Service Information

Document Title: Function Group: Information Type: Date:

Description 500 Service Information 2014/5/22
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Description
Service brakes
The machine is provided with an all-hydraulically controlled brake system divided into two circuits, where one circuit acts on
the front axle brakes and the other circuit on the rear axle brakes.
Both the front and rear axles are provided with wet disc brakes.
The system also consists of an hydraulic oil pump, a brake valve and accumulators.
The hydraulic oil pump serves both the brake and the servo systems and is mounted in tandem with the steering pump. The
oil is drawn from the hydraulic oil tank.
Each circuit has its own accumulator. These are precharged with nitrogen gas and their purpose is to store energy and to
safeguard braking capacity with a good margin.

Figure 1
Brakes (principle diagram)

1. Hydraulic tank
2. Brake pump
3. Warning lamp for low brake pressure
4. Accumulator
5. Wet disc brakes
6. Brake valve

If the pressure in the accumulator circuit for some reason drops below 9 MPa (1305 psi) this will be indicated by the brake
system warning lamp lighting up and the central warning will come into action and if the gear selector is moved to the
forward or reverse drive positions the buzzer will sound. If the machine is equipped with a display unit (optional equipment),
this will also show a warning of low brake pressure.

Figure 2
Instrument panel

1. Warning lamp, low brake pressure (LC6)

2. Central warning (LC9)

Brake valve
The brake valve includes control valve, unloading valve and foot brake valve.
The purpose of the control valve is to divide the oil flow from the pump to the brake system and the servo system.
The purpose of the unloading valve is to distribute the oil flow to the different brake circuits and control the pressure in
the system.
The foot brake valve is divided into two circuits, where one of the circuits acts on the front axle brakes and the other on the
rear axle brakes.

Figure 3
Brake valve

1. Brake valve
2. Pressure outlet for checking output brake pressure to circuit
3. Pressure sensor, transmission disengagement (SE2)
4. Accumulator, rear circuit (S1)
5. Pressure outlet, unloading pressure
6. Pressure sensor, low brake pressure (SE14)
 7. Accumulator for hydraulic parking brake (S3)
L90C Serial No. –15289 (EU), –62960 (US), –70176 (Brazil)
L120C Serial No. –12376 (EU), –62083 (US), –70172 (Brazil)
8. Adjusting screw, unloading pressure
9. Accumulator, front circuit (S2)
10. Pressure sensor, stop lights (SE29)
 Service Information

Document Title: Function Group: Information Type: Date:

Function 500 Service Information 2014/5/22
Profile:

Function
Charging, brake in resting position
When the engine has stated, the oil flow from pump (1) enters the brake valve through connection P.
The oil flow from the pump is greater than the amount restriction (2) will let through. This will cause piston (3) in the control
valve to begin to open and oil is supplied to the servo system via the connection marked N.
All oil to the brake system passes through restriction (2). If the system pressure is below 12 MPa (1740 psi), unloading spool
(4) will be in its upper position. The oil is supplied to the unloading spool via duct (5). From there the oil is conducted to the
control valve and in at the back of piston (3). The oil is also conducted through the duct in the unloading spool to the top of
the spool.
From restriction (2) the oil also flows through non-return valve (6). Through duct (7) the oil is conducted out to the parking
brake circuit. Non-return valve (9) lets the oil flow through to accumulator (11) at the connection marked S1 and via a duct
on to spool (13) in the foot brake valve.
Non-return valve (10) lets the oil flow through to accumulator (12) at the connection marked S2 and via a duct on to spool
(14) in the foot brake valve.
When the pressure has risen to the accumulator precharging pressure, approx. 5 MPa (725 psi), the nitrogen gas will be
compressed by the flowing into the accumulators at the same time as the pressure in the system rises.
During the charging stage the pressure is the same on both sides of piston (15). The system pressure acts directly on
unloading spool (4) and works against spring (16).

Figure 1
Charging

1 Brake and servo pump

2 Restriction (behind plug)
3 Piston
4 Unloading spool
5 Duct
6 Non-return valve
7 Duct
9 Non-return valve
10 Non-return valve
11 Accumulator, rear circuit
12 Accumulator, front circuit
13 Spool, rear circuit
14 Spool, front circuit
15 Piston
16 Spring
17 Checking point
18 Pressure sensor, low system pressure
19 Stroke limiter
A To hydraulic parking brake (optional equipment L90C, standard equipment L120C)
N To the servo system

Orange = Servo pressure

Pink = Build-up of pressure
Green = Return pressure

Unloading, brake in resting position

When the accumulators (one for each brake circuit) fill up with oil, the pressure in the system rises at the same time towards
the max. pressure, 15.5 MPa (2248 psi). The oil which exerts pressure on unloading spool (4) overcomes the force of spring
(16) and the spool is displaced downward. The space above unloading spool (4) will then have a return connection to tank.
The spool will be kept in the lower position by the system pressure which acts on piston (15). The "active" area of the piston
is slightly larger than the corresponding area on the spool. The space behind piston (3) in the control valve will also have a
return connection to tank. The pressure required to keep the valve open is reduced. This means non-return valve (6) will be
closed by the system pressure.
In this situation the entire oil flow from pump (1) passes piston (3) and moves on to the servo system.
When the brakes are used and the accumulated pressure drops to approx. 12 MPa (1740 psi), unloading spool (4) will be
displaced upward because of the spring force.
The return connection to tank through unloading spool (4) will be closed and the oil will be conducted to the underside of
piston (3) in the control valve. This will cause the pressure at the top of the piston to rise and the pump flow will be charging
the brake system via non-return valve (6). The difference between the unloading pressure and the cut-in pressure is
determined by the area difference on piston (15) and unloading spool (4).
Brake in resting position (not actuated)
When the foot brake valve is not actuated, return springs (19 and 20) are pressing spools (13 and 14) upward.
Pressure ducts (21 and 22) will then be closed and the brake connections marked B1 and B2 will be connected to tank from
the connection marked T via ducts in the valve housing, see [Invalid linktarget] .
Figure 2
Unloading

1 Brake and servo pump

2 Restriction (behind plug)
3 Piston
4 Unloading spool
5 Duct
6 Non-return valve
7 Duct
9 Non-return valve
10 Non-return valve
11 Accumulator, rear circuit
12 Accumulator, front circuit
13 Spool, rear circuit
14 Spool, front circuit
15 Piston
16 Spring
17 Checking point
18 Pressure sensor, low system pressure
19 Return spring, rear circuit
20 Return spring, front circuit
21 Pressure duct, rear circuit
22 Pressure duct, front circuit
23 Stroke limiter
N To the servo system

Orange = Servo pressure

Red = System pressure
Green = Return pressure

Partial brake application

If the brake pedal is partially depressed, spring (23) will be pretensioned. Spools (13 and 14) will then be displaced
downward, closing the tank connection from the brakes and oil from pressure ducts (21 and 22) can flow out to the brakes
via the connections marked B1 and B2. This causes the brakes to be applied and the pressure at connections B1 and B2 to
rise.
When this pressure corresponds to the force at which spring (23) has been pretensioned, the pressure will aid return spring
(19) in pushing up spool (13) and spring (20) in pushing up spool (14). In this way the oil flow to the brakes is closed and a
brake application corresponding to the depression of the brake pedal is obtained.
Full brake application
The downward movement of the foot brake pedal is limited by the foot brake pedal adjusting screw, see [Invalid linktarget] .
When the pedal is depressed to the end position, the valve still takes up a partial brake application position and the pressure
out to the brakes is limited to approx. 8 MPa (1160 psi).

Figure 3

1. Adjusting screw for output brake pressure

2. Security seal
Figure 4
Partial brake application

1 Brake and servo pump

2 Restriction
3 Piston
4 Unloading spool
5 Duct
6 Non-return valve
7 Duct
9 Non-return valve
10 Non-return valve
11 Accumulator, rear circuit
12 Accumulator, front circuit
13 Spool, rear circuit
14 Spool, front circuit
15 Piston
16 Spring
17 Checking point
18 Pressure sensor, low system pressure
19 Return spring, rear circuit
20 Return spring, front circuit
21 Pressure duct, rear circuit
22 Pressure duct, front circuit
23 Spring
24 Checking point
25 Pressure sensor, transmission disengagement
26 Pressure sensor, stop lights
27 Stroke limiter
Orange = Servo pressure
Pink = Partial pressure
Red = System pressure
Green = Return pressure
 Service Information

Document Title: Function Group: Information Type: Date:

Hydraulic diagram 500 Service Information 2014/5/22
Profile:

Hydraulic diagram
L90C

Figure 1
Hydraulic diagram, brake system L90C

MA67 (Optional Solenoid valve, parking brake

equipment)
S1 Accumulator, rear circuit (1.0 dm3 = 61 in3)
S2 Accumulator, front circuit (1.0 dm3= 61 in3)
SE2 Pressure sensor, transmission disengagement
SE6 (Optional Pressure sensor, control lamp parking brake
equipment)
SE14 Pressure sensor, control lamp low brake pressure, 7.2–8.8 MPa (1044–1276 psi)
SE29 Pressure sensor, stop lights
F Front axle
B Rear axle
N To the servo system
P (Optional Hydraulically operated parking brake
equipment)
1 Hydraulic oil tank
2 Hydraulic pump, steering
3 Hydraulic pump, brake and servo system
4 Brake valve
4.1 Control valve, brake and servo systems
4.2 Unloading valve for brake pressure, 15–15.5 MPa (2176–2248 psi)
4.3 Non-return valves
5.1 Pressure outlet, circuit pressure
5.2 Pressure outlet, unloading pressure
5.3 (Optional Pressure outlet, parking brake
equipment)
6 (Optional Accumulator, hydraulic parking brake (0.5 dm3 = 30 in3)
equipment) Serial No. –15289 (EU), –62960 (US), –70176 (Brazil)

L120C

Figure 2
Hydraulic diagram, brake system L120C

MA67 Solenoid valve, parking brake

S1 Accumulator, rear circuit (1.0 dm3= 61 in3)
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S2 Accumulator, front circuit (1.0 dm3= 61 in3)
SE2 Pressure sensor, transmission disengagement
SE6 Pressure sensor, control lamp parking brake
SE14 Pressure sensor, control lamp low brake pressure, 7.2–8.8 MPa (1044–1276 psi)
SE29 Pressure sensor, stop lights
F Front axle
B Rear axle
N To the servo system
P Hydraulically operated parking brake
1 Hydraulic oil tank
2 Hydraulic pump, steering
3 Hydraulic pump, brake and servo system
4 Brake valve
4.1 Control valve, brake and servo systems
4.2 Unloading valve for brake pressure, 15–15.5 MPa (2176–2248 psi)
4.3 Non-return valves
5.1 Pressure outlet, circuit pressure
5.2 Pressure outlet, unloading pressure
5.3 Pressure outlet, parking brake
6 Accumulator, hydraulic parking brake (0.5 dm3= 30 in3)
Serial No. –12376 (EU), –62083 (US), –70172 (Brazil)
 Service Information

Document Title: Function Group: Information Type: Date:

Brake 510 Service Information 2014/5/22
discs, checking wear (with
built-in wear indicator)
Profile:

Brake discs, checking wear (with built-in wear indicator)

Op nbr 5160151701

999 3831 Support

The following applies when checking:

Brakes: Applied

NOTE!
Exercise cleanliness when working with the brakes.

1. Start the engine and charge the accumulators. Raise the lifting arms. Secure the lifting arms with support 999 3831,
see [Invalid linktarget]
Stop the engine and apply the brake.

Figure 1

1. 999 3831 Support

CAUTION
The brake must be applied during the entire wear check.

2. Remove the plug from the wear indicator, see [Invalid linktarget] .