Brake

- Brake components location

- Brake control and adjustment

- Specific brake tooling

40
 POSITION OF THE BRAKES COMPONENTS

page

THE BRAKES COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40

(29/08/2012) 40-03-M205EN
 2 POSITION OF THE BRAKES COMPONENTS

THE BRAKES COMPONENTS

Brakes fluid
tank
Brakes pump

Brake pedal
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Front axle disk

brake

Rear axle disk

brake

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 CHECKING AND ADJUSTING THE BRAKES

page

40
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
BRAKES BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DEACTIVATE THE NEGATIVE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SETTING THE GEAR IN NEUTRAL (FOR TOWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
BRAKES SYSTEM LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SETTING VEHICLE PARAMETERS AND INCHING MRT EURO 3 PRIVILEGE
SAUER DANFOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
– MATERIAL NECESSARY FOR THE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– INSTRUCTIONS FOR CARRYING OUT THE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– INSTRUCTIONS FOR CARRYING OUT THE CALIBRATION OF THE INCHING PEDAL . 9

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 2 CHECKING AND ADJUSTING THE BRAKES

BLEEDING THE BRAKES AND ADJUSTING THE INCHING

40

PREPARATION AND SAFETY INSTRUCTIONS

Park the vehicle on a horizontal surface and switch off the I.C. engine.

Specific tools:
– Bleeding device.

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 CHECKING AND ADJUSTING THE BRAKES 3

BRAKES BLEEDING PROCEDURE

Disconnect the drainage pipe (Ref. 1) of the brakes fluid tank

and fit a hydraulic sealing cap.
Fill the brakes fluid tank completely.

Connect the brakes bleeding device (Ref. 2) on the tank S (see

“Brakes system layout”), on the dashboard.

40
Slacken the two bleed screws (Ref. 3) on the rear axle and fit
the transparent tubes on them.
Pressurise the brake bleed device, and wait for the air to flow
out completely through the transparent tubes.
Retighten the two bleed screws (Ref. 3) of the rear axle.
Repeat this procedure for the front axle.
Make sure the brake pump stroke is normal.
If this is not the case, adjust the brakes for both the axles.
( 30-06 - REMOVING THE AXLE).
3
– When the brakes bleeding procedure is complete, reconnect
the hydraulic tube (Ref. 1) to the exhaust manifold.

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 4 CHECKING AND ADJUSTING THE BRAKES

DEACTIVATE THE NEGATIVE BRAKE

Deactivate the action of the "negative" parking brake with the

1
help of a 19 mm hex wrench:
– Unscrew the nut (Ref. 1).
2 – Tighten the screw to fit flush (Ref. 2).
Repeat the operation on both sides of the front axle.

SETTING THE GEAR IN NEUTRAL (FOR TOWING)

1

1 If the vehicle is to be towed, the gear must be set in neutral.

Disconnect the tubes (Ref. 1) of the gear, remove or insert the
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2
pin (Ref. 2) (depending on the gear engaged) bringing it to the
central position.

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 CHECKING AND ADJUSTING THE BRAKES 5
BRAKES SYSTEM LAYOUT
Legend of brakes components:

FDAR Front axle disk brakes

FDAV: Front axle disk brakes
PF : Brake pedal
MC : Brakes pump
S
BRAKE BLEEDING DEVICE S: Brakes fluid tank
L R

200 bar 200 bar

Pressure Boost pressure
80 bar 33 / 35 bar
CST

PF
D (LS)
LS CR
4 4 MC
175 bar ID 8 8
P T 11 11

10 10

1 1

2 2
D (CF)

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12 12

VFP
A
FDAR PP B
FDAV

b
P T CFP
11.2cc MV (A)

b
51cc
PP CR (3) B A

T
VD
P

VD
480
480

bar
bar

M3
VSLR BLEED BRAKES ON THE
VBP b B A
1 2
AXLES
PP
7.5 microns

3,7 - 5,1 bar

5,6 - 0.9 bar

bar

T P
ΔP

450
ΔP

FDAR VCLR FDAV

450
bar
2
1

bar
34

17 cc

VBPA
C2

1,3 mm

CSC
2
1

78 cc

FA FR
VBP 250 microns 25 microns
VBPA R
1,3 mm

cw
flow out A

BLEED BRAKES ON THE AXLES

n

PH
C1

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 6 CHECKING AND ADJUSTING THE BRAKES
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 CHECKING AND ADJUSTING THE BRAKES 7

SETTING VEHICLE PARAMETERS AND INCHING MRT EURO 3 PRIVILEGE SAUER

DANFOSS
MATERIAL NECESSARY FOR THE SETTING

Control unit diagnostics socket connection cable.

Control unit/computer diagnostics socket connection cable.
Computer with “PLUS+1 GUIDE Service Tool” program installed.

INSTRUCTIONS FOR CARRYING OUT THE SETTING

Open the fuse box (Ref. 1) of the control unit ADM present inside
2
the cab (behind the driver's seat), acting on the two push-to-
1
lock closures (Ref. 2).
2

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Connect the connector (Ref. 3) to the diagnostics socket present
on the control unit.

Connect the other end of the cable connected to the diagnostics

socket on the control unit (Ref. 4) to the USB cable meant for
the port present on the laptop (Ref. 5).

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 8 CHECKING AND ADJUSTING THE BRAKES

Switch on the laptop and start up the program clicking on the

"PLUS+1 GUIDE Service Tool" icon (Ref. 6).

Turn the ignition key (do not start moving) of the forklift truck
and bring it to position "1" (Ref. 7).

7
40

Check to see that the "Connect" command (Ref. 8) (highlighted in

green) is displayed on the program screen page (at the bottom).
When the "Confirm" window is displayed, press "Yes" to confirm
(Ref. 9).

If this does not happen (connection to the forklift truck), click

on the "Communication", "Settings", "CG150" commands and
then "Enable" (Ref. 10).

10

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 CHECKING AND ADJUSTING THE BRAKES 9

Then click on the “File”, “Open” commands in succession and

select file “101076602_S0168_D0001” (with extension *.P1D)
(Ref. 11).
Confirm the selection by clicking on "Open" and wait for the
11
data to be downloaded.

After the data have been downloaded, select the "All Parameters
V157) command (present on the window to the LH) (Ref. 12).
Then click on the “Parameter” and “File Import” commands in
13 succession. Select file “10107602_S0168_P0001 FINAL TESTING
CENACCHI 28 NOVEMBER.xml” for Standard MRT models, or the
file “10107602_S0168_P0001 FINAL TESTING MACHINE FOR

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12 GERMANY.xml” for the MRT TUV models (Ref. 13).
Confirm the selection by clicking on "Open" and wait for the
data to be downloaded.

Then click on the “Parameter” and “Download” commands (Ref.

14) in succession to save the parameters on the control unit.

14

INSTRUCTIONS FOR CARRYING OUT THE CALIBRATION OF

THE INCHING PEDAL

On the menu select the“Parameter Function”, “Inputs”, “Inching”,

“Set Defaults” commands in succession (Ref. 15).

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 10 CHECKING AND ADJUSTING THE BRAKES

Check the brake pedal (Ref. 16) to make sure it is raised completely.

16

Select the “1” command in item “Calibrate Inch Potentiometer”

(Ref. 17).
Confirm the selection by clicking on “Download Parameters”
(Ref. 18)
and wait for the data to be downloaded.
Select the “0” command in item “Calibrate Inch Potentiometer”
(Ref. 17).
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18 17
Confirm the selection by clicking on “Download Parameters”
(Ref. 18)
and wait for the data to be downloaded.

On the menu select the “Log Function”, “Calibration”, “Pedal

Data” commands in succession (Ref. 19).

19

Select the "Start Logging" button (present in the upper part of

the program), lower the brake pedal completely (Ref. 16) and
wait for about 3 seconds to allow calibration to be completed
(displayed by the green icons present on the screen page).
20 Return to the "All Parameter V157" screen page (Ref. 12).
Confirm the selection by clicking on "Download parameters"
and wait for the parameters to be saved (Ref. 20).
16

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 CHECKING AND ADJUSTING THE BRAKES 11

On the menu select the “Log Function”, “System”, “Electrical”

commands in succession (Ref. 21).
21 With the brake pedal completely raised, check to make sure
the value displayed in the inching pedal window (Ref. 22) is
between 450 and 550 mV.

22

With the brake pedal completely lowered, check to make sure

the value displayed in the inching pedal window (Ref. 22)
21 is between 4400 and 4700 mV.

b If the values displayed are not within the above-mentioned

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ranges, proceed with the mechanical adjustment of the
inching potentiometer on the brake pedal. If the values
22 displayed are not changed by acting on the brake pedal,
check the inching potentiometer wiring.

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 12 CHECKING AND ADJUSTING THE BRAKES
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40-04-M205EN (25/06/2012)
 SPECIAL TOOLS FOR THE BRAKES

page

HYDRAULIC BRAKE VENTING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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(25/06/2012) 40-09-M205EN
 2 SPECIAL TOOLS FOR THE BRAKES

HYDRAULIC BRAKE VENTING VALVE

Venting valve complete with components necessary

for venting the brakes hydraulic systems for all Manitou
products.
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MANITOU reference

Hydraulic brake venting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554019

Spare parts:
Maximum pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 719980
Minimum pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981
Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .661913
Brake tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .661914

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