SERVICE BRAKING SYSTEM

braking system
KEY TO THE ELECTROMAGNETIC BRAKE COMPONENTS��������������������������������������������������������������������������������� 2
OPERATION���������������������������������������������������������������������������������������������������������������������������������������������������������������� 3
BRAKING systems�������������������������������������������������������������������������������������������������������������������������������������������������� 3
REMOVAL OF THE ELECTROMAGNETIC BRAKE������������������������������������������������������������������������������������������������� 4
ELECTROMAGNETIC BRAKE ADJUSTMENT���������������������������������������������������������������������������������������������������������� 6

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 BRAKING SYSTEM SERVICE

KEY TO THE ELECTROMAGNETIC BRAKE COMPONENTS

5 4

8 7

10

Ref. Description

1 Retaining screw
2 Electromagnet
3 Brake plate
4 Circlip
5 Adjusting screw
6 Pinion
7 Rotor
8 Friction disc
9 Dust cover
10 Disc

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 SERVICE BRAKING SYSTEM

OPERATION
The electromagnetic brake mounted on the traction motor is a spring-operated brake.
When the electromagnet is powered, it attracts the brake plate and releases the friction disc, allowing the
latter to rotate freely.
When the power supply to the electromagnet is cut, the springs push the brake plate down onto the friction
disc, thus applying the brake.

BRAKING systems
There are 4 braking systems used: drive control release
• Release braking
• Braking on direction reversal
• Emergency braking
• Parking brake

A) Release braking
Controls the deceleration ramp when the drive control is released.

B) Braking on direction reversal

Controls the deceleration ramp when the travel direction is inverted.
“Braking on direction reversal", also know as counter current braking, direction reversal
consists of reversing the current supplied to the motor, thus changing
the direction of travel when the truck is in motion.
The braking current must be adjusted so that the truck stops in a distance
that is at least not less than the length of the truck itself.

C) Emergency braking
Emergency braking occurs when an alarm is triggered that requires an
immediate arrest of truck traction or when the tiller sensor is deactivated
(tiller in rest position or fully lowered).
The braking action is performed by the electromagnetic brake mounted
on the traction motor.

D) Parking brake
The "parking brake" action is performed by the electromagnetic brake and is applied when the truck is
stationary and the tiller is in the rest position.

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 BRAKING SYSTEM SERVICE

REMOVAL OF THE ELECTROMAGNETIC BRAKE

Equipment and tools

Fig. 1

A
open ended span-
T handle hex key external circlip
ner scissors
5 mm pliers
15 mm

large cross-head
puller
screwdriver Fig. 2
C

Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Move the truck to a safe place, away from areas of transit
of other vehicles and pedestrians. Lower the forks to the
ground, turn the key switch to OFF and disconnect the
battery.

Fig. 3

When replacing the rotor, the pinion must also be repla-

D
ced.

Phase 1
Remove the motor compartment cover, the wheel cover and the motor
cover (see "REMOVAL OF THE COVERS” in the "MECHANICS" sec-
tion).
Fig. 4
E
F

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 SERVICE BRAKING SYSTEM

Phase 2
open ended spanner - 5 mm T handle hex key - scissors
Remove the dust cover (ref.A fig.1).
Using the open ended spanner, loosen the three adjustment nuts (ref.B fig.1).
Using the T handle hex key, unscrew the three screws securing the electromagnetic brake to the traction
motor (ref.C fig.2).
Use the scissors to cut the cable ties to release the electromagnetic brake power cable. Disconnect the
wiring connector and withdraw it from the tab.
Remove the electromagnetic brake from the motor (fig.2).

Phase 3
EXTERNAL CIRCLIP PLIERS - PULLER
Withdraw the rotor (ref.D fig.3) from the pinion.
Using the circlip pliers, remove the circlip from the drive shaft (ref.F fig.4). Using the extractor remove the
pinion (ref.E fig.4).

INSTALLATION

After installation, proceed with the adjustment of the electromagnetic brake.

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 BRAKING SYSTEM SERVICE

ELECTROMAGNETIC BRAKE ADJUSTMENT

A
B

Fig. 1

After re-installing the electromagnetic brake assembly, before using the truck, the friction disc must be
adjusted.
To obtain a good braking action, the distance between the friction disc and the brake plate (ref.A fig.1)
must not be greater than 0.35 mm. A feeler gauge of this size is therefore required.
With the three nuts loose (ref.B fig.1), insert the feeler gauge near one of the bolts, tighten the retaining
screw (ref.C fig.1) with the hex key and position the plate so the feeler gauge can be withdrawn with a little
friction. Repeat the operation with all three bolts.
Tighten the nuts using the open ended spanner (ref.B fig.1).