voltage > 1.4 Vand Voltage ≤ 4.5 V

Check brake pedal sensor

Check brake pedal sensor

Operating mode

OK

OK

(05/02/2016)40-04-M166EN


4 - CALIBRATION OF THE INCHING POINT

The inching point which is calibrated in this procedure corresponds to the Inching limit switch, or the start of braking.

– Switch on the PAD and connect the VCI.

bThe PAD must be at least version 11.28.

– Select "Diagnostic" and then confirm. – Select "Maniscopic châssis fixe" (Maniscopic fixed frame) and confirm. – Select the type of machine range and then confirm. – Select the type of machine and then confirm. – Switch on the ignition, start the machine and then confirm. – Select "Diagnostic global (tous les calculateurs)" (Overall diagnosis (all ECUs)) and confirm. – Select "Calculateur transmission" (Transmission ECU) and confirm. – If faults are present, consult and then delete them. – Select "Calibration" and then confirm. – Select "Calibration point Inching capteur pédale de frein" (Brake pedal sensor Inching point calibration)

and confirm.

– Connect a manometer to measure the pressure in the master cylinder and then confirm.

⇒ Pressure test port location:

e "Pressure test port" section

– Depress the brake pedal to obtain a pressure of 12 bar. Once this pressure has been obtained, push the confirm button to record the calibration point.

bThe instruction must not exceed 95%, otherwise calibration will fail.

– Confirm to record calibration.

– Switch off the ignition for 5 seconds to initialize the system.

(05/02/2016) 40-04-M166EN

40


BLEEDING PROCEDURE

Open the front cover (Item 1).

Location:

Key:

FDar: Rear brake discFDav: Front disc brake LFN: Negative Brake Lever (Optional)MC: Master cylinderRLF: Brake fluid tank

VAFR: Trailer braking valve (Optional)VP: Bleed screw

1

FDar

FDav

RLFMC

VAFR

LFN

VP

VP

VP

VP

VP

(05/02/2016)40-04-M166EN


Before bleeding, the brake fluid tank needs to be raised.Unscrew the two thumbscrews (Item 2) and raise the entire brake fluid tank (Item 3) to the two notches designed for this purpose.

Use a bleeder (Item 4): Pressure 1 to 1.2 bar.

Fit the brake bleeder adapter (Item 5) to the tank.

Place a transparent recovery hose onto the front right bleed screw (Item VP).

Operate the bleeder.

Loosen the bleed screw, then re-tighten it once the brake fluid is flowing without air bubbles.

Follow the same procedure for the three front and rear axle bleed screws and on the trailer brake valve.

Top up brake fluid level (Shell LHM S fluid).

5

4

VP

2 2

3

(05/02/2016) 40-04-M166EN

40


1

2

FREEWHEEL AND TOWING

b This operation is dangerous. Carefully chock the truck before towing because the parking brake system is out of service.

Put the forward/reverse selection lever and gear lever in neutral (mechanical transmission).

Chock up the lift truck.

RELEASING THE PARKING BRAKE

Remove the cap (Item 1).

Undo the screw (Item 2) to release the brake disc. Leave a minimum 5 mm clearance between the disc (Item 4) and the brake pads (Item 5).

bMechanical transmission: do not tow truck at a speed greater than 6 km/h. Maximum towing distance: 5 km.

PUTTING THE REDUCTION GEARBOX IN NEUTRAL (HYDROSTATIC TRANSMISSION)

Place a container under the hoses (Item 4), then undo them. Protect the hose end openings.Using a tool, slide the pin (Item 5) and mark the trip point of the three positions. Check that the pin is fully engaged in the intermediate (i.e. neutral) position.

Put the towing device in place.Remove the chocks.Switch on the hazard warning lights.

NOTE: Since there will be no steering or braking assistance, operate these controls slowly. Avoid sudden jerky movements.

bDo not tow truck at a speed exceeding 5 km/h. Maximum towing distance: 100 m.

2.5 mm2.5 mm

5 5

4

5

4

4

(05/02/2016)40-04-M166EN


– Apply hydraulic pressure to the brake (min. 80 bar). – Remove the cap (Item 1) and completely undo the adjusting screw (Item 2). – Undo the locknut (Item 4) and adjust the clearance to 0.3 mm from plate A using the adjusting screw

(Item 3). – Retighten the locknut (Item 4). – Adjust the clearance from plate B to 0.3 mm using the adjusting screw (Item 2). – Refit the cap (Item 1). – Check that the brake linings are free. – Lower the hydraulic pressure.

b If the total maximum clearance exceeds 2.5 mm, the parking brake needs to be adjusted.

0,3+1 00,3

+1 0

PARKING BRAKE

ADJUSTMENT PROCEDURE

When refitting the handbrake, tighten both screws (Item 5) by applying a rotation of 1.5 to 2 turns in order to compress the washers (Item 6) by about 1.5 to 2.0 mm.

55

66

2

1

Disc

4

3

(05/02/2016) 40-04-M166EN

40


BLEEDING PROCEDURE

bPosition on flat ground and chock up front and rear wheels.

– Start the truck to charge the accumulator.

– Stop the truck.

– Switch the ignition on again.

– Connect the cable (Part no. 265865) to the parking brake electrovalve (Item 1) and the cigarette lighter (Item 2).

– Open the bleed screw (Item 3).

– Close the bleed screw (Item 3) when the flow is constant (without air bubbles).

– Restart the lift truck to charge the accumulator.

– Steer far right then far left.

– Stop the truck.

– Open the bleed screw (Item 3).

– Close the bleed screw (Item 3) when the flow is constant (without air bubbles).

– Remove the cable (Part no. 265865).

90°

1

3

2

(05/02/2016)40-04-M166EN


(05/02/2016) 40-06-M166EN

40

BRAKE REMOVAL

pages

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MASTER CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MASTER CYLINDER REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

– BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

– PARKING BRAKE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(05/02/2016)40-06-M166EN

402 BRAKE REMOVAL

MASTER CYLINDER REMOVAL

Remove the floor mat.

Remove the 2 screws (Item 3) to remove the case (Item 2).

Disconnect the antenna (Item 4).

Remove the antenna cable (Item 5) and the cable support cover (Item 6).

Remove the case (Item 7).

PREPARATION AND SAFETY INSTRUCTIONS

⇒ Stabilize the machine on level ground. ⇒ Maneuver the machine a number of times in forward and reverse (wheels straight) in order to

release any stresses acting on the steering and tires. ⇒ Raise the boom to mid-height and secure in position. ⇒ Deactivate battery power supply by means of the battery cut-off.

4

4

33

2

7

6

(05/02/2016) 40-06-M166EN

40

3BRAKE REMOVAL

Disconnect the windscreen washer hose (Item 8).

Remove the attachment screw (Item 9) from the cab cover (Item 10).

Tilt the cab cover forward and disconnect the windscreen washer supply hose (Item 11).

Remove the cab cover.

Remove the pin (Item 12) and the rod (Item 13).

Undo the brake fluid supply hose (Item 14). Drain the brake fluid tank.Disconnect the coupling (Item 15).Disconnect and mark the hose (Item 16).Disconnect and mark the hose (Item 17).Remove the 2 retaining screws (Item 18).Detach the master cylinder, tip it forward and remove it.

MASTER CYLINDER REFIT

Perform the procedure in the opposite order to removal.Before operating the machine, perform operation:o 40 - BRAKE CONTROL AND ADJUSTMENT, Service brake bleeding procedure.

13

18

18

12

8

17

14

11

9

10

15

16

(05/02/2016)40-06-M166EN

404 BRAKE REMOVAL

PARKING BRAKE

2

2

BRAKE PADS

Remove the cap (Item 3) from the parking brake.

Unscrew the brake pads (Item 2) by undoing the adjusting screw (Item 4).

Undo the adjustment screw (Item 5).

Remove the brake pads.

Perform operation: o 40 - BRAKE CONTROL AND ADJUSTMENT, Parking brake - Adjustment

PARKING BRAKE UNIT

Unscrew the two side screws (Item 6).

Remove the parking brake unit (Item 1).

Perform operation: o 40 - BRAKE CONTROL AND ADJUSTMENT, Parking brake - Adjustment

3

4

5

1

6

6

12 2

MT 835 H ST3B / MT 1135 H ST3B / 1135 HA ST3BMT 835 ST3B / MT 1135 ST3B

(12/10/2012) 40-09-M166EN

40

SPECIFIC BRAKE TOOLING

pages

HYDRAULIC BRAKE BLEED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PARKING BRAKE BLEEDER HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

(12/10/2012)40-09-M166EN

402 SPECIFIC BRAKE TOOLING

HYDRAULIC BRAKE BLEED VALVE

PARKING BRAKE BLEEDER HARNESS

Bleed valve supplied with all the components required for bleeding the hydraulic brake circuits of Manitou products.Operating instructions included.

MANITOU Reference

HYDRAULIC BRAKE BLEED KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .554019

SPARE PARTS:

– TOP MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980

– BOTTOM MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981

– Membrane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913

– HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914

MANITOU Reference

PARKING BRAKE BLEED HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265865

1000

- brake characteristics and specifications - brake …

Documents