Linde Heavy Trucks

Division
Service Training 357-05

Linde Material Handling

Brake System Operation

 Linde Material Handling

357-05 Brake System Operation

357-05
 Linde Material Handling

357-05 Brake System Operation

Brake System : the components

 Linde Material Handling

357-05 Brake System Operation

Explanation of Brake Hydraulic System

After starting of the engine the brake oil pump (3) draws oil via the suction filter (2) out from the brake hydraulic oil tank (1) (Mounted
inside the left-hand side outer chassis module). The oil then passes through the high pressure filter 4 with integrated service warning
switch. After the filter the oil enters the multi-functional charge valve block 5 ( charging, cooling , park brake supply ) and depending
upon the amount of remaining pressure in the system (1 parker piston type accumulators (7) with a 80 Bar pre-charge of nitrogen) the
change over valve 5a (30 recharge setting) is in the filling, recharge or cooling position (the valve is a proportional valve and could be in
positions between the main functions) the spool is controlled by two pilot signals, one signal being spring assisted.
When the pressure in the system reaches 160 bar, the 160 bar change over or max valve 5b will switch to the unload position, the pilot
signal on the spring side of the spool 5a now gets drains back to tank. The spool 5a will move into the max flow and cooling position.
The check valve 8 will lock the charged pressure into the accumulator and the oil flow from the pump will reach the cooler only in free
flow condition (nearly zero bar) and returns back to tank via the multi-disc brake packs. As soon as the system pressure drops (by using
the brake system or internal leakage) the 160 bar valve will again move back to charge position and the pilot signal will building up
pressure, and together with the spring force the pilot signal will move the spool 5a into the recharge position .
The park brake is designed as a fail safe system, as soon as the pressure drops (burst hose or pipe) below 100 bar, the spring loaded piston
(9) will close the parking brake and the low pressure warning switch will energise the central warning light and warning buzzer via the
MDL. By pressing the green electrical switch on the armrest, the park-brake solenoid valve will be energized via the MDL and
pressurised oil will flow from the accumulator (7) to the spring loaded park brake piston. The pressure will press the piston against the
spring force of the park brake caliper (9) and the parking brake will release. Parking brake off
By pressing the central service brake pedal, the service brake spool (12) will switch to the open position and oil will flow from the
accumulator (7) to the service brake pistons (18). The delivery pressure is proportional to pedal position, 0 bar (pedal not pressed) to 110
Bar (pedal fully pressed) the pressure in the supply line to the brake pistons will also pressurise the service brake pressure switch (14).
The transmission dump switch is based on the left part of the brake pedal, the switch is a normal electrical closer switch and by pressing
this switch the transmission is switching into neutral.
The cooling circuit consists of a cooler (16) with electric driven fan, operated by a inline temperature sensor ( 55 °) (17). As soon as the
oil reaches 55 ° the cooling fan will start (the system works with a hysteresies of approx 10°). The oil flow, flows from the cooler into the
brake disc chambers and back to the tank. To prevent overheating in the case of a faulty cooling fan or if the brake oil temperature
reaches 70ºc the MDL limits the trucks speed to 5 km/hr.
 Brake system filling phase
1) Tank 100 Ltrs 7 12
2) Suction filter
13
3) Hydraulic pump 19cc
4) High Pressure filter 6
4a) Filter bypass Switch 1
5+5a) Charge valve
5) 130 bar change over valve 6 10
5a
5a) 160 bar max valve
6) Check Valves
7) Accumulator Park & Service Brake
11
8) Park Brake Solenoid Valve
9) Spring type Park Brake Caliper
8

5 Accumulators are empty;

charge valve is in filling position
14

4a
4 1
15
10) Check valve 9
11) System Pressure Transducer
12) Foot brake valve and Potentiometer
14) Service Brake Pressure Transducer 3 16 1
16) Cooler protection relief valve 5 bar
17) Cooler Temp switch for cooling fan 18
19 19
55 ° (High alarm 90º) 18
2
18) Brake pistons in drive axle
19) Brake disc chamber in drive axle
17
1 1
 Brake system fully charged with 160bar
70 12

160bar 13

6
1

6 10
5a

11

Oil return to
tank 8

5 5
3-5 bar
14

4 1
4a 15
9

3 16 1

Brake cooling 18
circuit 19 19
2 18
17
1 1
 Parking brake position “OPEN”
7 12

160bar 13

6
1

6 10
5a

8 11

Oil return to
tank 7

5 5
3-5 bar
14

4 1
4a 15
9

1
3 16

Brake cooling 18
circuit 19 19
2 18
17
1 1
 Service brake is operated
7 12

160bar 14
13

6
1

6 10
5a

8 11

Oil return to
tank 7

11

5 5
3-5 bar
14

4 1
15
9

3 16 1

Brake cooling 18
circuit 19 19
2 18
17
1 1
 Brake system in re-charge modus
7 12

160bar
130bar 13

6
1

6 5a 11

Charge valve is in re-

charging position 8 11

Oil cannot
returns to
7
tank to tank
return

Oil returns
to tank
5 5 5
160bar
130bar
14

4 1
4a 15
9

1
3 16

Brake cooling 18
circuit 19 19
2 18
17
1 1
 Linde Material Handling

357-05 Brake System Operation

Adjusting the charging valve pressures.

After removing the cap nut 1.
1 Loosen nut 2 & adjust setscrew 3 for
the charging pressure. 130 bar

Loosen nut 5 & adjust setscrew 4 for

the maximum pressure. 160 bar

4 5 3 2

PLEASE NOTE:
Screwing adjusters 3 & 4 in (CW) reduces
the pressures.
Screw out (CCW) to increase pressures.
 Linde Material Handling

357-05 Brake System Operation

 Linde Material Handling

357-05 Brake System Operation

SERVICE BRAKE PRESSURE ADJUSTMENT

 Linde Material Handling

357-05 Brake System Operation

 Linde Material Handling

357-05 Brake System Operation

Proportional inching on
100% 100%

Inch position %
Set in MDM
Clutch pressure

Brake pressure
35-40%
0% 100%
Pedal movement
 Linde Material Handling

357-05 Brake System Operation

Proportional inching

Warning: above 5km/h when actuating the accelerator

together with the brake pedal will result in driving
against the brakes & should be avoided.

Causes excessive heat in the braking system.

 Linde Material Handling

357-05 Brake System Operation

Proportional inching off

100% 100%

Inch position %
Set in MDM
Clutch pressure

Brake pressure
35-40%
0% 100%
Pedal movement
 Linde Material Handling

357-05 Brake System Operation

Brake oil cooling.

The brake oil cooler is located on the left hand side of
the truck behind the drivers access steps inside the
chassis.

It uses an electric fan motor, this is operated by a signal

to the relay K2 that comes from the IQAN XS module pin
20 (cab front).

The brake oil temperature sensor R7 is mounted on the

return line at the brake oil tank. This sends the brake oil
temperature information to the IQAN XT2 module pin 37
(chassis LHS).

Fan motor starts at 55C & stops at 44C.

 Linde Material Handling

357-05 Brake System Operation

Measuring the parking & service brake pressure.

On the charging valve for the

A parking brake pressure at point A
Min 130 bar
Max 160 bar
Apply the parking brake & measure

B
On the left hand side of the drive
axle at point B
Max 110 bar
Depress the service brake pedal fully
& measure
 Linde Material Handling

357-05 Brake System Operation

357-05