BRAKE

- BRAKE CHARACTERISTICS AND

SPECIFICATIONS

- BRAKE SCHEMATIC DIAGRAMS i70 - HYDRAULICS

- BRAKE COMPONENTS LOCATION i70 - HYDRAULICS
- BRAKE CONTROL AND ADJUSTMENT

- BRAKE REMOVAL

40
- BRAKE REFIT

- SPECIFIC BRAKE TOOLING

 BRAKE CHARACTERISTICS AND SPECIFICATIONS

pages

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

40
FREIN DE PARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(25/11/2020) 40-01-M238EN
 BRAKE CHARACTERISTICS AND
2 SPECIFICATIONS

SERVICE BRAKE

LHMS brakes liquid

ile
hu
ur
to
Re n
tio
ta
en le
l im hui
A

SERVICE BRAKE
40

FRONT AXLE

Planetary gear unit

R=1/6

Service brake in oil bath

Number of disks per wheel 3
REAR AXLE Braking surface per disk face 263 cm2
Total braking surface for an axle 1578 cm2
Total braking surface of truck 3156 cm2
Recommended operating pressure 35 bar
Clutch material Paper N266
Brand Wellman
Disk outer diameter 254 mm
Disk thickness 5.96 - 6.08 mm
Range of action 108.7 mm
40-01-M238EN (25/11/2020)
 BRAKE CHARACTERISTICS AND
SPECIFICATIONS 3

FREIN DE PARKING

Ø 254 x 176
PARKING BRAKE

40
Parking brake in oil bath
Number of disks 2
Braking surface per disk face 263 cm2
Total braking surface 1052 cm2
Clutch material Paper N266
Dynamic friction coefficient 0.115
Static friction coefficient 0.07
Brand Wellman
Disk outer diameter 254 mm
Disk thickness 5.93 - 6.08 mm
Maximum axial force 103,580 N
Piston outer diameter 277 mm
Piston inner diameter 85 mm
Piston area surface 545.88 cm2
Minimum theoretical pressure for release of the 21 bar
brakes
Minimum real pressure for release of the brakes 21 bar
Operating pressure 21 - 35 bar

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 BRAKE CHARACTERISTICS AND
4 SPECIFICATIONS
40

40-01-M238EN (25/11/2020)
 BRAKE CONTROL AND ADJUSTMENT

pages

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

40
– INCHING ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– MECHANICAL RELEASE OF NEGATIVE BRAKE ON FRONT AND REAR AXLE: . . . . . . . . 5
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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 2 BRAKE CONTROL AND ADJUSTMENT

SERVICE BRAKE

INCHING ADJUSTMENT PROCEDURE

1 - BRAKE PEDAL CONTROL AND ADJUSTMENT

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

– Tighten the lock nut (Ref. 3).

– Adjust the brake pedal clearance to 107 mm from the cab floor (without floor mat) undo the lock nut
(Ref. 4) and turn the push rod (Ref. 5).

– Tighten the lock nut (Ref. 4).

40

: Brake pedal position at rest

: Brake pedal position start braking

: Brake pedal position under braking

3
1
10
125

No floor mat
75

40-04-M238EN (25/11/2020)
 BRAKE CONTROL AND ADJUSTMENT 3

BLEEDING PROCEDURE

Location:

MC

FDAV
ACC

40
VCBR

PH

VCA

FDAR

Key:

ACC: Accumulator
FDAR: Real Axle Disk Brakes
FDAV: Front Axle Disk Brakes
MC: Brake pump
P.H.: Hydrostatic Pump
R: Oil Tank
VCA: Accumulators Charge Valve
VCBR: Parking brake & gear select combined valve

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 4 BRAKE CONTROL AND ADJUSTMENT

With the engine switched on, slacken the bleed screw

(Ref. 1) present on the front axle (Ref. 2), just enough to let a
small amount of oil fl ow out.

Press the brake pedal (Ref. 1) repeatedly until the oil flowing
out through the bleed connector is completely devoid of air
bubbles and then tighten the screw.

Repeat this operation on all the brakes, RH and LH, on the front
axle as well as on the rear axle.
40

40-04-M238EN (25/11/2020)
 BRAKE CONTROL AND ADJUSTMENT 5

MECHANICAL RELEASE OF NEGATIVE BRAKE ON FRONT AND REAR AXLE:

b This maneuver is dangerous. Put the lift truck carefully into neutral before towing, because
the parking brake system is out of service.

Towing can be carried out at very low speed and over short distances. How to intervene:
• Move the forward-reverse movement stalk switch in neutral (N).
• Deactivate the parking brake.
• Turn on the emergency lights.

Using a spanner, alternately tighten the two screws (Ref. 1)

through 1/4 of a turn at a time to compress the Belleville washer.
Slacken lock nuts (Ref. 2) of manual mechanical release screws
(Ref. 1); draw the nuts backwards by ± 8 mm.
2

40
Tighten screw (Ref. 1) so that it fits flush against disk-pusher
(Ref. 3).

3 2 1

Using a spanner, alternately tighten the two screws (Ref. 1)

through 1/4 of a turn at a time to compress the Belleville washer
and release the braking disks.
1 Note: The travel necessary for release corresponds to 1 turn.

b The opposite screws must be tightened by turning them

an equal number of turns.

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 6 BRAKE CONTROL AND ADJUSTMENT

ADJUSTMENTS AFTER EVERY MANUAL RELEASE

Remove screws (Ref. 1) complete with ring nuts (Ref. 2) and

gaskets (Ref. 3).
3 Replace gaskets (Ref. 3) lubricate screws (Ref. 2) with silicone
grease and refit the complete screws (Ref. 1, 2 and 3).
1 2

Adjust the projection of the screw heads with respect to the

axle arm to a value of 34 mm.

32 +10
40

Block the position of screws (Ref. 1) using the lock nuts (Ref. 2).

1
2
b Check again carefully to see if the screws project.

40-04-M238EN (25/11/2020)
 BRAKE CONTROL AND ADJUSTMENT 7

TIGHTENING TORQUES

30 Nm 50 Nm 50 Nm

50 Nm

40
FRONT AXLE

REAR AXLE

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 8 BRAKE CONTROL AND ADJUSTMENT
40

40-04-M238EN (25/11/2020)
 BRAKE REMOVAL

pages

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

40
– PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– BRAKE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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 2 BRAKE REMOVAL

SERVICE BRAKE
40

Key:

A - Master Cylinder.

PREPARATION AND SAFETY INSTRUCTIONS

This operation should preferably be carried out on a flat surface.

This operation is best carried out with the wheels straight.

Before fully unscrewing a hose coupling, detach the hose from the coupling to which it is attached to
check that there is no residual pressure in the circuit.

For the correct operation of the machine after repair, it is recommended to plug all open sections of
the hydraulic circuit.

40-06-M238EN (25/11/2020)
 BRAKE REMOVAL 3

BRAKE REMOVAL
3
Remove the 4 screws (Ref. 1)
from the cab's front fairing
3 (Ref. 2).
1 3

Open the inspection case

1 1 (Ref. 3) with the ignition key.
2

1 2

Remove the antenna cable from the casing (Ref. 1).

40
1

Remove the windscreen

washer hoses (Ref. 2) from
the fairing (Ref. 1).
2

Remove the floor mat A (Ref. 1) from inside the cab.

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 4 BRAKE REMOVAL

2 Unscrew the two screws (Ref. 1) securing the dashboard lower

casing (Ref. 2) and remove it.

b To avoid damaging the point of connection to the side

casing, apply pressure towards the front of the cab and
downwards.
40

Separate the brake pedal (Ref. 1) from the master cylinder (Ref. 2)
by removing the cotter pin and clevis pin.

1
2

b Pay attention to the friction washers (Ref. 1).

40-06-M238EN (25/11/2020)
 BRAKE REMOVAL 5

Remove the electric connectors (Ref. 1) and the hydraulic hoses

b
(Ref. 2).
1
2
Place an oil collection container under the cooler.
2

Remove the two screws (Ref. 1) securing the master cylinder

(Ref. 2).
2 Remove the master cylinder (Ref. 2).

40
1
1

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 6 BRAKE REMOVAL
40

40-06-M238EN (25/11/2020)
 BRAKE REFIT

pages

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

40
– PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– BRAKE REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(25/11/2020) 40-07-M238EN
 2 BRAKE REFIT

SERVICE BRAKE
40

Key:

A - Master Cylinder.

PREPARATION AND SAFETY INSTRUCTIONS

This operation should preferably be carried out on a flat surface.

This operation is best carried out with the wheels straight.

Special tooling.
Pliers for clip-on clamp.
Hydraulic syringe.
Brake circuit bleeding tools.

40-07-M238EN (25/11/2020)
 BRAKE REFIT 3

BRAKE REFIT

Install the master-cylinder (Ref. 2) and attach with the two

2 fastening screws (Ref. 1), to be tightened to the standard torque.

1
1

Attach the master cylinder

1 (Ref. 1) to the brake pedal
2
(Ref. 2) ensuring that the

40
friction washers (Ref. 3) are
3 3 correctly positioned.

1
Install the lower dashboard casing (Ref. 1) and attach with two
2
screws (Ref. 2).

Install the mat (Ref. 1).

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 4 BRAKE REFIT

Connect the hydraulic hoses (Ref. 1) and tighten them to the

standard torques.
Connect the electric connectors.
1

Fit the cab’s front fairing

16
2
(Ref. 1).
Connect the windscreen
washer hoses (Ref. 2).

2
40

1
15

Attach the antenna (Ref. 1).

Tighten the four screws (Ref. 2) securing the front fairing (Ref. 1).
Close the inspection case with the ignition key (Ref. 3).

218
3
b Bleed all the brake circuits, starting with that furthest away
from the master cylinder and ending with that which is
closest. ( y 40-04 BRAKE CONTROL AND ADJUSTMENT).

1 2 2

40-07-M238EN (25/11/2020)
 SPECIFIC BRAKE TOOLING

pages

HYDRAULIC BRAKE BLEED KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40
PARKING BRAKE BLEEDER HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(25/11/2020) 40-09-M238EN
 2 SPECIFIC BRAKE TOOLING

HYDRAULIC BRAKE BLEED KIT

Bleed valve supplied with all the components required for

bleeding the hydraulic brake circuits of all Manitou products.
40

MANITOU Reference

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

SPARE PARTS:
– TOP MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980
– BOTTOM MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981
– Membrane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913
– HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914

PARKING BRAKE BLEEDER HARNESS

1000

MANITOU Reference

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

40-09-M238EN (25/11/2020)