Service Information

Document Title: Function Group: Information Type: Date:

Hydraulic brake system, 520 Service Information 2014/7/4 0
description
Profile:
EXC, EW140C [GB]

Hydraulic brake system, description

Travel brake
Step 1
When the diesel engine is started, pump 76 supplies oil to brake valve 38. The oil flow passes through priority valve 38:1
and on via non-return valves 38:2, 38:3 and 38:4 to brake accumulators 74 and to valve 38:5, which controls the charging of
the brake system. The charging is controlled via signal lines to both sides of valve 38:5.

Figure 1
Step 1

20 Steering cylinder 77 Rear axle brake 38:1 Priority valve, brake

37 Priority valve, steering 78 Front axle brake 38:2 Non-return valve with spring
38 Brake valve A Servo pressure 38:3 Non-return valve
70 Centre passage B Return pressure 38:4 Non-return valve
74 Accumulator tank for brake C Pump pressure 38:5 Valve, charging accumulators
pressure
76 Pump D Trapped oil

Step 2
The area of the upper signal line on valve 38:5 is larger than the area of the lower signal line. Therefore valve 38:5 opens to
tank when accumulators 74 are fully charged. The pressure in the lower signal line on priority valve 38:1 drops and the
priority valve changes over to the middle symbol, if the steering is not actuated (draining to tank via port EF in steering valve
37). If the steering is actuated, the pressure in the upper signal line on priority valve 38:1 increases and the upper symbol is
engaged. The pump flow goes directly to the steering without passing through any restrictions.

Figure 2
Step 2

20 Steering cylinder 76 Pump C Pump pressure

37 Priority valve, steering 77 Rear axle brake E Raised return pressure
38 Brake valve 78 Front axle brake 38:1 Priority valve, brake
70 Centre passage A Servo pressure 38:5 Valve, charging accumulators
74 Accumulator tank for brake B Return pressure
pressure

Step 3
When the brake pedal is depressed, oil flows to both circuits T2 for the rear axle and T1 for the front axle. The pressure in
accumulators 74 and on top of valve 38:5 drops. When the pressure has dropped to below 11.5 MPa (1668 psi, 115 bar),
valve 38:5 changes position and the accumulators will begin to be charged again.
The signals from pressure sensor SE5201 and pressure monitors SE5205 pass via the machine control unit V-ECU.
Figure 3
Step3

20 Steering cylinder 76 Pump C Pump pressure

37 Priority valve, steering 77 Rear axle brake E Raised return pressure
38 Brake valve 78 Front axle brake 21:1 Pendulum axle
70 Centre passage A Servo pressure 38:5 Valve, charging accumulators
74 Accumulator tank for brake B Return pressure 38:6 Brake pedal
pressure

Digging brake
Mechanical locking
When the brake pedal 38:6 is depressed the pressure in the brake circuit reaches 0,5 MPa (72,5 psi, 5 bar), the brake lights
light up via pressure sensor SE5201 and brake light relay RE5201. When the pedal is locked with the catch 38:7 and the
brake pressure increases further to 4–5 MPa (580–725 psi, 40–50 bar) a signal from sensor SE5201 send's to the vehicle
control unit V-ECU and activate a “timer”. After two minutes' cut the voltage between V-ECU and the relay RE5201 which
result the brake lights LA5201 and LA5202 turnoffs.
Figure 4
Brake pedal with mechanical locking

38:6 Brake pedal

38:7 Catch

Figure 5
Hydraulic and electric sub-diagram

38 Brake valve 38:7 Catch RE5201 Relay brake lights

74 Accumulator tank for brake LA5201 Brake light, right SE5201 Pressure sensor brake
pressure
38:6 Brake pedal LA5202 Brake light, left V-ECU Vehicle control unit

Safety regulations

Figure 6
Symbols

LC3803 Central warning

LC5201 Brake pressure low

Basically:
If the pressure in the accumulators drops to below 8.0 MPa (1160 psi, 80 bar), this will be indicated on the instrument control
unit I-ECU via pressure monitor SE5205. The symbol LC5201 show's on the main screen, the central warning lamp LC3803
lights up and the buzzer sounds when the engine is running.
Function check:

 Charge accumulators then switch off engine and turn the ignition key to position ignition on.
  Depress the brake pedal until the pressure drops to the charging point of 11.5 MPa (1668 psi, 115 bar).
 After that depress the brake pedal twice at full stroke and the warning lamp on IECU must not light up.
 Remaining pressure must be > 8.0 MPa (1120 psi, 80 bar).
 Depress the brake pedal now slowly further until the warning lamp lights up. Then it must be possible to perform
four (4) full brake applications. At the fifth time there must be a minimum pressure of > 5.8 MPa (841 psi, 58 bar),
see 910 Hydraulic pressure, specifications. During full brake applications, the pedal must be pressed down
completely and then released. Between each application of the brake pedal there should be a regeneration time of
approx. 60 seconds.

Function check: brake lights and axle lock

If the pressure in the brake circuit increases to 0,5 MPa (72,5 psi, 5 bar), the brake lights light up via pressure sensor SE5201.
If the pressure increases further to 6.0 MPa (870 psi, 60 bar), pendulum axle 21:1 will be locked via pressure sensor SE5201
and the solenoid for axle locking MA9152 (without voltage).
 Service Information

Document Title: Function Group: Information Type: Date:

Service brakes, function 520 Service Information 2014/7/4 0
check
Profile:
EXC, EW140C [GB]

Service brakes, function check

Op nbr 510-005

After repair work has been completed in any of the system related hydraulic circuit, a function check must be performed as
described below:
Preconditions

 Function test must only be done within an area where it cannot cause accidents, neither to people nor to other
things.
 Function test must be done on dry horizontal asphalt, dry horizontal concrete or similar horizontal surfaces.
 Machine must not be loaded.
 Door must be closed and fasten seat belt before driving and operating the function.

1. Start the engine and leave the control lock out lever down in locked position.

2. Apply the brake pedal several times and check the loading function of brake accumulators.

3. Check the brake pressure, see 520 Brake system checking and adjusting

4. Operate the machine in forward direction in 1. gear and check if there is full brake application when pressing the
brake pedal against the stop. Ensure that the brakes stop the machine.

5. Inspect the brake system for leaks and damaged components.

6. Check also if any error messages are shown related to this system.
NOTE!
When operating the machine always observe the valid local traffic and safety regulations and, if necessary, make
sure beforehand that the machine is in a condition compatible with these regulations.
 Service Information

Document Title: Function Group: Information Type: Date:

Electrical digging brake, 520 Service Information 2014/7/4 0
description
Profile:
EXC, EW140C [GB]

Electrical digging brake, description

This function will lock the brake pedal electro-hydraulically.
Function conditions:

Figure 1
Brake pedal with toggle lever

(38) Electrical digging brake valve

1 Toggle lever

 Use the switch on the right instrument panel to select and apply the electric digging brake.
 Engine is running.
 Control lock out lever in upper position.
 Control mode switch in W- or C-mode.
 The toggle lever (1) must be locked in parallel position (as shown in the picture) to the brake pedal for the electrical
digging to function, otherwise the brake pedal will be locked mechanically.
 Machine is standing still.

NOTE!
Risk of injury, be aware when the electrical digging brake function is activated, the brake pedal works automatically with a
specified power.

Make sure that no parts are lying under the brake pedal what could interfere the brake function.

NOTE!
For VCADS-Pro the following parameter should be activated:

(HXV) Connect electrical digging brake

Figure 2
Electrical digging brake pedal with components

1. Control lock out lever

2. Control mode switch
3. SE4217 Travel pedal sensor
4. SE4213 T/M speed sensor
5. SW5205 Switch for electrical digging brake
6. MA5205 Solenoid for electrical digging brake

General:
When the electrical digging brake is activated via switch SW5205, the brake pedal will lock automatically.
The brake pedal gets automatically unlocked as soon as the travel pedal is applied to start driving, forward or reverse.
The IECU pop up screen appears for 5 seconds after activating or deactivating the switch for electrical digging brake.
The control lamp on IECU displays the current status of the electrical digging brake function:

 Electrical digging brake indicator green: function selected using switch (SW5205).
 Electrical digging brake indicator yellow: solenoid (MA5205) closed and pedal locked.
 Electrical digging brake indicator red: failure.

NOTE!
When the electrical digging brake function is switched off while engine is running the brake pedal will not be released
directly. It takes as long as the travel pedal will be applied to drive forward or reverse.

Schematic overview
Figure 3
Electrical digging brake schematics

Function description
When the engine is running, switch SW5205 is pressed, control lock out lever in upper position, W- or C-mode selected, the
V-ECU activates solenoid MA5205.
The solenoid MA5205 opens and oil flows via an external tube to the brake valve and the pedal will be activated, brakes will
be closed. Simultaneously the axle lock function will be activated. Axle lock function, see 301 Axle lock
When operator starts to drive again, Sensor SE4217 gives signal via V-ECU to solenoid MA5205 and the brake pedal will be
released also the axle lock function will be deactivated.
Sensor SE4213 is located on the transmission and checks if the machine is moving or not. As long as the machine is moving,
electrical digging brake function can not be activated.
Sensor SE5205 (sensor also on standard brake) is checking the brake pressure in the brake system and in case of too low
brake pressure, this sensor gives information for alarm indication on the display and the buzzer sounds.
 Service Information

Document Title: Function Group: Information Type: Date:

Brake system, check and 520 Service Information 2014/7/4 0
adjusting pressure in circuit
Profile:
EXC, EW140C [GB]

Brake system, check and adjusting pressure in circuit

Op nbr 520-005

11666051 Pressure gauge

Check the hydraulic oil temperature, see 900 Hydraulic system, warming up.

WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries

1. Park the machine in optional service position, see 091 Service positions.

2. Checking maximum output brake line pressure

Figure 1
Measuring max. output brake line pressure

T1' Testing nipple, output brake line front axle

T2' Testing nipple, output brake line rear axle
38 Brake (control) valve
SpT Pressure gauge
 Connect the pressure gauge to the test nipples T1' and T2' for the output brake lines.

3. Start the diesel engine.

4. After 10 seconds the accumulators should be fully charged.

5. Press down the brake pedal and read off the brake pressure in lines T1' and T2'.
Nominal value: see max. brake pressure front/rear 910 Hydraulic pressure, specifications.

6. Turn off the diesel engine.

Adjusting maximum output brake line pressure

7.

Figure 2
Adjusting output brake line pressure

1 Adjusting screw
2 Jam nut
38 Brake (control) valve

Loosen the jam nut 2.

8. Adjust the brake pressure with the adjusting screw (1) and tighten the jam nut (2).
NOTE!
To increase the brake pressure, turn the adjusting screw counter clockwise.

Checking minimum output brake line pressure

 9.

Figure 3
Measuring min. output brake line pressure

T1' Testing nipple, output brake line front axle

T2' Testing nipple, output brake line rear axle
38 Brake (control) valve
SpT Pressure gauge

Connect the pressure gauge to the test nipples T1' and T2' for the output brake lines.

10. Start the diesel engine.

11. After 10 seconds the accumulators should be fully charged.

12. Turn off the diesel engine.

13. Press down the brake pedal fully five (5) times and read off the brake pressure in lines T1' and T2'.

14. Nominal value: see min. brake pressure front/rear 910 Hydraulic pressure, specifications.

Actions in case of incorrect minimum output brake line pressure

15. If the pressure drops below the minimum value, it is an indication that there is a fault in the brake system. The fault
may be caused by:

 too low or no pre-charging pressure in one of the accumulators, e.g. because of a faulty diaphragm.
 air in the brake system, see 520 Brake system bleeding.

Checking digging brake pressure, mechanical locking

16.

Figure 4
Measuring digging brake pressure

T1' Testing nipple, output brake line front axle

T2' Testing nipple, output brake line rear axle
38 Brake (control) valve
SpT Pressure gauge

Connect the pressure gauge to the test nipple T1' or T2' for the output brake lines.

17. Start the diesel engine.

18. After 10 seconds the accumulators should be fully charged.

19.

Figure 5
Activated digging brake, mechanical locking

1 Catch
2 Lock pin

Activate the digging brake by pressing down the brake pedal so that the catch (1) hooks onto the lock pin (2).
 20. Read off the value on the pressure gauge.
Nominal value, see digging brake pressure 910 Hydraulic pressure, specifications.

21. Turn off the diesel engine.

Adjusting digging brake pressure, mechanical locking

22.

Figure 6
Adjusting digging brake pressure, mechanical locking

1 Nut
2 Lock pin

Loosen the nut (1) and move down the lock pin (2) for higher pressure, move up for lower pressure. Tighten the nut
(1).
 Service Information

Document Title: Function Group: Information Type: Date:

Brake system bleeding 520 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Brake system bleeding

Op nbr 52037

Drain hose

WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries

NOTE!
Draining oil shall be collected in a container.

1. Block the wheels.

2. Remove the protective cap on the bleeder screw.

Figure 1
Brake bleeder screw

1. Protective cap

3. Connect a cap key on the bleeder screw.

 Figure 2
Drain hose

1. Cap key
2. Drain hose

4. Connect the drain hose on the bleeder screw and the free end of the drain hose in a container.

5. Loose the bleeder screw 1/2 - 3/4 rev.

6. Start the diesel engine and press down the brake pedal until oil free of air flows out (about two-three litres).

7. Tighten the bleeder screw when the brake pedal is pressed in bottom.

8. Stop the diesel engine.

9. Remove the drain hose and cap key.

10. Refit the protective cap on the bleeder screw.

11. Repeat the steps for all wheels.

 Service Information

Document Title: Function Group: Information Type: Date:

Foot brake valve, replacing 525 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Foot brake valve, replacing

Op nbr 525-008

14360000 Vacuum pump / 24V

WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries

NOTE!
Draining oil from hoses and connections shall be collected in a container.

Disconnected hoses shall be plugged.

Brake valve, removal

1. Place the machine in adequate service position, see 091 Service positions and install wheel chocks in front and
behind the tires.

2. Depressurize the brake and hydraulic system, see 191 Safety when working with hydraulic systems

3. Connect the vacuum pump, see 900 Vacuum pump, connection.

4. Remove the rubber mat on the cab floor.

5. Remove the foot pedal (1).

Figure 1
Brake pedal removal

1. Foot pedal
2. Bolt
3. Nut

6. Remove the protection plate on the superstructure under the cab.

 Figure 2
Removing protection plate

1. Protection plate.

7. Disconnect hydraulic hoses from the brake valve.

NOTE!
Mark hydraulic hoses before disconnecting.

8. Disconnect the cable connections from the foot brake valve sensors.

9. Remove the brake valve's attaching bolts (1) and the latch pin stirrup and also remove the valve.

Figure 3
Fastener bolts on brake valve

10. Transfer the hose connections, the measuring nipples and the sensor to the new brake valve.

Brake valve, installation

11. Install the brake valve and the latch pin stirrup and mount the bolts.
 Figure 4
Fastener bolts on brake valve

12. Connect hydraulic hoses to the valve and cables to the sensors.

13. Remove the vacuum pump, see 900 Vacuum pump, disconnection.

14. Install the foot pedal (1).

Figure 5
Installation of brake pedal

1. Foot pedal
2. Bolt
3. Nut

15. Adjustment of foot pedal's angle:

1. Measure angle and correct if necessary to 38° on rear adjusting screw (2).
 Figure 7
Adjusting screws

1. Front adjusting screw.

2. Rear adjusting screw.

2. Readjust the front adjusting screw (1) until it contacts the foot pedal.

16. Adjust mechanical locking catch (1) with lowest possible space to lock pin (2) in order to get the highest brake
pressure when pedal is hooked.

Figure 8
Activated digging brake, mechanical locking

1. Catch
2. Lock pin

17. Refit the rubber mat.

18. Start the diesel engine and check for leaks.

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

20. Check the brake pressure according to 520 Brake system checking and adjusting
 Service Information

Document Title: Function Group: Information Type: Date:

Brake accumulator, 527 Service Information 2014/7/4 0
description
Profile:
EXC, EW140C [GB]

Brake accumulator, description

See, 914 Pressure accumulator, description.
 Service Information

Document Title: Function Group: Information Type: Date:

Discarded accumulators 527 Service Information 2014/7/4 0
Profile:
EXC, EW140C [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 (1.18 in) drill.

Figure 1
Accumulator

A. Drill here with a Ø3 mm (1.18 in) drill

1. Nitrogen gas space

2. Rubber diaphragm
3. Connection for oil
 Service Information

Document Title: Function Group: Information Type: Date:

Brake accumulator 527 Service Information 2014/7/4 0
charging pressure,
adjusting
Profile:
EXC, EW140C [GB]

Brake accumulator charging pressure, adjusting

Op nbr 527-014

88830055 Pressure checking set

WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries

1. Warm up hydraulic oil to operating temperature, see 900 Hydraulic system, warming up.

2. Place the machine in service position F, see 091 Service positions.

3. Secure the machine against roll away.

4. Connect pressure gauge to port PB.

5. On the pressure gauge select display mode for max. pressure measuring.

Figure 1
Special tool pressure gauge connected on port PB

1. Port PB
2. Display mode for max. pressure
3. Special tool 88830055, pressure gauge

6. Remove cover plate (1) under cabin.

 Figure 2
Cover plate under cabin

7. Start the engine and run in low idle.

8. Delete previous min. and max. values on the pressure gauge.

9. Press digging brake pedal at least three times down and wait approx. 20s.

10. Stop the engine.

11. Read off the max. pressure value on the pressure gauge and compare with pressure from the specification, see
910 Hydraulic pressure, specifications

12.

Figure 3
Brake valve with accumulator
1 Protection cap
2 Adjusting screw
3 Lock nut
38 Brake valve
74 Brake accumulator
Remove cap (1) from adjusting screw (2).

13. Loosen the lock nut (3) and turn adjusting screw (2).
Turn the adjusting screw clockwise to lower or counterclockwise to raise the pressure.
Tighten the lock nut (3).
 NOTE!
½ revolution corresponds to approx. 5 bar.

14. Install cap (1) on adjusting screw.

15. Repeat steps 7-14 until the required pressure value is adjusted.

16. Install cover plate under cabin.

 Service Information

Document Title: Function Group: Information Type: Date:

Parking brake, description 550 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Parking brake, description

General
The parking brake is a negative-action disc brake integrated in the gearbox. Negative brake action means that the brake is
applied using spring force.
The parking brake is activated either by selecting position P on the mode selector switch SW3611 in the operator's cab or
automatically when the diesel engine is stopped and the start key is in position 0 or when the safety lever is in locked (down)
position.
There is one multi-disc clutch LK and one multi-disc brake LB in the gearbox. The clutch locks the input shaft 2 and the sun
gear 2:c to the ring gear 2:a. The brake locks the ring gear 2:a to the transmission housing 9. The clutch and brake are
applied by force from the cup springs 1 and the shaft cannot rotate, which means that the parking brake is activated.

Figure 1
Gearbox 2 HL 250/270/290, cut away view
1 Cup springs 2:a Ring gear LB Multi-disc brake
2 Input shaft 2:c Sun gear LK Multi-disc clutch
9 Transmission housing

Parking brake activated

When the parking brake is activated, solenoid valves for low and- high gear MA4302, MA4303 does not receive any
voltage. The middle symbol in the gearshift valve 75:b engages and the control pressure goes to the valve's blocked port.
Since the pressure in the brake and- clutch piston's chambers 9:LB, 9:LK are drained to tank, the multi-disc brake LB and
multi-disc clutch LK are compressed and the parking brake is activated.

Figure 2
Oil circuit diagram for gearbox with parking brake activated

9 Gear box transmission 75 Valve block 9:LB Brake piston chamber

10 Travel motor 76 Servo pump 9:LK Clutch piston chamber
40 Servo block LB Multi-disc brake A Servo / control pressure
65 Hydraulic oil tank LK Multi-disc clutch B Return pressure
70 Centre passage 75:a Pressure valve C Suction line lube oil pump
75:b Gearshift valve D Trapped oil

Parking brake deactivated

When the parking brake is released, solenoid valve MA4302 or MA4303 receives voltage and the left or right symbol
applies. The control pressure goes to either the brake or clutch piston's chambers 9:LB, 9:LK and at this time either the
brake or clutch LB, LK is open, i.e hydraulically released and the parking brake is deactivated.
Figure 3
Oil circuit diagram for gearbox with parking brake deactivated in creep speed

9 Gear box transmission 76 Servo pump 9:LK Clutch piston chamber

10 Travel motor LB Multi-disc brake A Servo / control pressure
40 Servo block LK Multi-disc clutch B Return pressure
65 Hydraulic oil tank 75:a Pressure valve C Lubrication oil, transmission
70 Centre passage 75:b Gearshift valve D Lubrication pressure
75 Valve block 9:LB Brake piston chamber E Suction line lube oil pump
 Service Information

Document Title: Function Group: Information Type: Date:

Parking brake, function 550 Service Information 2014/7/4 0
check
Profile:
EXC, EW140C [GB]

Parking brake, function check

Op nbr 550-023

After repair work has been completed in any of the system related hydraulic circuit, a function check must be performed as
described below:
Preconditions

 Before checking the parking brake the function of the service brake must be verified.
 Function test must only be done within an area where it cannot cause accidents, neither to people nor to other
things.
 Function test must be done on dry asphalt, dry concrete or similar surfaces.
 Machine must not be loaded.
 Door must be closed and fasten seat belt before driving and operating the function.

1. Drive the machine onto an incline with at least a 20% grade.

2. Turn the mode selector switch to position P-mode, park position.

3. Release the service brakes. The parking brake should hold the machine stationary.

4. Check the function of the parking brake indicator lamp to verify proper operation.

5. Check also if any error messages are shown related to this system.
NOTE!
When operating the machine always observe the valid local traffic and safety regulations and, if necessary, make
sure beforehand that the machine is in a condition compatible with these regulations.
 Service Information

Document Title: Function Group: Information Type: Date:

Manual release of parking 550 Service Information 2014/7/4 0
brake
Profile:
EXC, EW140C [GB]

Manual release of parking brake

Op nbr 550-015

Activate the emergency actuation on the gearbox

WARNING
Block the wheels to prevent accidental machine movement.

1. Turn off the diesel engine.

2. Press in grease in the grease nipple 2 by a grease gun pump until it comes out at the pressure relief valve 1.

Figure 1
Activate the emergency actuation

1 Pressure relief valve

2 Grease nipple
9 Gearbox
10 Travel motor

Deactivate the emergency actuation on the gearbox

3. Open (loose) the bleeder nipple 3.

4. Start the diesel engine and select on-road gear (high speed).
(Too release the emergency system from grease must a control pressure of 30–35 bar applied.)

5. Close (tighten) the bleeder nipple 3.

6. Collect the grease and clean around the nipple.

Figure 2
Deactivate the emergency actuation

3 Bleed nipple
9 Gearbox
10 Travel motor
 Thank you for your purchase.
Have a nice day.

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