Copyright

SECTION INDEX

BRAKES

Section Title Section Number

Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001

Hydraulic Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002
Brake Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7003
Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7008

Copyright 2007 CNH Italia S.p.A.

CNH Italia S.p.A. All rights reserved.
Viale delle Nazioni, 55
41100 Modena Printed in E.C.
Italia 87551879A Issued January, 2007
Copyright
 Copyright

7001
Section
7001

REMOVAL AND INSTALLATION OF BRAKE

COMPONENTS

Copyright 2007 CNH Italia S.p.A.

CNH Italia S.p.A. All rights reserved.
Viale delle Nazioni, 55
41100 Modena Printed in E.C.
Italia 87551879A Issued January, 2007
 Copyright

7001-2

TABLE OF CONTENTS
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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1
4

BC05M136

1. FRONT AXLE 5. FRONT ACCUMULATOR

2. REAR AXLE 6. REAR ACCUMULATOR
3. BRAKE VALVE 7. BRAKE PUMP
4. PARKING BRAKE ACCUMULATOR 8. CONNECTOR TO FAN VALVE
COMPONENT LOCATION ILLUSTRATION

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BRAKE VALVE

Removal
1. Park the machine on a level surface and lower
the loader bucket to the floor. Stop the engine.
2. Put blocks on both sides of each tire to prevent
machine movement.
3. Make sure the brake accumulators are
completely discharged. Push down and release
the brake pedals at least 30 times.
4. Turn the master disconnect switch to the OFF
position.
5. Remove the cab skirts located under the cab or
canopy.
Installation
1. Install the brake valve (1) in the cab or canopy.
Refer to the illustration on page 5.
2. Remove the plugs from the hydraulic lines and
connect the hydraulic lines to the brake valve (1).
3. Stop the vacuum pump and remove.
4. Connect all of the electrical connections.
5. Turn the master disconnect switch to the ON
position.
6. Bleed the brake system. See Section 7002.
7. Install the cab skirts.

6. To release the pressure on the parking brake 8. Check the hydraulic reservoir oil level and add oil
accumulator, the line at the accumulator must be as required. See Section 1002 for the correct oil.
SLOWLY cracked open. A pan will be needed to
catch the hydraulic oil.
7. Connect a drain hose to the quick disconnect
couplings in each brake circuit to release any
pressure in the brake circuit.
8. Clean the brake valve (1) and lines, refer to the
illustration on page 5.
9. Put identification tags on all electrical and
hydraulic lines that are connected to the brake
valve (1).
10. Connect a vacuum pump to the hydraulic
reservoir. Start the vacuum pump
11. Disconnect the lines from the brake valve (1) and
put plugs in each line.
12. Remove the brake valve (1).

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1
6
2 7

9
4 10
8
5
BC05M137

1. BRAKE VALVE 6. FRONT BRAKE LINE

2. REAR ACCUMULATOR LINE 7. REAR BRAKE LINE
3. PARKING BRAKE LINE 8. FRONT ACCUMULATOR
4. BRAKE PUMP INPUT 9. RETURN TO TANK
5. BRAKE VALVE DISCHARGE 10. PARKING BRAKE ACCUMULATOR
BRAKE VALVE ILLUSTRATION

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SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS

Removal Installation
1. Park the machine on a level surface and lower 1. Mount the accumulators (1) in the accumulators
the loader bucket to the floor. Stop the engine. clamps (7), do not tighten clamps at this time.
Refer to illustration on page 7.
2. Put blocks on both sides of each tire to prevent
machine movement. 2. Connect the tubes to both brake accumulators
(1) and tighten.
3. Make sure the service brake accumulators (1)
and the parking brake accumulator (2) are 3. Tighten accumulator clamp studs (7) to 17Nm
completely discharged. Push down and release (13 pound feet).
the brake pedal at least 30.
4. Install the parking brake accumulator (2) into the
4. Turn the master disconnect switch to the OFF bracket.
position.
5. Install the nut (3) and tighten.
5. Remove the left cab skirt located under the cab
6. Connect the line to the parking brake
or canopy to gain access to accumulators.
accumulator (2).
6. To release the pressure on the parking brake
7. Stop the vacuum pump and remove.
accumulator, the line at the accumulator must be
SLOWLY cracked open. A pan will be needed to 8. Install the left cab skirt.
catch the hydraulic oil.
9. Turn the master disconnect switch to the ON
7. Connect a drain hose to the quick disconnect position.
couplings in each brake circuit to release any
10. Bleed the brake system. See Section 7002.
pressure in the brake circuit.
11. Refer to Section 7008 and perform the Parking
8. Clean the brake accumulators (1), parking brake
Brake Test Procedure.
accumulator (2) and lines. Refer to illustration on
page 7. 12. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.
9. Put identification tags on the line that is
connected to the parking brake accumulator (2).
10. Connect a vacuum pump to the hydraulic
reservoir. Start the vacuum pump.
11. Disconnect the tubes from both brake
accumulators (1).
12. Loosen the clamp stud (8) on the accumulator
clamp (7).
13. Remove the accumulators (1) from the
accumulator clamps (7).
14. Install plugs in the tubes.
15. Disconnect the hose from parking brake
accumulator (2).
16. Remove the nut (3), remove the parking brake
accumulator (2).
17. Install a plug in the hose.

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2 3

6
4
7

8
7
1

1
BC05M138

1. BRAKE ACCUMULATORS 5. TUBE FRONT BRAKE ACCUMULATOR

2. PARKING BRAKE ACCUMULATOR 6. TUBE REAR BRAKE ACCUMULATOR
3. MOUNTING NUT 7. CLAMP ACCUMULATOR
4. HOSE PARKING BRAKE ACCUMULATOR 8. CLAMP STUD
BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION

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7001-8
BRAKE PUMP
Removal
1. Park the machine on a level surface and lower
the loader bucket to the floor. Stop the engine.
2. Put blocks on both sides of each tire to prevent
machine movement.
3. Turn the master disconnect switch to the OFF
position.
4. Clean the brake pump (1) and lines, refer to the
illustration on page 9.
5. Put identification tags the lines that are
connected to the brake pump (1).
6. Connect a vacuum pump to the hydraulic
reservoir. Start the vacuum pump.
7. Disconnect the lines from the brake pump (1)
and put plugs in each line.
8. Remove the mounting bolts (2) and washers (3)
from the brake pump (1) and remove the brake
pump (1).
87551879A
Copyright
Installation
1. Install gear (6) onto the pump shaft, install
washer (7) and slotted nut (8), torque nut to 70 to
79 Nm (52 to 58 pound feet). Refer to the
illustration on page 9.
2. Install the cotter pin (9).
3. Install the brake pump (1), mounting bolts (2)
and washers (3).
4. Torque mounting bolts (2) to 57 to 65 Nm (42 to
48 pound feet).
5. Remove the plugs or caps and connect the lines
to the brake pump (1).
6. Stop the vacuum pump and remove.
7. Turn the master disconnect switch to the ON
position.
8. Bleed the brake system. See Section 7002.
9. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.
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9 8

7
6

3
2

BC05M139

1. BRAKE PUMP 4. SUCTION HOSE 7. WASHER

2. MOUNTING BOLT (2) 5. PRESSURE HOSE 8. SLOTTED NUT
3. WASHER (2) 6. DRIVE GEAR 9. COTTER PIN
BRAKE PUMP ILLUSTRATION

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NOTES

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7002
Section
7002

HYDRAULIC BRAKE TROUBLESHOOTING

Copyright 2007 CNH Italia S.p.A.

CNH Italia S.p.A. All rights reserved.
Viale delle Nazioni, 55
41100 Modena Printed in E.C.
Italia 87551879A Issued January, 2007
 Copyright

7002-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECKING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake Valve Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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SPECIFICATIONS
Brake pump output ..............................................................................................................42 to 45 L/min at 172 bar
(11 to 12 gpm at 2500 psi at 2000 rpm)

Accumulator nitrogen charge pressure...........................................................................48 to 59 bar (700 to 850 psi)

Accumulator valve cut in pressure......................................................................... 157 to 167 bar (2280 to 2420 psi)
Accumulator valve cut out pressure ...................................................................... 190 to 196 bar (2755 to 2845 psi)
Brake warning pressure switch (normally closed) opening set point......................106 to 115 bar (1530 to 1670 psi)
Brake redundant pressure switch (normally closed) opening set point ..... 55 to 69 bar decreasing (800 to 1000 psi)
Brake light pressure switch (normally open) closing set point.............................. 5 to 6 bar increasing (75 to 85 psi)
Modulation pressure front brake cylinders..................................................................80 to 87 bar (1160 to 1260 psi)
Modulation pressure rear brake cylinders ..................................................................78 to 85 bar (1130 to 1230 psi)

SPECIAL TOOLS

G
94L95
CAS-10899 NITROGEN CHARGING KIT USED TO CHECK AND
CHARGE THE ACCUMULATOR WITH NITROGEN.
BC04A001
380001168 ACCUMULATOR CHARGING ADAPTER

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7002-4
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM
NOTE: The hydraulic brake schematic is included in
the hydraulic schematic. Refer to the rear pocket of
this manual.
1. Check the oil level in the hydraulic reservoir; add
oil as necessary.
2. Push and release the brake pedal many times
with the engine stopped to remove all hydraulic
pressure from the brake system until there is no
pressure on the pedal.
3. Install two 207 bar (3000 psi) pressure gauges to
front and rear hydraulic brake accumulator test
ports, refer to page 7 for the locations of the test
ports.
4. Make sure that the pressure gauge hoses are
long enough so the gauges can be read while
sitting in the operators seat.
NOTE: The gauges can not be connected to the test
ports if hydraulic pressure remains in the system.
5. Start the engine. Run the engine at low idle while
reading the pressure gauges. The alarms
(buzzer, master warning light and brake pressure
warning light) should shut off when the
accumulator with the lowest pressure reaches
106 to 115 bar (1530 to 1670 psi), approximately
40 seconds at any engine speed.
6. After the alarms stop, run the machine at high
idle to finish charging the accumulators. The
pressure must increase on both gauges until 190
to 196 bar (2757 to 2843 psi) is reached. This is
the accumulator valve cut-out pressure. It is
normal for the pressure to drop slightly once the
cut-out pressure is reached.
7. With the engine running at high idle, push and
release the brake pedal rapidly while reading the
drop in pressure on the gauges. The pressure
drops may not be equal, but as the lowest
pressure reaches 157 to 167 bar (2280 to 2420
psi), the system pressure must start to increase.
This is the valve cut in pressure.
NOTE: The brake cut-in and cut-out pressures of the
brake system charge valve are factory preset and are
not adjustable.
NOTE: If the pressure on one of the pressure
gauges is lower than specified, the problem can be a
bad accumulator valve.
87551879A
Copyright
8. Stop the engine. Turn the ignition switch to the
ON position. Push and release the brake several
times while reading the pressure on the gauges.
Each push and release of the pedal will result in
a slight drop in pressure, but not necessarily
equal on the two gauges. As the lowest pressure
reaches 106 to 115 bar (1530 to 1670 psi) the
brake warning lamp and alarm buzzer must
actuate. If the warning lamp and alarm buzzer
fail to work, test the low brake pressure warning
switches and electrical circuit. If the warning
lamp and alarm buzzer actuate at a higher or
lower pressure than specified, test the low brake
pressure warning switches and replace as
needed.
9. As the lowest pressure reaches 106 to 115 bar
(1530 to 1670 psi) the brake warning lamp and
alarm buzzer must actuate. If the warning lamp
and alarm buzzer fail to work, test the low brake
pressure warning switches and electrical circuit.
If the warning lamp and alarm buzzer actuate at
a higher or lower pressure than specified, test
the low brake pressure warning switches and
replace as needed.
10. After the low brake pressure light activates,
press the brake pedal eight more times.
11. Record the readings on the pressure gauges.
The pressure gauges should read at or above
48 to 59 bar (700 to 850 psi).
12. If the pressures are at or above 48 to 59 bar (700
to 850 psi), the test is complete.
13. If the pressures are not within the required
specifications, then the brake system must be
bled.
14. After bleeding the brake system, perform the
brake system check again.
15. Continue to slowly push and release the brake
pedal several times until the gauge pressure
suddenly drops to zero. The last pressure
reading before the drop to zero is the nitrogen
charge pressure in the accumulator. Test the
pressure in both accumulators. If the pressure is
below 48 to 59 bar (700 to 850 psi), charge or
replace the accumulator(s) (see page 5).
NOTE: Nominal temperature of 20 C (68 F), colder
temperature will reduce pressure, hotter temperature
will increase pressure.
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CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator is
completely discharged by doing the following: E
C
A. Stop the engine.
B. Push down and release the brake pedal many
times to release the pressure.
F
2. Connect a drain hose to the test connector in
each brake circuit to release any pressure in the
brake circuit.
3. Close valves B and C on the nitrogen charging
kit, refer to the illustration.
D B A
4. Turn the stem out of valve F until the stem stops.
94L95
5. Remove the cap screws and guard from the NITROGEN CHARGING KIT
accumulator.
8. Make sure that valve D is open.
6. Remove the cap from the accumulator valve
9. Turn the stem into valve F and read the pressure
stem.
gauge E.
7. Connect valve F to the accumulator valve stem.
10. The pressure must be 48 to 59 bar (700 to 850
psi). If the pressure is too low, charge the
accumulator with dry nitrogen.

CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator
according to the instructions in Checking the
Nitrogen Charge in the Accumulator. Keep the
nitrogen charging kit connected to the accumulator.
1. Close (turn counterclockwise) valve A and open
valve B. Close valves C and D.
2. Turn the stem out of valve F until the stem stops
moving. Disconnect valve F from the
accumulator valve stem.
3. Connect the nitrogen charging kit to a dry
nitrogen tank.
4. Slowly turn valve A clockwise and read gauge E
until the pressure is 48 to 59 bar (700 to 850 psi).
Stop turning valve A.
5. If the pressure increases above 59 bar
(850 psi), quickly open and close valve D and
read gauge E. If the pressure is still too high,
close valve A (turn counterclockwise) a small
amount and quickly open and close valve D. The
pressure shown on gauge E is the charge
pressure.
6. Connect valve F to the accumulator valve stem.
Turn the stem into valve F until the stem stops
moving and open valve D to charge the
accumulator.
7. After the accumulator stops charging, turn the
stem out of valve F until the stem stops moving.
8. Close valve B and disconnect the nitrogen
charging kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem.
Install the guard and cap screws on the
accumulator.

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BLEEDING THE BRAKE SYSTEM

1. Check the level of hydraulic fluid in the reservoir. 8. Start the engine and run at low idle.
Add fluid to the reservoir if necessary.
9. Push the brake pedal all the way down and
IMPORTANT: If machine is equipped with slowly release for one cycle.
quick-attached components, disconnect them from
10. Close all four wheel end bleed screws.
machine prior to proceeding.
11. Fully depress the brake pedal three times in 5
second cycles.
12. With the brake pedal partially depressed, open
the bleed screw on the left front axle. Hold the
brake pedal in position until the oil is clear (no
bubbles). Close the bleed screw.
13. Open the bleed screw on the right front axle.
Repeat step 12.
1 14. Open the bleed screw on the left rear axle.
Repeat step 12.
15. Open the bleed screw on the right rear axle.
BD03A092
Repeat step 12.
1. SAFETY LINK 16. Replace all bleed screws, caps and plugs.
17. Check the hydraulic fluid and add as necessary.
2. Raise loader arms and install the safety link (1)
for safe access to the front axle bleed screws.
3. Apply the parking brake.
4. Keep the engine speed at high idle until both
brake accumulators are fully charged.
NOTE: This will be approximately 30 seconds after
the low brake pressure light goes out.
5. Stop the engine.
6. Pump the brake pedal until there is no hydraulic
pressure in the brake system (approximately 20
pumps).
7. Remove the plastic and rubber caps from each
wheel end and slowly open all four bleed screws.
NOTE: Attach a hose to the bleed screws to prevent
spilling any fluids.

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BRAKE MODULATION PRESSURE CHECK
2 3
1. FRONT AXLE TEST PORT
2. REAR AXLE TEST PORT
Testing the Brake Modulation
Pressure
1. Make sure the hydraulic accumulator cut-in and
cut-out pressures are correct. Refer to page 4 of
this section.
2. Stop the engine. Pump the brake pedal until
there is no pressure in the brake system.
3. Remove the cab skirts to gain access to the
brake test ports.
4. Connect two 207 bar (3000 psi) pressure gauges
to the front brake test port (1) and the rear brake
test port (2).
5. Connect two 207 bar (3000 psi) pressure gauges
to the front brake accumulator test port (4) and
the rear brake accumulator test port (3).
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7002-7
BD06F145
3. FRONT BRAKE ACCUMULATOR TEST PORT
4. REAR BRAKE ACCUMULATOR TEST PORT
6. Start the engine.
7. Operate the machine at low idle and watch the
pressure gauges on the brake accumulators until
the gauges rise above 170 bar (2645 psi).
8. Apply and hold the brakes for 10 to 15 seconds.
9. Make a note of the pressure on the gauges for
the front and rear brakes.
10. The front brake pressure should read 80 to 87
bar (1160 to 1260 psi). This is the modulation
pressure for the front axle.
11. The rear brake pressure should read 78 to 85 bar
(1130 to 1230 psi). This is the modulation
pressure for the rear axle
12. If the pressures are not within the specified
range, it will be necessary to adjust the
modulation pressures.
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7002-8

Adjusting the Brake Modulation
Pressure
NOTE: The adjusting bolt to adjust the modulation
pressure is located in the cab, under the brake pedal.
2 4. Repeat these steps until the brake modulation
1
1. Remove the tamper evident cover (1).
NOTE: This is a tamper evident cover and it will be
necessary to install a new cover after the modulation
pressure is adjusted.
2. Turn the adjusting bolt (2) to adjust the
modulation pressure.
NOTE: The rear brake modulation pressure cannot
be adjusted separately from the front brake
modulation pressure.
3. Repeat steps 5 through 10 in the Testing the
Brake Modulation Pressure procedure.
pressure is within the specified range.

BD00N121

1. TAMPER RESISTANT COVER

2. ADJUSTING BOLT

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SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY)
2 3
1. FRONT AXLE TEST PORT
2. REAR AXLE TEST PORT
NOTE: Prior to doing this procedure make sure that
the accumulator pressures are correct.
1. Check the level of the hydraulic fluid in the
reservoir, add as needed.
1 times.
BD00M030
1. ARTICULATION LOCK
2. Install the articulation lock (1) before doing this
test.
3. Remove the left side cab skirt to gain access to
the brake accumulator test ports.
4. Pump the brake pedal until there is no hydraulic
pressure in the brake system (approximately 20
pumps).
5. Connect two 207 bar (3000 psi) pressure gauges
to the test ports 3 and 4.
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7002-9
4
BD06F145
3. FRONT BRAKE ACCUMULATOR TEST PORT
4. REAR BRAKE ACCUMULATOR TEST PORT
6. Start the engine and let idle until both the front
and rear accumulators 3 and 4 are fully charged.
The accumulators are fully charged at 190 to 196
bar (2755 to 2842 psi).
7. Stop the engine.
8. Push the brake pedal down slowly, allowing for
full piston actuation.
NOTE: Depress the brake pedal at the rate of three
strokes per minute.
9. Continue pressing the brake pedal down. The
low brake pressure light should activate when
the pressure reaches 106 to 115 bar (1530 to
1670 psi). After the low brake pressure light
activates, press the brake pedal eight more
10. Record the readings on the pressure gauges.
The pressure gauges should read at or above
48 to 59 bar (700 to 850 psi).
11. If the pressures are at or above 48 to 59 bar (700
to 850 psi), the test is complete.
12. If the pressures are not within the required
specifications, then the brake system must be
bled.
13. After bleeding the brake system, perform the
brake system check again.
Issued 1-07 Printed in E.C.
 Copyright

7002-10

BRAKE PUMP OUTPUT TEST

1. Connect the flowmeter to the brake pump as
shown, refer to the illustration below.
2. Make sure the load control of the flowmeter is
open. Start the engine. Run the engine at full
throttle. Make sure the oil is at operating
temperature.
3. Measure the flow at 0 bar (0 psi). Record the flow
reading. Slowly close the load valve on the
flowmeter and read the flow at 170 bar (2500
psi). Record the flow reading.
4. Divide the flow reading at 170 bar (2500 psi) by
the reading at 0 bar (0 psi). Multiply the result by
100. This is the percent efficiency of the pump. If
the efficiency of the pump is less than 85%,
repair or replace the pump.

NOTE

4
3

BS03B021

1. BRAKE PUMP 3. FLOWMETER INLET HOSE 5. FILTER INLET MANIFOLD

2. PUMP OUTPUT ELBOW 4. FLOWMETER OUTLET HOSE 6. FILTERS
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

87551879A Issued 1-07 Printed in E.C.

 Copyright

7002-11
NOTES

87551879A Issued 1-07 Printed in E.C.

 Copyright

7002-12

2 4

30 5
31
6
32

14 5
33 21
5 30
34
2 7
35 29
5
36 8

27 15
28 10

26 15
11
16 14
24 25 12
14
17
5

23 18 19
15
2

22 5 13
5
21 20

BC05G011
BRAKE VALVE EXPLODED VIEW

87551879A Issued 1-07 Printed in E.C.

 Copyright

7002-13

1. CAP SCREW (T 22 NM (16 LB-FT)) 13. CAP (T 60 NM (44 LB-FT)) 25. CHECK VALVE
2. O-RING 14. SPOOL 26. CARTRIDGE
3. BUSHING 15. PLUG (T 10 NM (88.5 LB-IN)) 27. PLUG (T 60 NM (44 LB-FT))
4. SLEEVE 16. PLUG (T 60 NM (44 LB-FT)) 28. JET
5. SPRING 17. PLUG (T 22NM (16 LB-FT)) 29. WVI UNIT
6. SPRING RETAINER 18. VALVE SEAT 30. PLUG (T 60 NM (44 LB-FT))
7. SPRING RETAINER 19. THROTTLE SCREW 31. PLUG (T 100 NM (74 LB-FT))
8. CIRCLIP 20. PLUG (T 22NM (16 LB-FT)) 32. RV UNIT
9. SHAFT SEAL 21. CAP 33. SPRING RETAINER
10. SLEEVE LVE 22. SLEEVE 34. SLEEVE
11. GUIDE RING 23. SPRING RETAINER 35. THRUST RING
12. O-RING 24. SLEEVE 36. SLEEVE LVV

87551879A Issued 1-07 Printed in E.C.

 Copyright

7002-14
NOTES

87551879A Issued 1-07 Printed in E.C.

 Copyright

Section
7003

7003
BRAKE PUMP

Copyright 2007 CNH Italia S.p.A.

CNH Italia S.p.A. All rights reserved.
Viale delle Nazioni, 55
41100 Modena Printed in E.C.
Italia 87551879A Issued January, 2007
 Copyright

7003-2

TABLE OF CONTENTS
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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7003-3

14
17 15

16

10

18
10

19 13
7
8
9
11
12
11
9 10
8
7

5
4 6
3
2
1
BC06F594

1. RETAINING RING 8. BACKUP SEAL 14. WASHER

2. SEAL RETAINER 9. CHANNEL SEAL 15. BOLT
3. 0-RING 10. DOWEL PIN 16. DRIVEN GEAR
4. OUTER LIP SEAL 11. THRUST PLATE 17. DRIVE GEAR
5. INNER LIP SEAL 12. GEAR HOUSING 18. DRIVE SCREW
6. SHAFT END COVER HOUSING 13. PORT END COVER HOUSING 19. NAME PLATE
7. QUAD RING
PUMP ILLUSTRATION

87551879A Issued 1-07 Printed in E.C.


7003-4
BRAKE PUMP
Disassembly
1. Secure the pump by the port end cover (13) in a
soft jawed vise.
2. Draw a line the length of the pump to assist
during assemble.
3. Loosen and remove bolts (15).
4. Tap the shaft end cover housing (6) with soft
hammer to loosen it, remove the shaft end cover
housing (6).
5. Remove the backup seal (8), channel seal (9),
and thrust plate (11).
6. Remove the drive gear (17) from the gear
housing (12).
7. Remove the driven gear (16) from the gear
housing (12).
8. Tap the gear housing (12) with a soft hammer to
loosen it, remove the gear housing (12).
9. Remove the backup seal (8), channel seal (9),
and thrust plate (11).
10. Remove the retaining ring (1) form the shaft end
cover housing (6).
11. Remove the seal retainer (2), O-ring (3), and
outer lip seal (4) from the shaft end cover
housing (6).
12. Remove the inner lip seal (5) from the shaft end
cover housing (6).
Inspection
1. Discard all seals and quad rings. Clean all parts
in cleaning solvent. Check all machined surfaces
for damage or wear.
2. Hold a straightedge across each gear housing
and use a feeler gauge to measure the amount
of wear caused by the gear teeth in the gear
pocket. If the wear in any gear pocket is more
than 0.18 MM. (0.007 inch), use a new gear
housing.
3. Inspect the thrust plates for scoring, pitting, or
other damage.
4. Inspect the gears for wear and damage. There
must be no scoring on the gear hubs or on the
outside edges of the gear teeth. There must be
no more than 0.05 MM. (0.002 inch) wear in the
seal area of the drive shaft. If any gear must be
discarded, you must use a new hydraulic pump.
87551879A
Copyright
Assembly
1. Install a new lip seal (3) into the seal retainer (2)
so the lip of the seal will be facing away from the
gears when the seal retainer (2) is installed into
the shaft end cover housing (6).
2. Install a new lip seal (4) into the shaft end cover
housing (6) with the lip of the seal facing towards
the gears.
3. Install a new O-ring (3) onto the seal retainer (2),
lubricate the O-ring with hydraulic oil.
4. Press the seal retainer (2) into the shaft end
cover housing (6) and install the retaining ring
(1).
5. Place the shaft end housing (6), facing down,
into a soft jawed vise.
6. Install new backup seals (8) and channel seals
(9) into the thrust plates (11).
7. Place a thrust plate (11) onto the shaft end cover
housing (6).
IMPORTANT: Be sure to place the thrust plate (11)
onto the shaft end cover housing (6) in the position
shown in the illustration on page 3.
8. Lubricate the driven gear (16) with hydraulic oil,
slide the driven gear (16) through the thrust plate
(11) into the shaft end cover housing (6).
9. Lubricate the drive gear (17) with hydraulic oil,
slide the drive gear (17) through the thrust plate
(11) into the shaft end cover housing (6).
10. Install a new quad ring (7) into the gear housing
(12). Check that dowel pins (10) are in place
either in the gear housing (12) or the shaft end
cover housing (6).
11. Align the marks made during disassembly,
carefully place the gear housing (12) onto the
gears.
12. Slide the thrust plate (11) onto the shafts of the
gears.
IMPORTANT: Be sure to place the thrust plate (11)
onto the gears in the position shown in the illustration
on page 3.
13. Install a new quad ring (7) into the gear housing
(12). Check that dowel pins (10) are in place
either in the gear housing (12) or the port end
cover housing (13).
14. Align the marks made during disassembly, place
the port housing (12) onto the gear housing (12).
15. Install bolts (15) with clean and dry threads,
washers (14). Torque bolts to 192 5.5 Nm
(141.5 4 pound feet).
Issued 1-07 Printed in E.C.
 Copyright

Section
7004

7004
BRAKE ACCUMULATORS

Copyright 2007 CNH Italia S.p.A.

CNH Italia S.p.A. All rights reserved.
Viale delle Nazioni, 55
41100 Modena Printed in E.C.
Italia 87551879A Issued January, 2007
 Copyright

7004-2

TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

87551879A Revised 1-07 Printed in E.C.


SPECIAL TOOL
C E
D B A
94L95
CAS10899 NITROGEN CHARGING KIT
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR
1. Remove cover from accumulator charge port.
Loosen the Allen screw in the charge port.
NOTE: Do not turn the Allen screw more than 1/8 of
a turn or gas will escape uncontrolled.
2. Install adapter on accumulator, use the
CAS10899 nitrogen charging kit to discharge the
accumulator, refer to illustrations above. The tool
must be disconnected from the nitrogen tank.
3. Close valves B, C and D.
4. Adjust the regulator A to the minimum pressure
setting by turning the knob counterclockwise.
5. Turn the T-handle on valve F fully out.
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR
1. Make sure that the oil side of the accumulator is
completely discharged by doing the following:
A. Stop the engine.
B. Push down and release the brake pedal 21
times to release the pressure.
2. Connect a drain hose to the test connector in
each brake circuit to release any pressure in the
brake circuit.
3. Close valves B and C on the nitrogen charging
kit, refer to the illustration.
4. Turn the stem out of valve F until the stem stops.
87551879A
Copyright
7004-3
G
BC04A001
380001168 ACCUMULATOR CHARGING ADAPTER
6. Connect valve F to the valve stem on the
adapter.
7. Turn the T-handle inward on valve F to engage
the pin in the valve stem, open valve G.
8. Open valve D and check the charge pressure on
gauge E.
9. To discharge the accumulator, partially open
valve B. The accumulator charge will bleed down
through the regulator.
10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem and
remove adapter.
5. Remove the cap from the accumulator. Loosen
the Allen screw in the charge port.
NOTE: Do not turn the Allen screw more than 1/8 of
a turn or gas will escape uncontrolled.
6. Connect adapter to accumulator.
7. Connect valve F to the adapter valve stem.
8. Make sure that valve D and G are open.
9. Turn the stem into valve F and read the pressure
gauge E.
NOTE: See chart below for pressure readings.
10. If the pressure is too low, charge the
accumulator with dry nitrogen.
Revised 1-07 Printed in E.C.
 Copyright

7004-4

CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator 6. Connect valve F to the adapter valve stem. Turn
according to the instructions in Checking the the stem into valve F until the stem stops moving
Nitrogen Charge in the Accumulator. Keep the and open valve G and D to charge the
nitrogen charging kit connected to the accumulator. accumulator.
1. Close (turn counterclockwise) valve A and open 7. After the accumulator stops charging, turn the
valve B. Close valves C, D, and G. stem out of valve F until the stem stops moving
and close valve G.
2. Turn the stem out of valve F until the stem stops
moving. Disconnect valve F from the adapter 8. Close valve B and disconnect the nitrogen
valve stem. charging kit from the adapter valve stem, remove
the adapter.
3. Connect the nitrogen charging kit to a dry
nitrogen tank. 9. Torque the Allen screw to 20 Nm (15 lb-ft), install
the cover on the accumulator valve stem.
4. Slowly turn valve A clockwise and read gauge E
until the pressure is equal to charge pressure
required for accumulator being charged. Stop
TEMPERATURE CHARGE PRESSURE
turning valve A.
0 C 32 F 51.2 BAR 743 PSI
5. If the pressure increases above required 5 C 41 F 52.2 BAR 757 PSI
pressure, quickly open and close valve D and 10 C 50 F 53.1 BAR 770 PSI
read gauge E. If the pressure is still too high, 15 C 59 F 54.1 BAR 784 PSI
close valve A (turn counterclockwise) a small 20 C 68 F 55.0 BAR 798 PSI
amount and quickly open and close valve D. The 25 C 77 F 55.9 BAR 811 PSI
pressure shown on gauge E is the charge 30 C 86 F 56.9 BAR 825 PSI
pressure. 35 C 95 F 57.8 BAR 839 PSI
40 C 104 F 58.8 BAR 852 PSI

TEMPERATURE/CHARGE PRESSURE BRAKE

ACCUMULATOR

87551879A Revised 1-07 Printed in E.C.

 Copyright

Section
7008

PARKING BRAKE

7008

Copyright 2007 CNH Italia S.p.A.

CNH Italia S.p.A. All rights reserved.
Viale delle Nazioni, 55
41100 Modena Printed in E.C.
Italia 87551879A Issued January, 2007
 Copyright

7008-2

TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

87551879A Issued 1-07 Printed in E.C.

 Copyright

7008-3

PARKING BRAKE

Disassembly STEP 7

STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.

STEP 2
Place wheel chocks on each wheel to prevent
machine movement.

STEP 3

BD03A185

Loosen the jam nut, turn adjusting bolt

counterclockwise until the brake pads are loose.

STEP 8

BD01F143

Install the articulation lock.

STEP 4
Place the master disconnect switch in the OFF
position.

STEP 5 BD03A186
Remove the retainer pin and brake pin.
Pump the brake pedal at least 30 times to discharge
the accumulators.
STEP 9
STEP 6

BD03A187
Remove the two brake pads from the parking brake
BD03A184 assembly.
Loosen and remove the cover from the parking
brake.

87551879A Issued 1-07 Printed in E.C.

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7008-4

Inspection STEP 14
Disengage the parking brake.
STEP 10 NOTE: Hydraulic pressure will not be applied to the
Clean and inspect all parts for wear and damage. parking brake until the parking brake rocker switch is
Inspect the brake disc for wear and damage. turned off, the service brakes applied and the
transmission is put into gear.
Replace all parts that are worn or damaged.
A. Place the parking brake rocker switch in the
OFF position.
Assembly
B. Apply the service brake and put the machine
STEP 11 into gear.
C. The parking brake light on the cluster will turn
off at this time.
Place the transmission back into neutral before
proceeding.

STEP 15

BD03A187

Install the two brake pads in the parking brake

assembly.

STEP 12

BD0CA185

Turn the adjusting bolt clockwise until both brake

pads contact the brake disc, then turn the adjusting
bolt counterclockwise one turn. Tighten the jam nut
to secure the adjusting bolt.

STEP 16
Install the cover on the parking brake.

STEP 17
Perform the Parking Brake Test Procedure as
BD03A186
described in this section.
Install the brake pins and retainer pins.
STEP 18
STEP 13
Remove the articulation lock.
Start the machine and run the engine at low idle with
the bucket resting on the ground.
STEP 19
IMPORTANT: It will be necessary to have an Place the master disconnect switch to the ON
assistant help for this procedure. An operator must position.
be present in the cab at all times to apply the service
brakes and shut down the machine in the event of
mechanical failure.

87551879A Issued 1-07 Printed in E.C.

 Copyright

7008-5

PARKING BRAKE TEST PROCEDURE

STEP 20 STEP 25
While testing, the machine must be on a clear level
surface with the bucket in the travel position.

WARNING: Always know the location of all

workers in your area. Warn them before you
start working the machine. Always keep all
other persons away from your area. Serious
injury or death can result if you do not follow
these instructions.
SA015

STEP 21
Start the machine and run the engine at low idle in BD06F142
third gear neutral. Use up or down arrow and highlight config, press the
enter key to select the config menu.
STEP 22
Place the Transmission-Auto switch to the manual STEP 26
position.

STEP 23
Place the Parking Brake switch to the ON position.

STEP 24

BD06F143

Press the up or down arrow and high light brake test,

press the enter key.

BD06F141

Press and hold the enter key for 2 to 3 seconds until

the instrument cluster monitor display changes to the
select screen.

87551879A Issued 1-07 Printed in E.C.

 Copyright

7008-6
STEP 27 STEP 33
Verify that the machine does not move.

STEP 34
Reduce the engine speed to low idle and return the
transmission to neutral.

STEP 35

BD06F144

Monitor will display Test Park Brake if all conditions

are met to test the brake, press the enter key.
NOTE: If all conditions are not met to test the brake
the monitor will display the condition that needs
corrected prior to proceeding. BD06F141

Press the escape switch on the key pad to exit the

STEP 28 test mode.
Monitor will display Test Park Brake Ready.
STEP 36
STEP 29 If any machine movement was detected, the parking
Shift the gear selector into third gear forward and brake must be adjusted, see procedures this section.
slowly increase the engine speed to wide open
throttle.

STEP 30
Verify that the machine does not move.

STEP 31
Reduce the engine speed to low idle and return the
transmission neutral.

STEP 32
Shift the gear selector to third gear reverse and
slowly increase the engine speed to wide open
throttle.

87551879A Issued 1-07 Printed in E.C.