- BRAKE CHARACTERISTICS AND SPECIFICATIONS - BRAKE …
Transcript of - BRAKE CHARACTERISTICS AND SPECIFICATIONS - BRAKE …
BRAKE
- BRAKE CHARACTERISTICS AND SPECIFICATIONS
- BRAKE CONTROL AND ADJUSTMENT
- BRAKE REMOVAL
- BRAKE REFIT
- SPECIFIC BRAKE TOOLING
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BRAKE CHARACTERISTICS AND SPECIFICATIONS
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SERVICE BRAKE (MECHANICAL AND HYDROSTATIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PARKING BRAKE (MECHANICAL TRANSMISSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
PARKING BRAKE (HYDROSTATIC TRANSMISSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
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BRAKE CHARACTERISTICS AND SPECIFICATIONS
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
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3BRAKE CHARACTERISTICS
AND SPECIFICATIONS
PARKING BRAKE (MECHANICAL TRANSMISSION)
Disc brake on gearbox
Number of discs 1
Braking area per disc face 46.8 cm2
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
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BRAKE CHARACTERISTICS AND SPECIFICATIONS
PARKING BRAKE (HYDROSTATIC TRANSMISSION)
BlockPower supply +
Accumulator
Disc brake on gearbox
Number of discs 1
Braking area per disc face 46.8 cm2
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
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BRAKE CONTROL AND ADJUSTMENT
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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
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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
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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
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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
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5BRAKE CONTROL AND ADJUSTMENT
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
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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.
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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
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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
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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
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– 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
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11BRAKE CONTROL AND ADJUSTMENT
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
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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
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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
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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
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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
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SPECIFIC BRAKE TOOLING
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HYDRAULIC BRAKE BLEED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PARKING BRAKE BLEEDER HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
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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