Service Information

Document Title: Function Group: Information Type: Date:

General description 500 Service Information 2014/3/24
Profile:
WLO, L120E [GB]

General description
The machine is equipped with a fully hydraulic brake system that has two circuits: one for the front axle and one for the rear
axle.
The system consists of a foot brake valve and accumulator block with three accumulators. One accumulator is for the front
circuit, one is for the rear circuit and the third is shared.
The accumulators are pre-charged with nitrogen gas. Their purpose is to store pressure and to ensure good braking
performance by a wide margin.
The brake system is supplied with oil via the central block from Pump 3 (P3), Pump 1 (P1) or Pump 2 (P2). P3 is located on
the engine's power take-off on the machine's left side. P2 is located on the transmission's left side. P1 is located on the
transmission's right side.
P3 supplies the cooling fan and ensures brake charging during transport operation. P2 supplies the brake system passively
when using the working hydraulics and the system pressure exceeds 12 MPa. P1 supplies the brake system passively if the
steering is used and pressure exceeds 12 MPa.
As brake charging may take place from two different pumps, it is necessary to perform two different pressure checks when
checking function.
The purpose of the central block is to distribute the oil and pressure to the brakes, steering (prioritized) and servo and
working hydraulics.
If the brake pressure drops below 9.0 MPa (1300 psi), this is indicated on the display panel. The warning light and the central
warning will come on and a buzzer will sound.
The front and rear axles have wet disc brakes.
The brakes are cooled by means of each disk having a pump rotor which act as a circulation pump for the axle oil.
The axles have integrated wear indicators for checking brake disc wear.
Description of central block, refer to Section 9.
Figure 1
Brakes, principle illustration

1. Foot brake valve

2. Accumulators (3 pcs.)
3. Hydraulic pumps (P1 and P2)
4. Hydraulic oil tank
5. Hydraulic pump (P3)
6. Hydraulic oil cooler
7. Central block
8. Axles with wet disc brakes

Hydraulic pumps
Pump 2, hydraulic (passive) brake pressure charging
Pump 2 (P2) feeds the central block and thus primarily supplies the steering with oil. When the steering is saturated with oil,
the priority spool (4) shifts to brake pressure charging, servo system and working hydraulics. The pressure reducing valve (3)
uses the priority spool to limit the maximum steering system pressure to 21.5 MPa (3120 psi). If all of the oil flow to the
steering isn't used, then P2, via the priority spool, will supply the pressure reducing valve (1) providing a brake pressure of 16
MPa (2320 psi) and pressure reducing valve (2) providing a servo pressure of 3.5 MPa (510 psi). The excess capacity can be
used by the working hydraulics via connection (PW).
Figure 2

1 Pressure reducing valve, max. hydraulic brake

charging pressure
2 Pressure reducing valve, max. servo pressure
3 Pressure limiting valve, max. steering pressure A Central block
4 Priority spool, steering C Pump 2 (P2)
5 Shuttle valve, selects highest LS pressure
6 Shuttle valve, selects highest pressure to ensure SE201 Sensor, engine speed
brake charging
7 Restriction SE2606 Sensor, engine coolant temperature
8 Restriction SE210 Sensor, coolant temperature, radiator
outlet
9 Pressure check connection, P3 SE211 Sensor, fan speed
10 Brake accumulator block SE406 Sensor, transmission oil temperature
11 Diaphragm accumulators SE502 Sensor, warning light, low brake pressure
12 Diaphragm accumulator, common SE504 Sensor, electrically controlled brake
charging
13 V-ECU, I-ECU, single unit SE906 Sensor, hydraulic oil temperature/
hydraulic oil level
14 Cooling fan motor (axial piston pump) MA202 Proportional valve, controls P3 work, LS
pressure
15 Hydraulic tank MA502 Solenoid valve, restricts oil flow to fan for
electrically controlled brake pressure
charging
16 Pump 3 (P3) A/B Brake/Fan position (PWM signal)
17 Caliper SE2501 Sensor, intake air temperature
18 Control piston SE2507 Sensor, charge-air temperature
19 Max. pressure compensator
20 Flow compensator
21 LS-connection
22 Hydraulic oil cooler

Pump 3, electrically controlled brake charging

When the pressure in the working hydraulics is not high enough the brake system is charged instead, controlled electrically
by the fan pump (P3). Pump 3 supplies oil to port (PF) of the central block and from there to the fan motor via port (PFF).
The oil flow is controlled via the proportional pressure-limiting valve MA202 which creates a pressure to the pump's LS-
connection via port LSF.
When the pressure monitor SE504 indicates that the brake pressure falls below 12 MPa, the valve MA202 sets a pump
pressure of 16 MPa. MA502 sets a restriction of 1 mm in the fan circuit and thus a pressure is obtained for charging the
brake system via the shuttle valve (6).

When the V-ECU receives a signal from SE504 it changes the signal controlling proportional valve MA202 from fan mode to
brake charging mode (A/B). MA202 in turn controls the work of P3. The oil is now provided at the correct pressure.
The signal controlling MA202 is of PWM type. If the requirement for cooling is great, the fan motor receives a large flow of
oil producing a high fan speed. If the pressure exceeds 12 MPa (1740 psi) the brake accumulators are charged automatically.
If the pressure in the brake accumulators drops below 9 MPa (1300 psi), SE502 provides a warning via the instruments and
display.
Foot brake valve
The foot brake valve is of proportional type, which means that the output brake pressure is proportional to the angle of the
brake pedal. The valve has two circuits: one for the front axle brakes and one for the rear axle brakes. The maximum output
brake pressure is limited to 8 MPa (1160 psi). This reduced brake pressure can be adjusted on the underside of the valve by
increasing or reducing the travel of the pedal.
Figure 3
Foot brake valve

1 Piston
2 Adjusting screw for circuit pressure
3 Security seal
4 Adjusting screw for pedal clearance
5 Pressure check connection
SE301 Sensor, brake lights
SE501 Sensor, output brake pressure,
log/transmission disengagement

Figure 4
Hydraulic diagram, cooling fan, brake system (see Section 9 for larger diagram)

A Hydraulic oil pump, P3, cooling fan, brake charging

B Hydraulic oil pump, P1 and P2, brake, servo and working hydraulics resp. steering brake, servo and working
 hydraulics
C Hydraulic oil filter
D Central block
G Fan motor
L Foot brake valve
M Accumulator block, brakes
N Solenoid valve, parking brake
O Hydraulic oil cooler
 Service Information

Document Title: Function Group: Information Type: Date:

Wear indicator, description 510 Service Information 2014/3/24
Profile:
WLO, L120E [GB]

Wear indicator, description

The wear indicator consists of a pin pressed into a spring pin for each individually adapted hub reduction length.
The wear indicator is permanently mounted in the axle housing and should be used for checking individual brake disc wear.
 Service Information

Document Title: Function Group: Information Type: Date:

Brake discs, checking wear 510 Service Information 2014/3/24
Profile:
WLO, L120E [GB]

Brake discs, checking wear

Op nbr 51701

9993721 Service display unit

9993831 Support

The following applies when checking:

Brakes: Brakes must be applied.

NOTE!
Brake work should be conducted under clean conditions.

1. Start the engine and charge the accumulators. Raise the lift arms. Secure the boom with support 999 3831.
Stop the engine and apply the brake fully. Connect the service display unit to the machine or a pressure gauge to
the pressure check connection for output brake pressure to check that the brake is fully applied.

NOTICE
The brake must be applied during the whole wear check.

Figure 1

1. 999 3831 Support

2. Remove the wear indicator cap.

 Figure 2

1. Wear indicator

3. Press in the wear indicator pin until it stops.

Figure 3
Press in the wear indicator pin

4. Brake disc wear is indicated by the position of flat surface B on the wear indicator pin in relation to flat surface A of
the nipple.
The position of the flat pin surface varies depending on the extent of brake disc wear. For new brake discs, the
indicator pin cannot be pressed in farther once the flat pin surface protrudes 2.3 mm (0.1 in) from the flat nipple
surface.

Figure 4
Checking brake disc wear

A. Nipple, flat surface

B. Indicator pin, flat surface

1. Wear indicator pin

2. Nipple
3. Back-pressure plate
4. Brake disc
5. Brake piston

5. The brake disc is worn and must be changed when the flat surface B of the wear indicator pin is flush with the flat
 surface A of the nipple.

Figure 5
Brake disc is worn

A. Nipple, flat surface

B. Indicator pin, flat surface

1. Wear indicator pin

2. Nipple

6. Refit the wear indicator cap.

Release the brake pedal.

7. Check the remaining brake discs.

8. Remove the support and lower the boom.

 Service Information

Document Title: Function Group: Information Type: Date:

Brake discs, changing 510 Service Information 2014/3/24
Profile:
WLO, L120E [GB]

Brake discs, changing

Op nbr 51704

9993802 Lifting device

9993875 Adjusting tool

Removing
NOTE!
The brake disc is delivered as a spare part without pump rotor. Transfer the pump rotor to the new disc and centre it. Use
the new bolts, lock nuts and spring pins that are supplied with the new disc.

1. Lift up the machine and position axle stands under the axle. Remove the wheels.

2. Drain the oil from the hub reductions and the axle housing.
AWB 30 oil volume, including hub reductions: approx. 41 l (10.8 US gal)
AWB 31 oil volume, including hub reductions: approx. 36 l (9.51 US gal)

3. Release the brake system pressure by depressing the brake pedal repeatedly (30–40 times).

4. Mark up the hub reduction's position in relation to the axle housing, connect lifting device 999 3802 to the hub
reduction. Remove the retainer bolts and remove the hub reduction.
Hub reduction weight: approx. 250 kg (551 lbs)
NOTE!
Sometimes the drive shaft and the brake disc may remain in the hub reduction and may come out complete.

Figure 1
Removing hub reduction

1. 999 3802

5. Remove the brake disc.

 Remove the brake plate and the guide pins.

Figure 2
Brake plate and guide pins

1. Brake plate
2. Guide pins, 4 pcs.

6. Loosen the lock nuts. Turn out the adjusting screws for the brake piston approx. 1 turn.
Clean and check the parts for any wear and damage.

Figure 3

1. Adjusting screws with lock nuts

7. The wear indicator pin on the front axle must be fitted from the hub side when the front frame prevents removal
from the outside. The brake piston must be removed and the seal rings must be changed.

Centring pump rotor on brake disc

8. Remove the pump rotor from the old brake disc.

9. Centre the pump rotor on the new brake disc as follows:

  Position the new brake disc on a flat surface with one half of the pump rotor on each side. Centre the
pump rotor halves on the brake disc by knocking in two spring pins (6.35 x 24 mm) in two diametrically
opposed bolt holes.
 Fit the bolts in the other two holes.
Tightening torque:12 Nm (8.9 lbf ft)
 Knock out the spring pins and fit the bolts.
Tightening torque:12 Nm (8.9 lbf ft)

Figure 4
Centring pump rotor halves on brake disc

1. Spring pins for centring of pump rotor halves

NOTE!
Applies only to the front axle, where the wear indicators must be fitted from the hub side when the front frame
prevents removal. For the rear axle, continue under the heading Installing.

Brake piston, removing and installing

10. Fully depress the brake pedal and block it in that position with a suitable tool. When the brake pedal is blocked in
the depressed position, the oil in the hydraulic tank is prevented from running out to respective brake piston.
NOTE!
The brake pedal must remain blocked until the front axle is refitted.

11. Remove the brake piston using a pry bar. Collect the oil that drains.
Brake piston weight: 17 kg (37.5 lbs).
Clean and check the parts for any wear and damage.
 Figure 5
Removing brake piston

12. Grease the brake piston and the O—rings. Fit the O—rings with the flat surface against the bottom of the groove
on the brake piston.

Figure 6

1. O—rings

13. If the wear indicator's pin cannot be fitted after the brake piston has been installed:
Adjust the length of the wear indicator's pin so that it is 89 mm (3.5 in) (basic adjustment)

Figure 7
Basic adjustment, wear indicator

A. 89 mm (3.5 in)

14. Fit the wear indicator pin.

Figure 8
Installing wear indicator's pin

15. Fit the brake piston.

Fit the bleeder screw.
 Figure 9
Installing brake piston

1. Hole for wear indicator

2. Clamps

Installing

16. Fit the O—ring on the axle housing.

Fit the brake disc.

Figure 10
Installing brake disc (principle illustration)

1. Brake disc
2. O-ring

17. Fit the brake plate and the guide pins, 4 pcs.
 Figure 11

1. Brake plate
2. Guide pins, 4 pcs.

18. Connect lifting device 999 3802 to the hub reduction.

Hub reduction weight: approx. 250 kg (551 lbs)
Fit the hub reduction.
NOTE!
Check that the guide pins in the hub reduction are aligned in the brake piston recess.

Figure 12
Installing hub reduction

1. 999 3802

19. Tighten down the hub reduction.

Tightening torque: 310 Nm (229 lbf ft)

Brake piston, adjusting stroke

 20. Bleed the brake system, see 520 Brake system, bleeding.

WARNING
Oil under high pressure!

Figure 13

21. Start the engine and run up the brake pressure. Stop the engine and apply the foot brake.
NOTE!
The brakes should be applied until the wear indicator setting is completed and setting tool 999 3875 has been
removed.

22. Turn in the adjusting screws against the activated brake piston.
Then, turn out the adjusting screws 1/2 turn. Lock the adjusting screws with the lock nuts.
NOTE!
This procedure is only performed if a new brake disc has been installed.

Adjusting wear indicator

23. Remove the wear indicator.

24. Adjust the length of the wear indicator's pin so that it is 89 mm (3.5 in) (basic adjustment)

Figure 14
Basic adjustment of wear indicator

A. 89 mm (3.5 in)

25. Fit the wear indicator.

Fit the adjusting tool 999 3875 for the wear indicator and tighten until it bottoms out.
 Figure 15
Adjusting wear indicator

1. 9993875

26. Remove the adjusting tool, still with the brake applied. Fit and tighten the plug on the wear indicator.

27. Release the brake.

28. Fill oil in the axle.

AWB 30 oil volume, including hub reductions: approx. 41 l (10.8 US gal)
AWB 31 oil volume, including hub reductions: approx. 36 l (9.51 US gal)

29. Fit the wheels and remove the supports.

30. Check function.

 Service Information

Document Title: Function Group: Information Type: Date:

Brake system, retardation, 520 Service Information 2014/3/24
checking function
Profile:
WLO, L120E [GB]

Brake system, retardation, checking function

Op nbr 52002

999 3721 Service display unit

The following applies when checking:

 The machine must not be loaded.

 Machine speed must be above 20 km/h (12.4 mph).
 The ground surface must be level and provide adequate friction; dry asphalt, dry concrete or similar surfaces.
 Brakes must be applied without locking up the wheels.
 Do not pump or release the brake pedal during braking.
 Together with a supervisor, select a location where the brake test can be performed without risk for accidents, rear-
end collisions, etc.

WARNING
The brake test must only be performed in a place where there is no risk of accidents.

1. Start the engine.

2. Scroll to group “BRAKES”.

BRAKES
Br.press.in
Br.press.out xxxxxx
yy zzz

3. Scroll down to sub-menu “BRAKE TEST LOG”.

BRAKE TEST LOG

zz,z zz,z zz,z m/s2
xxx xxx xxx yyy

4. Turn the gear selector control to position A.

5. If the menu for the brake test is selected, the buzzer will emit a short signal when travel speed exceeds 20 km/h
(12.4 mph), indicating that the brake test can be performed.

6. Brake the machine fully without releasing the pedal.

7. Read the retardation value.

8. The service display unit shows the four latest measured values with the most recent value placed furthest to the left.
 BRAKE TEST LOG
zz,z zz,z zz,z m/s2
xxx xxx xxx yyy

9. If the latest measured retardation value is below 4.75 m/s2 (0.48 grams), the test should be conducted again. If the
re-test value is below 4.75 m/s2, check the brake system according to
520 Brake system, checking hydraulic function and 510 Brake discs, checking wear.
 Service Information

Document Title: Function Group: Information Type: Date:

Brake system, checking 520 Service Information 2014/3/24
hydraulic function
Profile:
WLO, L120E [GB]

Brake system, checking hydraulic function

Op nbr 52001

11666020 Pressure gauge 0–25 MPa (0–250 bar) (0–3625 psi), 2 pcs.
11666037 Hose, 2 pcs
9993721 Service display unit

Figure 1

1. Pressure check connection, brake pressure

2. SE502
3. SE504
4. Accumulator pressure

NOTICE
Before checking the function of the brake system hydraulics, the maximum pressure of the cooling fan pump (pump
3) must be checked and adjusted. See Section 2 "Cooling fan pump, checking and adjusting".

NOTE!
The brake system should be free from air.

Maximum brake pressure, checking

1. Release the brake system pressure in order to connect the pressure gauge by depressing the brake pedal
repeatedly (30–40 times). Connect the pressure gauge to the pressure check connection on the accumulator block.

2. Start the engine and charge the brake system. Make sure that the engine is running at low idle speed and has
reached normal working temperature.

3. Check the maximum brake pressure by tilting in towards the end position and reading the pressure on the pressure
gauge.
 Max. brake pressure: 16.5 ±0.5 MPa (165 ±5 bar) (2395 ±73 psi)
Adjustment is performed on the brake pressure valve on the central valve.

NOTICE
Adjustment should be carried out with the engine turned off.

Figure 2

1. Adjusting brake pressure

2. Central block

Electrically controlled brake charging function, checking

4. Start the engine and charge the brake system.

When the unloading (cut-out) pressure is reached, sensor SE504 should restrict the connection for oil flow to the
fan motor through MA502.
Check brake charging by carefully depressing the brake pedal a few times so that the pressure drops. When cut-in
(charge) pressure is reached, SE504 should close the circuit which starts the electric brake charging until the
unloading pressure is reached.
Cut-in pressure: 12.0 ±0.3 MPa (120 ±3 bar) (1740 ±43 psi)Cut-out (unloading) pressure (electric): 13.7 ±0.3
MPa (137 ±3 bar) (1987 ±43 psi)

Brake capacity, checking

5. Stop the engine, leave the ignition on, and carefully brake down the pressure to 13 MPa (130 bar) (1885 psi).
Read the pressure gauge connected to the accumulator block.
Then, check the level of the pressure-drop after four "full brake applications". The pedal should be fully depressed
and completely released before the pressure drops below 9 MPa (90 bar) (1305 psi) (control light for low brake
pressure flashes on the instrument panel).
If the number of full brake applications is not completed, check the precharge pressure for all accumulators.

Common accumulator, checking

6. Start the engine and charge the brake system. Stop the engine.

7. Depress the brake pedal several times to release the brake pressure while checking the reading on the pressure
gauge.
The pressure in the common accumulator slowly drops to the accumulator precharge pressure, and then the
pressure continues to drop rapidly.
NOTE!
If the precharge pressure in the accumulator is below 3.5 MPa (35 bar) (507 psi), it should be changed.
Front, rear (and common) accumulator, checking

8. The front and rear accumulators can be checked on the condition that the common accumulator precharge
pressure is within the specified range.

9. Release the brake system pressure by depressing the brake pedal repeatedly (30–40 times).
Connect a pressure gauge to the brake accumulator block.

Figure 3

1. Pressure check connection, brake pressure

2. SE502
3. SE504
4. Accumulator block

10. Connect the service display unit to the socket in the rear wall.

Figure 4

11. Start the engine and find the correct screen for brake pressure on the service display unit under Brake menu.

BRAKES
Br.press.in xxxxxx
Br.press.out yy zzz

12. Connect a pressure gauge to the foot brake valve to check the precharge pressure in the accumulator for the front
brake circuit.
 Figure 5

1. 11666020, 11666037

13. Start the engine and allow the brake system to charge.

14. Stop the engine.

The corresponding accumulator pressures can be checked by depressing the brake pedal repeatedly and
simultaneously recording the pressure before it drops to 0 MPa (0 psi) on the service display unit and on both
pressure gauges.
Read off the pressure of the rear accumulator from the information display unit.
The common accumulator pressure is displayed on the pressure gauge connected to the brake accumulator block.
On the pressure gauge connected to the foot brake valve, read off the pressure for the front accumulator.

CAUTION
If the precharging pressure in the accumulator is below 3.5 MPa (508 psi), it should be replaced.
 Service Information

Document Title: Function Group: Information Type: Date:

Pressure in circuit, checking 520 Service Information 2014/3/24
and adjusting
Profile:
WLO, L120E [GB]

Pressure in circuit, checking and adjusting

Op nbr 52005

11666020 Pressure gauge 0–25 MPa (0–3625 psi)

11666037 Hose
9993721 Service display unit

Figure 1

1. 11666020, 11666037

NOTE!
The system must be free of air before the function check is performed.

Checking

1. WARNING
Oil under high pressure!

Make sure that the system has reached normal working temperature.
Start the engine and charge the brake system. Turn off the engine.
Connect the pressure gauge to the pressure check connection on the foot brake valve (front brake circuit).

2. Connect the service display unit to the socket in the rear wall.
 Figure 2

3. Start the engine and locate the correct information on the service display unit under the Brakes menu.

BRAKES
Br.press.in xxxxxx
Br.press.out yy zzz

4. Depress the brake pedal so that it rests on the adjusting screw. Read off the pressure on the pressure gauge and
service display unit.
Brake circuit pressure: 8.0 ± 0.6 MPa (80 ±6 bar) (1160 ±87 psi)

Figure 3
Foot brake valve

1 Piston
2 Adjusting screw for circuit pressure
3 Security seal
4 Adjusting screw for pedal clearance
5 Pressure check connection
SE301 Sensor, brake lights
SE501 Sensor, output brake pressure,
log/transmission disengagement

Adjusting

5. Break the security seal on the adjusting screw.

6. Adjust the pressure with adjusting screw 2. The adjusting screw limits brake pedal movement and when adjusting,
the piston's stroke is varied.

7. Depress the brake pedal so that it rests on the adjusting screw.

Read off the pressure on the pressure gauge.
 8. If the pressure requires adjusting, release the brake pedal and adjust adjusting screw 2. Adjust and check again
according to the previous step.

9. Seal the adjusting screw after adjustment.

10. Check that the clearance between brake pedal and piston is according to specifications.
Eventual adjustment is performed on adjusting screw 4.
Clearance between the brake pedal and piston: 0.4 ±0.2 mm

11. Remove the pressure gauge.

 Service Information

Document Title: Function Group: Information Type: Date:

Brake system, bleeding 520 Service Information 2014/3/24
Profile:
WLO, L120E [GB]

Brake system, bleeding

Op nbr 52037

Plastic hose, inside diameter approx. 6 mm (0.236 in), length approx. 1 m (3 ft)

The brake system is divided into two circuits which implies that if only one circuit has been opened (a line has been
disconnected, etc.), only that circuit requires bleeding.

WARNING
Oil under high pressure!

1. Check the oil level in the hydraulic oil tank.

2. Fully depress the brake pedal and hold it in position with a suitable tool.

3. Start the engine and run it at idling speed.

4. Make sure the parking brake is applied.

5. Connect the plastic hose and carefully open the bleeder screw. Close the bleeder screw when oil free from air flows
out.

Figure 1
Bleeding brakes

1. Plastic hose
2. Bleeder screw

6. Turn off the engine. Adjust the oil level in the hydraulic oil tank.

7. Check function.
 Service Information

Document Title: Function Group: Information Type: Date:

Foot brake valve, 525 Service Information 2014/3/24
description
Profile:
WLO, L150E, L120E, L180E, L60E, L110E, L70E, L330E, L90E, L50E, L220E [GB]

Foot brake valve, description

The foot brake valve is of the proportional type, which means that the output brake pressure is proportional to the pedal
angle. The valve is divided into two circuits, one for the brakes on the front axle and one for the brakes on the rear axle. The
maximum brake pressure can be adjusted by altering the stroke on the pedal.

Figure 1

1 Piston
2 Adjusting screw, pressure
3 Security seal
4 Adjusting screw, pedal free travel
5 Checking point
SE310 Sensor, stop lights
SE501 Sensor, output brake pressure / transmission declutch

Brakes not applied

When the brake pedal is not actuated, return springs (3, 4) hold spools (1, 2) in position, so that BR1 and BR2 have
connection to tank (T). The connection between pressure ducts (SP1, SP2) and the ducts for output brake pressure (BR1, BR2)
is closed.
Figure 2
Brakes not applied

1 Spool, rear circuit (L50— T Connection to tank

L120E, L330E)
front circuit (L150—L220E)
2 Spool, front circuit (L50— BR1 Output brake pressure
L120E, L330E)
rear circuit (L150—L220E)
3 Return spring, rear circuit BR2 Output brake pressure
(L50—L120E, L330E)
front circuit (L150—L220E)
4 Return spring, front circuit SP1 Input brake pressure from
(L50—L120E, L330E) accumulator block
rear circuit (L150—L220E)
5 Piston, actuated by the pedal SP1 Input brake pressure from
accumulator block
6 Return spring, pedal

Brakes partly applied

If the brake pedal is pressed down slightly, piston (5) actuates the spring (6). The spring force presses spools (1, 2) down and
close the connection to tank. Oil from pressure ducts (SP1, SP2) can flow to the brakes through the ducts for output brake
pressure (BR1, BR2). The brakes are applied and the pressure increases in ducts BR1 and BR2. When the pressure
corresponds to the power that the brake pedal exerts on spring (5) this helps return springs (3, 4) in actuating spools (1, 2).
The flow to the brakes is interrupted and a brake pressure is obtained that corresponds to the distance the brake pedal was
depressed (spring force).
Figure 3
Brakes partly applied

Full brake application

The brake pedal movement is limited by the adjusting screw. This means that the maximum brake pressure is limited to a
limit value for the respective machines, see 525 Brake valve, specifications. When the brake pedal is pressed right down the
spring force from spring (6) increases and this actuates spools (1,2). The connection between pressure ducts (SP1,SP2) is
opened and the oil is conducted to the brakes via the ducts for output brake pressure (BR1, BR2). The pressure in the ducts
increases and when it corresponds to the maximum output brake pressure it, together with return springs (3, 4), actuates
spools (1,2). Again the oil flow to the brakes is closed and maximum output brake pressure (limited by the adjusting screw) is
obtained.
Figure 4
Full brake application
 Service Information

Document Title: Function Group: Information Type: Date:

Foot brake pedal, adjusting 525 Service Information 2014/3/24
angle and pedal clearance
Profile:
WLO, L120E [GB]

Foot brake pedal, adjusting angle and pedal clearance

Op nbr

1. Remove the foot brake pedal in order to be adjust the pedal angle.

2. Move the bolt under the pedal in order to adjust the pedal to a 35°, 40°, 45° or 50° angle. Pos. A corresponds to a
45° pedal angle.

Figure 1
Adjusting foot brake pedal angle

3. Adjust the “free pedal travel” by turning the adjusting screw (B) until the clearance between the brake pedal (1) and
the piston (2) is 0.4 ±0.2 mm (0.0157 ±0.0078 in).
 Service Information

Document Title: Function Group: Information Type: Date:

Foot brake valve removed, 525 Service Information 2014/3/24
reconditioning
Profile:
WLO, L50E, L60E, L120E, L90E, L330E, L220E, L180E, L110E, L70E, L150E [GB]

Foot brake valve removed, reconditioning

Op nbr 525-009

Dismantling

Figure 1

1. Remove the pedal rubber and remove the pedal together with the attaching plate as one unit (1).

2. Secure the valve housing in a vice. Remove sleeve (2).

NOTE!
 Clamp the valve housing across the narrow sides.

3. Remove the springs and spring guide (3). Remove the valve housing from the vice.

4. Remove pushrod (4).

5. Remove plug (5) together with the testing nipple.

Remove spring (9), piston (8), spring (7) and piston (6).

6. Remove seal ring (A) and bushes (B) from sleeve (2).
Use a Ø 2 mm (0.08 in) pointed steel wire as a tool when removing the bushes.
Remove O-rings (D) and (E).

7. Clean and inspect with regard to damage or wear. Replace damaged or worn parts.

Assembling

8. Secure sleeve (2) in a vice, with the threaded part upward.

9. Install a new bush (B). Coat the bush with grease.

10. Turn the sleeve in the vice. Install a new bush (B) and a new seal ring (A). Coat the seal ring and the bush with
grease.
Install pushrod (4).
NOTE!
If the pushrod has been dismantled, coat the threads on the bolt with locking fluid medium before assembling.

11. Install a new O-ring on plug (5). Lubricate the O-ring with clean hydraulic oil.

12. Secure the valve housing in the vice, with the hole for the sleeve facing upward. Install piston (6), the shorter spring
(7), the piston (8), the longer spring (9) and plug (5), from underneath.
Tightening torque, plug: 60 N m (44 lbf ft).

13. Install the spring guide and springs (3).

14. Lubricate with oil and install a new O-ring on the sleeve. Coat the threads on the sleeve with locking fluid medium
and install it in the valve housing.
Tightening torque: 60 N m (44 lbf ft).

15. Check that it is possible to press down the pushrod a bit by hand, and that it springs back.

16. Install the pedal on the valve.

Tightening torque, attaching bolts: 30 N m (22 lbf ft).

17. When the foot brake valve has been installed in the machine, carry out 520 Brake system, bleeding,
520 Checking and adjusting pressure in circuit and possibly 525 Brake pedal, adjusting angle
 Service Information

Document Title: Function Group: Information Type: Date:

Accumulator, checking 527 Service Information 2014/3/24
(removed)
Profile:
WLO, L120E [GB]

Accumulator, checking (removed)

Op nbr 52701

11666019 Pressure gauge 0–6 MPa (0–60 bar) (0–870 psi)

11666041 Pump
11666037 Hose
E 1234 Nipple
E 1281 Nipple

NOTE!
All work on the brake system must be conducted in the cleanest possible conditions. Wipe clean all pipe and hose
connections before they are disconnecting. Plug all pipes, hoses and similar equipment immediately after disconnecting.

If the functional check of the brake system indicates that one or more accumulator has insufficient precharge pressure or
lacks precharge pressure, check each accumulator as follows:
Removing

1. WARNING
An accumulated pressure remains in the brake system even if the engine has been stopped. If the system is
opened without first releasing the pressure, oil under high pressure will jet out.

Release the brake system pressure by depressing the brake pedal repeatedly (30–40 times).

2. Carefully remove the connection pipes to the accumulators and plug the connections.

NOTICE
There may be a residual pressure in the brake system.

3. Remove the accumulators.

Pressure checking

4. Check the accumulators one at a time.

 Figure 1
Checking removed accumulator

A. Accumulator

1. 11666041
2. 11666037
3. E 1234
4. 11666019
5. Included in 11666037
6. E 1281

5. Pump oil into the accumulator.

After a few pump strokes, the pressure will increase rapidly to the precharge pressure and will continue to increase
slowly.
Precharge pressure: min. 3.5 MPa (507.5 psi)
If the precharge pressure is below 3.5 MPa (507.5 psi), the accumulator must be discarded, see Discarded
accumulators.

Installing

6. Install the accumulators.

7. Start the engine and let it run at increased rpm until the unloading (cut-out) pressure is 13.4–14.0 MPa (134–140
bar) (1943–2030 psi).

8. Check function according to 520 Brake system, checking hydraulic function.

 Service Information

Document Title: Function Group: Information Type: Date:

Discarded accumulators 527 Service Information 2014/3/24
Profile:
WLO, L120E [GB]

Discarded accumulators
Op nbr

WARNING
A discarded accumulator which is not punctured may still contain high pressure and must always be handled with
great care.

1. WARNING
Use safety glasses.

Accumulators that are to be discarded must not constitute a hazard.

This is completed by carefully puncturing the accumulator with a Ø3 mm (0.118 in) drill.

Figure 1
Accumulator

A. Drill here with a Ø3 mm (0.118 in) drill

1. Nitrogen gas space

2. Rubber diaphragm
3. Connection for oil
 Service Information

Document Title: Function Group: Information Type: Date:

Parking brake, description 550 Service Information 2014/3/24
Profile:
WLO, L120E [GB]

Parking brake, description

The parking brake is a disc brake located in the transmission on the output shaft. The brake is operated hydraulically.
Pressure oil from the accumulator block flows to the parking brake valve MA501 and then to the parking brake for release.

Figure 1

1. Switch SW501, parking brake

Application of the parking brake takes place with spring pressure, and this takes place every time the engine is stopped
(ignition key in position 0) or when switch SW501, to the left on the instrument panel, is activated.
When the engine is started again, the parking brake must be released by making sure that switch SW501 is in position 1
(applied parking brake) and then moved to position 0 (released parking brake).

Figure 2
Parking brake (principle illustration)

1. Plug (3 pcs.)

Parking brake, electrical system, description

See wiring diagram 15B.Released parking brake: SW501 (p-brake switch) supplies voltage to pin P2.15, I-ECU.
Solenoid valve MA501 is supplied with voltage by V-ECU, pin EC4.
Pin EA9, V-ECU, is supplied with voltage if SE503 is pressurized (p-brake released), and the control light goes off. When
SE503 is pressurized, the current to the light in SW501 is cut off, and thus only provides a guide light with the current via
FU15 and the integrated resistor.
The parking brake is released if:
  P-brake switch is set to position RELEASE P-brake, for at least 0.2 sec, diesel engine running and gear in neutral
position.
 The machine has been off, the P-brake is applied automatically.
Diesel engine >1600 rpm and gear (F/R) engaged and P-brake switch is in position RELEASE P-brake.

NOTE!
In all other cases, the parking brake is applied.

WARNING
Applied
Parking brake

Figure 3

Applied parking brake, diesel engine running and directional gear engaged gives the following:

 - Control light parking brake is on

 - Red central warning
 - Warning shown on information display unit
 - Buzzer sounds

Figure 4
Wiring diagram 15B
 Service Information

Document Title: Function Group: Information Type: Date:

Parking brake, mechanical 550 Service Information 2014/3/24
release
Profile:
WLO, L120E [GB]

Parking brake, mechanical release

If the engine cannot be started, or if it for any other reason is not possible to build up pressure for releasing the parking
brake, it can be released mechanically.
Mechanical release is done by removing three plugs, see figure, and temporarily replacing these with three (M10 x 90 mm)
bolts and washers, (the bolts are included in the machine"s tool bag). These long bolts should be tightened alternately until
they bottom in order to release the parking brake.
NOTE!
This must only be done to enable towing. Immediately after towing has been completed, the long bolts should be removed
and the ordinary plugs be re-installed.

Figure 1
Parking brake (principle diagram)

1. Plug (3 pcs)
 Thank you for your purchase.
Have a nice day.

file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/3/24 15:38:56]