Clark ESC17-30 EV100S Index:

Contents
About this class ………………………………………………………………………………………… 3
About safety …………………………………………………………………………………………….. 4
Section 1. Principles of Braking ………………………………………………………………… 5
Newton’s Laws ……………………………………………………………………………….. 5
First Law (Inertia Law) …………………………………………………………………… 5
Second Law (Acceleration Law) ………………………………………………………… 5
Third Law (Action and Reaction Law) ………………………………………………. 5
Application of the Braking Principle …………………………………………………. 6
How Brake Linings, Shoes, Drums and the Road Work Together ……….. 6
Basic Objectives in Brake Design …………………………………………………….. 9
Brake Stopping Torque ……………………………………………………………………. 9
Shoe Energization ………………………………………………………………………….. 9
Shoe Leverage ………………………………………………………………………………… 9
Lining Characteristics …………………………………………………………………….. 10
Drum Deflection and Thermal Expansion …………………………………………. 10
Section 2. Methods of Actuating Brakes …………………………………………………….. 11
Hydraulic Brake Actuation ………………………………………………………………. 11
Hydrovac Brake Actuation ………………………………………………………………. 13
Hydraulic Brake Operation ……………………………………………………………… 13
Hydrovac Brake Operation ………………………………………………………………. 19
Air Brake Actuation ………………………………………………………………………… 22
Section 3. Components of the Braking System …………………………………………… 23
Master Cylinder ……………………………………………………………………………… 23
Residual Check Valve ……………………………………………………………………… 24
Wheel Cylinder ……………………………………………………………………………….. 24
Hydraulic Inching …………………………………………………………………………… 25
Brake Selector Valve ……………………………………………………………………….. 26
Brake Adjusters ……………………………………………………………………………… 26
Hydraulic Brake Tubes and Hose ……………………………………………………… 27
Brake Fluid …………………………………………………………………………………….. 28
Drum and Shoe Brakes ……………………………………………………………………. 29
Disc Brakes …………………………………………………………………………………….. 30
Wet Disc Brakes ……………………………………………………………………………… 32
Parking Brakes ……………………………………………………………………………….. 33
Section 4. Pre-Service Brake Inspection …………………………………………………….. 34
Brake System Inspection …………………………………………………………………. 34
Brake Pedal Check ………………………………………………………………………….. 34
Brake Lining and Drum Inspection ………………………………………………….. 36
Chassis Inspection ………………………………………………………………………….. 38
Master Cylinder Check ……………………………………………………………………. 39
Parking Brake Check ………………………………………………………………………. 39
Section 5. Drum and Shoe Maintenance and Repair …………………………………… 41
Drum and Shoe Replacement or Overhaul ………………………………………… 41
Installing Wheel Cylinders ………………………………………………………………. 44
Checking and Shimming Adjuster Gaps ……………………………………………. 44
Replacing Brake shoes …………………………………………………………………….. 45

Resurfacing Drums …………………………………………………………………………. 46
Section 6. Disc Brakes Maintenance and Repairs ……………………………………….. 49
Inspection ………………………………………………………………………………………. 49
Replacing brake disc lining ……………………………………………………………… 50
Replacing brake piston lining ………………………………………………………….. 50
Caliper Replacement ……………………………………………………………………….. 50
Section 7. Bleeding the Brake System ……………………………………………………….. 52
When to Bleed the System ……………………………………………………………….. 52
Bleeding Provisions and Objectives ………………………………………………….. 52
Bleeding Problems ………………………………………………………………………….. 52
Three Bleeding Methods ………………………………………………………………….. 52
Bottom Up Bleeding ………………………………………………………………………… 52
Manual Bleeding …………………………………………………………………………….. 52
Pressure Bleeding …………………………………………………………………………… 52
Brake and Inching Circuit Bleeding …………………………………………………. 54
Hydraulic Brake Fluid and Bleeding Precautions ……………………………… 55
Section 8. Component Reconditioning ………………………………………………………… 67
Reconditioning the Master Cylinder …………………………………………………. 67
Reconditioning the Two Stage Master Cylinder …………………………………. 70
Reconditioning the Wheel Cylinders …………………………………………………. 72
Section 9. Genesis Hydraulic Brake Valve ………………………………………………….. 74
Brake Valve Description ………………………………………………………………….. 74
Brake Valve Operation ……………………………………………………………………. 75
Brake Valve Removal ………………………………………………………………………. 76
System Bleeding ……………………………………………………………………………… 77
Brake Valve Overhaul …………………………………………………………………….. 78
Section 10. Repairing Wet Disc Brakes ………………………………………………………. 80
Checking Brake Pedal Linkage …………………………………………………………
Checking Master Cylinder ……………………………………………………………….
Checking Loss of Transmission Fluid ………………………………………………..
Isolating Between the Master Cylinder,
Inching, and the Right or Left Brakes ……………………………………………….
Removing the Wheel Axle Assembly ………………………………………………….
Further Isolating Fluid Loss …………………………………………………………….
Removing Discs and Drum ……………………………………………………………….
Reassembling the Wheel/Axle Assembly ……………………………………………
Installing Parking Brake Arm ………………………………………………………….
Parking Brake Adjustment ………………………………………………………………
Troubleshooting Guide …………………………………………………………………….