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

(02/09/2016) 40-01-M236EN
 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 2106 cm2
Total braking surface of truck 4212 cm2
Recommended operating pressure 55 bar
Clutch material Paper N266
Brand Wellman
Disk outer diameter 254 mm
Disk thickness 4.75-4.85 mm
Range of action 107.5 mm
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 BRAKE CHARACTERISTICS AND
SPECIFICATIONS 3

PARKING BRAKE

PARKING BRAKE

40
Parking brake in oil bath
Number of disks 3
Braking surface for disk face 263 cm2
Total braking surface 2104 cm2
Clutch material Paper N266
Dynamic friction coefficient 0.115
Static friction coefficient 0.095
Brand Wellman
Disk outer diameter 254 mm
Disk thickness 4.75-4.85 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 19.3 bar
brakes
Minimum real pressure for release of the brakes 21.4 bar
Operating pressure 38 bar

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 BRAKE CHARACTERISTICS AND
4 SPECIFICATIONS
40

40-01-M236EN (02/09/2016)
 BRAKE COMPONENTS LOCATION

pages

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

40

(07/10/2016) 40-03-M236EN
 2 BRAKE COMPONENTS LOCATION

THE BRAKES COMPONENTS

Brakes fluid tank

Brakes pump

Brake pedal

MAX
MIN
40

Front axle disk

brake
Accumulator

Rear axle disk

brake

40-03-M236EN (07/10/2016)
 BRAKE CONTROL AND ADJUSTMENT

pages

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

40
–– INCHING ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– DEACTIVATE THE NEGATIVE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– SETTING THE GEAR IN NEUTRAL (FOR TOWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 under braking

1
120

107

40-04-M236EN (10/10/2016)
 BRAKE CONTROL AND ADJUSTMENT 3

BLEEDING PROCEDURE

Location:
RLF MC

FDAV
MAX
MIN

R VP

VP

VP

40
VP

VP VFR

EFS
ACC
PH

FDAR
Key:

ACC: Rear brake disc

FDAR: Front brake disc
FDAV: Front brake disc
PH: Hydrostatic Pump
R: Oil Tank
RLF: Brake fluid tank
MC: Master cylinder
RLF: Brake fluid tank
VP: Bleed screw
VFR: Trailer braking valve
Open the front cover (Ref. 1).

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 4 BRAKE CONTROL AND ADJUSTMENT

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.
3

2 2

5 Use a bleeder (Item 4): Pressure 1 to 1,2 bar.

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

40

Place a transparent recovery hose onto the front right bleed

screw (Item VP).

Operate the bleeder.

VP

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

Carry out the same procedure for the three front and rear bridge
vent screws and on the trailer brake valve.

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

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 BRAKE CONTROL AND ADJUSTMENT 5

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

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

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

40
2
central position.

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 6 BRAKE CONTROL AND ADJUSTMENT
40

40-04-M236EN (10/10/2016)
 BRAKE CONTROL AND ADJUSTMENT 7

TIGHTENING TORQUES

X
MA
MIN

15 Nm

15 Nm

40
27 Nm

REAR AXLE

P2

FRONT AXLE

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 8 BRAKE CONTROL AND ADJUSTMENT
40

40-04-M236EN (10/10/2016)
 BRAKE REMOVAL

pages

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

40
–– PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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 2 BRAKE REMOVAL

SERVICE BRAKE

X
MA
MIN

A
40

P2

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-M236EN (02/09/2016)
 BRAKE REMOVAL 3

Remove the 4 screws (Item 1)

3 from the cab's front fairing
(Item 2).

3
3
Open the inspection case
1
(Item 3) with the ignition key.

1 1
2

1 2

Remove the antenna cable from the casing (Item 4).

40
4

5 Remove the windscreen

washer hoses (Item 5) from
the fairing (Item 2).

Remove the floor mat A (Item 6) from inside the cab.

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 4 BRAKE REMOVAL

8 Unscrew the two screws (Item 7) securing the dashboard lower

casing (Item 8) and remove it.
7

bb 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 (Item 9) from the master cylinder

(Item 10) by removing the cotter pin and clevis pin.

9
10

bb Pay attention to the friction washers (Item 11).

11

11

40-06-M236EN (02/09/2016)
 BRAKE REMOVAL 5

bb
Remove the hydraulic connectors (Item 12).
12
Place an oil collection container under the cooler.

12

12

Remove the filling hose (Item 13) from the master cylinder
(Item 10).

40
13

10

10 Remove the two screws (Item 14) securing the master cylinder
(Item 10).

14

14

Remove the master cylinder (Item 10).

10

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 6 BRAKE REMOVAL
40

40-06-M236EN (02/09/2016)
 BRAKE REFIT

pages

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

40
–– PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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 2 BRAKE REFIT

SERVICE BRAKE

X
MA
MIN

A
40

P2

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-M236EN (02/09/2016)
 BRAKE REFIT 3

Install the master-cylinder

(Item 1) and attach with
the two fastening screws
(Item 2), to be tightened to
the standard torque.
2
1

Attach the master cylinder

(Item 1) to the brake pedal
(Item 3) ensuring that the
friction washers (Item 4) are
1
3 correctly positioned.

40
4 4

5 Install the lower dashboard

casing (Item 5) and attach
6 with two screws (Item 6).
7
Install the mat (Item 7).

Install the filling hose (Item 8) of the master cylinder (Item 1),
together with the clamp (Item 9) that holds it.
8
1

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 4 BRAKE REFIT

Connect the hydraulic hoses (Item 10) and tighten them to the
standard torques.
10

10

10

Fill the brake fluid tank (Item 11).

40

11

Install the bleeding tool

(Item 12) and pressurize the
brake circuit to 0,8 bar.

12

12

Bleed the brakes by acting on the coupling (Item 13) until all
the air is removed from the circuit.

13 bb leed all the brake circuits, starting with that furthest

B
away from the master cylinder and ending with that
which is closest.

40-07-M236EN (02/09/2016)
 BRAKE REFIT 5

After bleeding, decompress the circuit and remove the bleeding

14 tool.
Remove the excess brake fluid with a syringe (Item 14).
Clean any oil stains off the machine if required.
Perform a brake test in a secure area.
Check for any hydraulic leaks.

Fit the cab's front fairing

16 (Item 15).
Connect the windscreen
washer hoses (Item 16).

16

40
15

15

Attach the antenna (Item 17).

17

Tighten the four screws (Item 18) securing the front fairing
(Item 15).
Close the inspection case with the ignition key (Item 19).

19
18

18 18
15

18

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 6 BRAKE REFIT
40

40-07-M236EN (02/09/2016)
 SPECIFIC BRAKE TOOLING

pages

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

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

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 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-M236EN (02/09/2016)