Jungheinrich ETM/V10-12 Forklift Main Brake Cylinder Service Guide

The main brake cylinder is used to initiate and control the braking action.

 

Main brake cylinders for brake systems incorporating drum brakes are fitted with a bottom valve to ensure a rapid brake response at short pedal travel.The bottom valve (1) ensures that the brake fluid contained in the brake system is constantly kept under a slight over pressure (pilot pressure 0.4 -1.7 bar pressure gauge reading) when the brake pedal is not operated so that the braking action will commence immediately when the brake pedal is depressed.

 

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Main brake cylinders for brake systems incorporating disc brakes are fitted with special bottom valves (bottom valve provided with throttle bore), as contrary to drum brake systems, no pilot pressure must exist in the brake system(pressure gauge reading 0 bar when the brake pedal is not operated).

 

To avoid any confusion between the two different brake cylinders,the main brake cylinders destined for disc brake systems are fitted with a metal or adhesive tape bearing the inscription “Cylinder is fitted with special bottom valve”.

 

To avoid any confusion between the two different brake cylinders,the main brake cylinders destined for disc brake systems are fitted with a metal or adhesive tape bearing the inscription “Cylinder is fitted with special bottom valve”.

 

Servicing and Repair servicing Intervall

Every 500 operating hours / 3 months:

Visual inspection of the line connections for security and tightness(screwed connection must be dry).

Check the dust protection cap for security，cleanliness and damage.

 

Adjustments

Following the removal or replacement of the main brake cylinder,the clearance “s” between the piston and the spindle must be checked and readjusted, if necessary, to ensure that the vent hole(4) is not covered by the primary sleeve (3).

Prior to performing the adjustment,remove the bolt (8), unscrew the check nut (9) and turn the fork head (10) until the prescribed clearance of s= 1.0 mm

has been obtained. Refit the fork head and tighten the check nut.

 

Repair

Remove the cylinder.Temporarily blank off the tube coming from the compensating vessel to prevent any brake fluid from escaping.Remove the connection pipe, the attachment bolts and the pedal linkage. Dismantle the cylinder and clean all parts thoroughly using white spirit or brake fluid.

 

Check the cylinder bore for scoring and pitting. lf any existing scoring or pitting cannot be removed by gentle polishing, discard and replace the cylinder.

 

When performing repairs, all parts of the repair kit must be used.Always adhere strictly to the mounting instructions supplied with the parts.

 

For more Jungheinrich trouble repair case,please refer to Jungheinrich Trouble Repair