Slide 1

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

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Slide 2

4.0 Brake system

- Brake system logic

Brake valve

Brake pilot supply valve

Pump

Brake actuator

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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

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Slide 4

4.0 Brake system

- DL160 Brake Supply System

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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

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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

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This valve is unique to the DL200.

Slide 7

4.0 Brake system

- DL200 Brake / Pilot & Fan Supply Valve

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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

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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)

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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

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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

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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

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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
5
6 : Pilot cut off solenoid valve - C8
7 : Parking brake release solenoid valve – C9 7

8 : Low pressure warning switch (65bar)

9 : Parking brake warning switch (65 bar) 5 6

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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

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Slide 15

4.1 Brake pedal valve

4.1 Brake pedal valve

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Slide 16

4.1 Brake pedal valve

- Brake valve (I)

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Slide 17

4.1 Brake pedal valve

- Brake valve (I)

Model Supply Pressure (P1, P2) Secondary Pressure (BR1, BR2)

Minimum Maximum Neutral Fully Applied

DL160 140 Bar 200 Bar Tank 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
DL400
S/No 5001 ~5120 120 Bar 190 Bar Tank 80 ± 5 Bar
S/No 5121 ~ 120/140 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

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Slide 18

4.1 Brake pedal valve

- Brake valve (II)

1. Stop lamp switch (5.0 bar)

① - 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

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Slide 19

4.1 Brake pedal valve

- Brake actuator

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Slide 20

4.1 Brake pedal valve

Items To Check On The Brake Pedal Valve:

3

In the pedal release position:

1. Clearance between Cam & Dome.
2
2. Dirt build up around heel of pedal.
3. The tightness of the bolt to the dummy pedal link.
1

In operation:
1. The maximum pressure at the axle is set by the travel of
the brake pedal valve.

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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)

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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 Maker Front Rear Ratio Comments
DL160 Dana Front TPD
Rear TPD
DL200 Dana Front TPD
Rear TPD
Front LSD 45% Option
Rear LSD 45% Option
DL250 ZF Front LSD 45%
Rear LSD 45%
DL300 ZF Front LSD 45%
Rear LSD 45%
DL350 ZF Front LSD 30%
Rear LSD 45%
DL400 ZF Front LSD 30%
DL420 Rear LSD 45%
DL450 ZF Front LSD 30%
Rear LSD 45%
DL500 ZF Front LSD 45%
Rear LSD 45%

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Slide 23

4.2 Dana Axles

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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
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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.

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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

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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

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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

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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

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Slide 30

4.2 Z.F. MTL Axles

- Exterior view
4
5

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

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Slide 31

4.2 Z.F. MTL Axles

- Planetary gear and carrier
Out put

Brake housing
Planetary gear

Planetary carrier

Sun gear

Ring gear

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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

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Slide 33

4.2 Z.F. MTL Axles

- Brake system (I)
Steel disc
Brake piston

High pressure brake oil

Return spring
Friction disc

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Slide 34

4.2 Z.F. MTL Axles

- Brake system (II)

Brake oil

Brake released Brake applied

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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).

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Slide 36

4.2 Z.F. MTL Axles

Pressed brake pedal condition
- Wear limit value
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)

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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 support pin gap between cup spring and the snap ring to 10.5mm.

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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 Pins For Sintered Type Linings

126 125

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

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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)

Model Disc Material Qty Friction Disc Steel Discs

DL450 (Front & Rear) Sintered 8 9 off 2.4mm
DL400 / DL420 Front)
DL400 / DL420 (Rear) Sintered 6 1 off 4.0mm 7 off 2.4mm
DL350 (Front & Rear) ring gear end
DL300 (Front) Paper 5 2 off 2.0 mm 4 off 4.0 mm
(1 each end)
DL300 (Rear) Paper 5 2 off 2.0 mm 4 off 4.0 mm
(1 each end)
DL250 (Front) Paper 4 2 off 2.0 mm 3 off 4.0 mm
(1 each end)
DL250 (Rear) Paper 4 2 off 2.0 mm 3 off 4.0 mm
(1 each end)

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Slide 40

4.2 Z.F. AP Axles

- Exterior view

1 3

1. Oil drain port for differential 2. Oil drain port for hub reduction
3. Oil filler / level check port

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Slide 41

4.2 Z.F. AP Axles

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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 3.2 ~3.6mm

Maximum Permissible Piston Travel 6.4mm

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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)

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Slide 44

4.3 Parking brake

- Parking brake I

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

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Slide 45

4.3 Parking brake

- Parking brake II

lock nut

Screw cap

Adjusting screw

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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
Lock nut
Brake piston
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.
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)

5) Tighten the lock nut & then refit & tighten the screw cap.
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Slide 47

4.4 Axle Oil Cooling (DL500 Only)

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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

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