Doosan Dl Hydraulic Training 2j351b

Slide 1

4. Brake system 4.0 Brake system 4.1 Brake pedal valve 4.2 Axle 4.3 Parking brake

C/S Team

Slide 2

4.0 Brake system - Brake system logic

Brake valve

Brake pilot supply valve

Pump

Brake actuator C/S Team

Slide 3

4.0 Brake system - Brake system

1. Brake pedal valve 2. Brake, pilot & fan motor supply valve 3. Accumulator (3 Brakes) 4. Accumulator (1 Pilot) 5. Brake pump 6 Brake filter 7 Parking brake 8 Rear axle 9 Front axle

C/S Team

Slide 4

4.0 Brake system - DL160 Brake Supply System

C/S Team

The DL160 uses a brake & pilot supply valve that is unique to this model.

Slide 5

4.0 Brake system - DL160 Brake / Pilot & Fan Supply Valve

C/S Team

This valve is unique to the DL160 in that it has a pressure reducing valve that limits the maximum pressure to the parking brake release to 30 bar.

TP1 – Remote pilot pressure test port (28 bar, controlled by cartridge C2) TP2 – Remote brake pressure charging pressure (140 bar, controlled by cartridge C1) Slide 6

4.0 Brake system - DL200 Brake / Pilot & Fan Supply Valve

C/S Team

This valve is unique to the DL200.

Slide 7

4.0 Brake system - DL200 Brake / Pilot & Fan Supply Valve

C/S Team

This valve is unique to the DL200 in that it has a pressure reducing valve that limits the maximum pressure to the parking brake release to 60 bar. TP1 – Remote pilot pressure test port (28 bar, controlled by cartridge C2) TP2 – Remote brake pressure charging pressure (80 bar, controlled by cartridge C1)

Slide 8

4.0 Brake system - Hydraulic system (Brake / Pilot & Fan Supply) Brake valve

Brake actuator

Parking brake Pilot pump Pilot filter

Joystick lever

Fan motor Brake pilot supply valve C/S Team

This valve is used on: DL300

5001~

DL400

5001~5120

DL350

5001~

DL500

5001~5025

Slide 9

4.0 Brake system - Brake / Pilot & Fan supply valve (I)

① : Sequence valve - C1 (120 bar) ② : Reducing valve - C2 (28 bar) ③ : Relief valve - C6 (190 bar) ④ : Check valve – C3-1 ⑤ : Pilot cut off solenoid valve - C4 ⑥ : Parking brake release solenoid valve – C5 ⑦ : Low pressure warning switch (65bar) ⑧ : Parking brake warning switch (65 bar)

C/S Team

Slide 10

4.0 Brake system - Brake / Pilot & Fan supply valve (II)

C1 : Sequence valve ( 120 bar)

C2 : Pressure reducing valve ( 28 bar)

C3 : Check valves

C4 : Pilot cut off solenoid valve

C5 : Parking brake release solenoid valve

C6 : Relief Valve ( 190 bar)

A1 : Low pressure warning switch

PK : Parking brake release warning switch C/S Team

Slide 11

4.0 Brake system - Brake / Pilot & Fan supply valve system pressure

28 bar

120 bar

Brake charging pressure : 120 bar, pilot pressure : 28 bar C/S Team

Slide 12

4.0 Brake system - Hydraulic system (No Fan Supply) Brake valve

Brake actuator

Pilot filter Parking brake

Joystick lever Pilot pump Brake pilot supply valve C/S Team

This system was introduced when the separate cooling fan pump was introduced: DL400

5121~

(At 5502 a new pilot solenoid valve was introduced)

DL420

5001~

(Always had the new type pilot solenoid)

DL450

5001~

(Always had the new type pilot solenoid)

DL500

5026~

(At 5061 a new pilot solenoid valve was introduced)

The early type solenoid valves caused a delay in activating the parking brake, but all machines built with these should have been reworked under a recall campaign.

Slide 13

4.0 Brake system - Brake / Pilot supply valve (I)

5

1 : Priority valve - C10

2

2 : Unloading valve – C6 (120~140 bar) 3 : Relief valve – C12 (190 bar)

1 4

4 : Relief valve – C7(30 bar) 3

5 : Check valve – C1 / C2 / C3 / C4 / C5 6 : Pilot cut off solenoid valve - C8

5

7 : Parking brake release solenoid valve – C9

7

8 : Low pressure warning switch (65bar) 9 : Parking brake warning switch (65 bar)

5

6

C/S Team

Slide 14

4.0 Brake system - Brake / Pilot supply valve system pressure

120 bar

30 bar

Brake charging pressure : 120 bar, pilot pressure : 28 bar C/S Team

Slide 15

4.1 Brake pedal valve

4.1 Brake pedal valve

C/S Team

Slide 16

4.1 Brake pedal valve - Brake valve (I)

C/S Team

Slide 17

4.1 Brake pedal valve - Brake valve (I)

Model

Supply Pressure (P1, P2)

Secondary Pressure (BR1, BR2)

Minimum

Maximum

Neutral

DL160

140 Bar

200 Bar

Tank

Fully Applied 40 ± 5 Bar

DL200

80 Bar

150 Bar

Tank

45 ± 5 Bar

DL250

120 Bar

150 Bar

Tank

60 ± 5 Bar

DL300

120 Bar

190 Bar

Tank

60 ± 5 Bar

DL350

120 Bar

190 Bar

Tank

60 ± 5 Bar

S/No 5001 ~5120 S/No 5121 ~

120 Bar 120/140 Bar

190 Bar

Tank

80 ± 5 Bar

DL420

120/140 Bar

190 Bar

Tank

80 ± 5 Bar

DL450

120/140 Bar

190 Bar

Tank

80 ± 5 Bar

DL500

120/140 Bar

190 Bar

Tank

60 ± 5 Bar

DL400

C/S Team

Slide 18

4.1 Brake pedal valve - Brake valve (II)

①

1. Stop lamp switch (5.0 bar) - This switch works the brake lights

2. Transmission cut off switch (25.0 bar) - When the operator selects the transmission cut off function, this switch gives signal to the transmission controller (EST 37A), to shift the transmission in to neutral

②

C/S Team

Slide 19

4.1 Brake pedal valve - Brake actuator

C/S Team

Slide 20

4.1 Brake pedal valve

Items To Check On The Brake Pedal Valve:

3

In the pedal release position: 2 1

1.

Clearance between Cam & Dome.

2.

Dirt build up around heel of pedal.

3.

The tightness of the bolt to the dummy pedal link.

In operation: 1.

The maximum pressure at the axle is set by the travel of the brake pedal valve.

C/S Team

In the released position there MUST be a clearance between to Cam & Dome Build up of dirt around the pedal can prevent the pedal fully releasing the brakes. The bolt connecting the dummy pedal link to the pedal MUST not clamp the 2 parts together, but must allow some movement.

Slide 21

4.2 Dana Axles

Dana Type

Machine Model

176/318

DL160 Front

176/319

DL160 Rear

176HD/324

DL200 Front

176/326

DL200 Rear

176HD/325

DL200 Front (LSD option)

176/327

DL200 Rear (LSD option)

C/S Team

The LSD option axles for the DL200 are listed in the “option” section of the parts book as “Axle & Drive Shaft-Super Max. Trac”

Slide 22

4.2 Axles Model DL160

Maker Dana

DL200

Dana

DL250

ZF

DL300

ZF

DL350

ZF

DL400 DL420 DL450

ZF

DL500

ZF

ZF

Front Front Rear Front Rear Front Rear Front Rear Front Rear Front Rear Front Rear Front Rear Front Rear

Rear TPD TPD TPD TPD LSD LSD LSD LSD LSD LSD LSD LSD LSD LSD LSD LSD LSD LSD

Ratio

Comments

45% 45% 45% 45% 45% 45% 30% 45% 30% 45% 30% 45% 45% 45%

Option Option

C/S Team

Slide 23

4.2 Dana Axles

C/S Team

Slide 24

4.2 Dana Axles

With the brakes fully applied measure the distance between 2 adjacent intermediate steel discs Minimum permitted thickness is 4.5mm C/S Team

Slide 25

4.2 Dana Axles - Front Axle Brake Adjustment

1.

Chock the machine to prevent it from rolling

2.

Release the parking brake

3.

Remove bolt & Locking Plate

4.

Apply brakes & hold brakes with 25 ~35 bar

5.

Turn square adjuster counter clockwise till it stops (8 Nm)

6.

Adjust gap by turning clockwise 3 complete turns.

7.

Release pressure from brakes & refit Locking Plate & bolt.

C/S Team

To release the parking brake the “Starter Switch” must be “On” & the “Parking Brake Accumulator” charged, but the engine does not need to be running.

Slide 26

4.2 Dana Axles - Rear Axle Brake Adjustment

C/S Team

Slide 27

4.2 Dana Axles - Rear Axle Brake Adjustment

1.

Release the lock nuts on each of the 3 adjusters (Equally spaced at 120°)

2.

Turn the adjusters counter clockwise until they stop

3.

Turn the adjusters back ¾ turn (equal to 0.75mm clearance)

4.

Retighten the lock nuts

C/S Team

Slide 28

4.2 Dana Axles - Emergency Manual Brake Release 1.

Chock the machine to prevent it from rolling

2.

Release the lock nuts, on both sides of the housing

3.

Tighten the adjusting bolts until they stop Parking Brake is now released

4.

To reset it return the adjusting bolts back to a protruding length of 47mm & tighten the lock nuts

C/S Team

Slide 29

4.2 ZF Axles

ZF Type

Machine Model

MTL-3075

DL250 Rear

MTL-3085

DL250 Front DL300 Rear

MTL-3095

DL300 Front DL350 Front & Rear DL400 / DL420 Rear

MTL-3105

DL400 / DL420 Front DL450 Front & Rear

AP420R

DL500 Front & Rear C/S Team

Slide 30

4.2 Z.F. MTL Axles - Exterior view 4 5

4

2 3

1

2 1. Oil drain port for differential

2. Oil drain port for hub reduction

3. Oil filler / level check port

4. Brake oil bleeder

5. Case breather

C/S Team

Slide 31

4.2 Z.F. MTL Axles - Planetary gear and carrier Out put

Brake housing Planetary gear

Planetary carrier Sun gear Ring gear

C/S Team

To replace the brakes you require ZF special tools 5870 912 028 & 5870 656 078 to undo the large retaining nut on the planetary carrier. (This nut must be loosened to only finger tight before removing the brake housing from the machine.)

When refitting the large nut on the planetary carrier it must be tightened to a torque of: MT-L 3095 & 3105

3,000 Nm

(see Z.F. Service Information dated 2007-06-27)

MT-L 3065/3075/3085

2,000 Nm

(see Z.F. Service Information dated 2007-06-27)

Slide 32

4.2 Z.F. MTL Axles

C/S Team

Slide 33

4.2 Z.F. MTL Axles - Brake system (I)

Steel disc Brake piston

High pressure brake oil

Return spring Friction disc

C/S Team

Slide 34

4.2 Z.F. MTL Axles - Brake system (II)

Brake oil

Brake released

Brake applied

C/S Team

Slide 35

4.2 Z.F. MTL Axles - Self adjustment of the brake disc clearance (MTL)

1) When the brake pedal is pressed, the brake piston moves to compress the cup springs and to press on the brake discs. 2) If necessary the snap rings are moved towards the cup springs as the piston presses on the brake discs (This is the self adjusting action). 3) When the brake pedal is released, the brake piston is pushed back by the cup springs (1.5mm).

C/S Team

Slide 36

4.2 Z.F. MTL Axles - Wear limit value

Pressed brake pedal condition Minimum gap (Paper lining) 4.0 mm (Steel to steel disc) Minimum gap (Sintered lining) 3.4 mm (Steel to steel disc)

Released brake pedal condition Maximum gap 1.0 ~2.0 mm (Steel and friction disc)

C/S Team

Slide 37

4.2 Z.F. MTL Axles - Changing brake discs 10.5mm

Original gap

After using gap 1) When changing the friction discs you should also change the steel discs. 2) You MUST also reset the brake pin gap between cup spring and the snap ring to 10.5mm.

C/S Team

To set these correctly you need to use ZF special tool 5870 345 096

Slide 38

4.2 Z.F. MTL Axles - Changing brake discs (Mega 400VFL)

Pins For Paper Type Linings

126

Pins For Sintered Type Linings

125

NOTE: When changing the friction discs material from “Paper Type” to “Sintered Type” you MUST also change the self adjuster pins.

C/S Team

Slide 39

4.2 Z.F. MTL Axles - Maintenance 1. Oil change interval : Every 1000 Hours ( First 500 Hours) 2. Check oil level : Every 1 month 3. Oil grade : See Z.F. List TE-ML05 (www.zf.com/)

- Quantity of brake disc & steel disc (Each output hub) Disc Material

Qty Friction Disc

Steel Discs

DL450 (Front & Rear) DL400 / DL420 Front)

Model

Sintered

8

9 off 2.4mm

DL400 / DL420 (Rear) DL350 (Front & Rear)

Sintered

6

1 off 4.0mm ring gear end

7 off 2.4mm

DL300 (Front)

Paper

5

2 off 2.0 mm (1 each end)

4 off 4.0 mm

DL300 (Rear)

Paper

5

2 off 2.0 mm (1 each end)

4 off 4.0 mm

DL250 (Front)

Paper

4

2 off 2.0 mm (1 each end)

3 off 4.0 mm

DL250 (Rear)

Paper

4

2 off 2.0 mm (1 each end)

3 off 4.0 mm

C/S Team

Slide 40

4.2 Z.F. AP Axles - Exterior view

2

3 1

3 3

1 1. Oil drain port for differential

2. Oil drain port for hub reduction

3. Oil filler / level check port

C/S Team

Slide 41

4.2 Z.F. AP Axles

C/S Team

On the AP420 axles it is possible to change the brake discs without removing the wheels.

Slide 42

4.2 Z.F. AP Axles - Checking brake disc wear

Piston Travel New Maximum Permissible Piston Travel

3.2 ~3.6mm 6.4mm

C/S Team

On the AP420 axles it is possible to change the brake discs without removing the wheels.

Slide 43

4.3 Parking Brake

4.3 Parking Brake (DL250 ~ DL500)

C/S Team

Slide 44

4.3 Parking brake - Parking brake I

1. Transmission 2. Parking brake disc 3. Parking brake caliper

C/S Team

Slide 45

4.3 Parking brake - Parking brake II

lock nut

Screw cap

Adjusting screw C/S Team

To release the parking brake manually, having chocked the machine: Remove the screw cap Undo the lock nut Turn the adjusting screw counter clockwise until the parking brake is free To reset the brake see next slide

Slide 46

4.3 Parking brake (ZF transmission) - Parking brake adjustment

Cup springs Screw cap Housing

Brake pad Brake disc Adjusting screw Brake piston

Lock nut

1)

Park the machine on level ground and place wheel chocks to prevent the machine rolling.

2)

Release the parking brake.

3)

Release the screw cap and lock nut.

4)

Tighten the adjusting screw until the pads are touching the disc, then loosen the adjusting screw.

5)

Model

DL250 / DL300 / DL350

DL400 /DL420 / DL450 / DL500

Gap (mm)

1.0±0.5 (1/2 Turn back)

2.0±1.0 (4 / 5ths Turn back)

Tighten the lock nut & then refit & tighten the screw cap.

C/S Team

Slide 47

4.4 Axle Oil Cooling (DL500 Only)

C/S Team

The Mega 500-V & DL500 both have fitted as standard axle oil coolers. The system consists of:1 double gear pump (one pump section fore each axle) that is directly driven off the engine (flywheel end) 2 separate axle oil to hydraulic oil coolers (contained in 1 unit mounted on top of the flywheel housing) 2 independent suction & return lines (one for each axle).

Slide 48

4.4 Axle Oil Cooling (DL500 Only)

Axle Oil Suction Cooled Axle Oil Return Hydraulic Oil Suction Hydraulic Cooling Fan Pressure Oil Hydraulic Cooling Fan Return Oil

C/S Team

The axle cooler uses the returning oil from the hydraulic cooling fan circuit to cool the axle oil.