Model: N SC E & Sprinter E

Status quo: September 2015

Version: 5.10
Author: J. Maier, A. Weiss

© 2015, Terex MHPS GmbH

The contents of this publication and parts thereof may not be disclosed to third parties without the written permission
of the Terex MHPS GmbH. All technical data, drawings etc. are subject to the laws of copyright.

Terex MHPS GmbH • Albert-Einstein-Str. 3 • D-97080 Würzburg • Germany • Phone: +49 (0) 931 2053 0 • Fax: +49 (0) 931 2053 10

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08.1_Brake_System_N_SC_E_EN_V5.10
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The brake pump is feeding continuously oil into the accumulators located at engine platform, cabin
column, gantry frame left and gantry frame right.
The system pressure is limited to 160 bar by the pressure regulator of the pump, a secondary
pressure relief valve will limit the pressure to 190 bar in case the pump regulator fails. A pressure
switch adjusted to 105 bar is reporting the PLC a sufficient brake system pressure.
The setup of the brake system is equal at both gantry frames. Brake circuit 1 is applying the brake of
the front driven wheel and brake circuit 2 is applying the brake of the rear driven wheel. The parking
brakes are released at both driven wheels together.
The operation and parking brakes are using the same disk packages and are included into the wheel
gear drives.
The accumulators ensure enough remaining volume of oil to stop the machine in case of a pump or
engine failure.
A 2-circuit brake pedal valve is used to create a brake pressure (0-120bar) depending on the pedal
position, each circuit is acting to a 1:1 pressure ratio relay on either side. The output of each relay
valves is connected to one operating wet disk brake.
The parking brakes are spring applied and released by pressure using a solenoid valve on each
gantry frame. A pressure switch is reporting the pressure (> 100bar) to the PLC.
The parking brake can also be opened using a hand pump, which is mounted on top of each gantry
for emergency situations.

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The brake pump is feeding continuously oil into the accumulators located at engine platform, cabin
column, gantry frame left and gantry frame right.
The system pressure is limited to 160 bar by the pressure regulator of the pump, a secondary
pressure relief valve will limit the pressure to 190 bar (180 bar for older models) in case the pump
regulator fails. A pressure switch adjusted to 105 bar is reporting the PLC a sufficient brake system
pressure.
The setup of the brake system is equal at both gantry frames. Brake circuit 1 is applying the brake of
the front driven wheel and brake circuit 2 is applying the brake of the rear driven wheel. The parking
brakes are released at both driven wheels together.
The operation and parking brakes are using the same disk packages and are included into the wheel
gear drives.
The accumulators ensure enough remaining volume of oil to stop the machine in case of a pump or
engine failure.
A 2-circuit brake pedal valve is used to create a brake pressure (0-120bar) depending on the pedal
position, each circuit is acting to a 1:1 pressure ratio relay on either side. The output of each relay
valves is connected to one operating wet disk brake.
The parking brakes are spring applied and released by pressure using a solenoid valve on each
gantry frame. A pressure switch is reporting the pressure (> 55bar) to the PLC.
The parking brake can also be opened using a hand pump, which is mounted on top of each gantry
for emergency situations.

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Each winch brake is separately released by a solenoid valve.
An analogue pressure sensor after each valve gives a feed back of the actual pressure to the
PLC. On a lift or lower demand the winch brake valves are energized by the PLC, if the
pressure exceeds 50bar the hoist unit is released to lift or lower. Whenever the hoist
procedure is ended the winch brake valves are de-energized by the PLC to close the brake.
The PLC checks now with the analogue pressure sensors if there is no pressure remaining
on either winch brake to ensure each brake is completely closed. If pressure remains a fault
will be created.

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Each winch brake is separately released by a solenoid valve.
An analogue pressure sensor after each valve gives a feed back of the actual pressure to the
PLC. On a lift or lower demand the winch brake valves are energized by the PLC, if the
pressure exceeds 50bar the hoist unit is released to lift or lower. Whenever the hoist
procedure is ended the winch brake valves are de-energized by the PLC to close the brake.
The PLC checks now with the analogue pressure sensors if there is no pressure remaining
on either winch brake to ensure each brake is completely closed. If pressure remains a fault
will be created.
For Straddle Carrier E build in 2011 or earlier:
Every time during opening of the winch brakes the brakes are flushed.
A solenoid valve controls the oil flow over two separate adjustable flow control valves to
each side of the hoist brake.

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A variable piston pump is supplying the brake system with a constant pressure of 160bar.
A pressure relief valve (190bar) secures the system against overpressure.
A pressure switch is monitoring the existence of a sufficient system pressure.
During the engine start a solenoid valve (-Y103) is relieving the pressure created by
the brake pump to the tank, this way the brake pump is not putting an extra load onto
the engine starter.
The same solenoid valve is acting as a filling valve for the hydraulic tank, the valve is
energized whenever the main contactor is on, the engine is off and the hydraulic tank level
is below 100%.
The other two solenoid valves (-Y356 & -Y357) on the hydraulic control block deliver
hydraulic pressure to the winch brakes when energized (to open the brakes) and release
the pressure to the tank when de-energized (to close the brakes).
Each solenoid valve is for one winch brake, after each of these two valves is a pressure
sensor installed, to give a feedback of the actual pressure to the PLC.
With this pressure reading the PLC evaluates the status of the hoist brake
(pressure < X bar = brake is open / pressure > X bar = brake is closed).

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This adjustment is necessary on commissioning, after replacement of the brake pump or the
hydraulic valve / control block.
The brake system should be operational.
The diesel engine should be operational.
The hydraulic tank should be full.
A pressure gauge with a minimum range of 200 bar should be connected to the above shown
test port.
Switch on ignition and start the engine.

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Loosen the lock nuts of the pressure regulator of the brake pump.
Observe the pressure at the hydraulic pressure gauge.
Screw in the pressure regulator of the pump, until the pressure gauge shows a pressure of
approx. 200 bar. If the pressure of 200 bar can't be reached using the pressure regulator, the
pressure relief valve on the brake system on the hydraulic block must be screwed in until
changes of the pump regulator lead to changes of the pressure and therefore 200 bar can
be set.
Now adjust the pressure relief valve in such a way that the pressure gauge reads 190 bar.
In this position the lock nut of the pressure relief valve has to be tightened.
Then screw out the pressure regulator of the brake pump until the pressure gauge reads a
pressure of 160 bar.
If no pressure decrease will be measured during this adjustment, apply the brake pedal
frequently to drain pressure from the accumulators.
At 160 bar the lock nut of the pressure regulator must be tightened again.

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Loosen the lock nuts of the pressure regulator of the brake pump.
Observe the pressure at the hydraulic pressure gauge.
Screw in the pressure regulator of the pump, until the pressure gauge shows a pressure of
approx. 190 bar. The pressure of 190 bar shouldn't increase anymore if the pressure
regulator of the pump is screwed in even more.
The pressure relief valve of the hydraulic block has to be replaced if the pressure stops to
increase way below 190bar or way above 190bar.
Then screw out the pressure regulator of the brake pump until the pressure gauge reads a
pressure of 160 bar.
If no pressure decrease will be measured during this adjustment, apply the brake pedal
frequently to drain pressure from the accumulators.
At 160 bar the lock nut of the pressure regulator must be tightened again.

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Loosen the lock nuts of the pressure regulator of the brake pump and of the pressure relief
valve of the brake system on the hydraulic valve / control block.
Observe the pressure at the hydraulic pressure gauge.
Screw in the pressure regulator of the pump, until the pressure gauge shows a pressure of
approx. 190 bar. If the pressure of 190 bar can't be reached using the pressure regulator, the
pressure relief valve on the brake system on the hydraulic block must be screwed in until
changes of the pump regulator lead to changes of the pressure and therefore 190 bar can be
set.
Now adjust the pressure relief valve in such a way that the pressure gauge reads 180 bar. In
this position the lock nut of the pressure relief valve has to be tightened.
Then screw out the pressure regulator of the brake pump until the pressure gauge reads a
pressure of 160 bar.
If no pressure decrease will be measured during this adjustment, apply the brake pedal
frequently to drain pressure from the accumulators.
At 160 bar the lock nut of the pressure regulator must be tightened again.

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While opening the parking brake the whole brake system pressure gets delivered to the
parking brake.
At the wheel gear test port of the parking brake should be a pressure of approx. 160 bar.
One solenoid valeve is located on each gantry frame to switch the brake system pressure to
the two parking brakes. The solenoid valve is controlled by the PLC system.

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Only if installed (non-existent from the year 2011)!
Mount a flow meter into the flushing line (hose).
Switch on the solenoid valve with 24V (or with parameter 12 [flush_hoist_brake]).
Observe flow rate during adjustment.
The flow regulator has to be changed, if the volume reading differs by much from 1,5 l/min.

Alternatively you can disconnect and direct the flushing feed line into a bucket and switch
on the solenoid valve for flushing a certain time.
For example in 20 seconds the volume should be about 0,5 liter.
The flow regulator has to be changed, if the volume in the bucket differs by much from
0,5 liter.

Repeat this procedure at the second winch.

After adjustments put everything back to the original condition of the system.

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Mount a flow meter into the flushing line (hose).
Switch on the solenoid valve with 24V (or with parameter 12 [flush_hoist_brake]).
Observe flow rate during adjustment.
Adjust flow to 1 l/min.

Alternatively you can disconnect and direct the flushing feed line into a bucket and switch
on the solenoid valve for flushing a certain time. In 15 seconds the volume should be about
0,25 liter.

Repeat this procedure at the second winch.

After adjustments put everything back to the original condition of the system.

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Connect test hoses one after another to all the test ports of the brake system in the gantry
frame and direct them into an open container.
With each bleeding procedure press the brake pedal several times until the hydraulic oil exit
from the respective test port without any air bubbles. Then continue with the next test port
and repeat the procedure.
Keep the following order of bleeding points

1. Test ports P (system pressure brake) at the accumulators

2. Test ports P (system pressure brake) at the relay valves
3. Test ports PCtr (control pressure operating brake) at the relay valves
4. Test ports PBr (operating pressure brake) at the wheel gear drives
5. Test ports PCtr 1 & PCtr 2 (control pressure circuit 1 & 2) on top of the machine deck

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Secure the Straddle Carrier against rolling.
Connect a test hose to the test port of the parking brake at the wheel fork and direct other
end into an open container.
Start the engine.
Push the parking brake button and put the Straddle Carrier into gear to open the parking
brake.
Toggle the gear switch back and forth several times to switch parking brake on and off.
Watch the oil coming out of the test hose. As soon as the oil is free of bubbles the parking
brake bleeding is finished.
Remove the test hose and screw the protection cap back on.
Repeat the whole procedure for the other three parking brakes.

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Connect a hose to the test and bleeding port of the winch brake and drain the oil into an
open container.
For every bleeding cycle lift or lower the hoist to open the winch brake. Repeat lifting or
lowering until the oil runs out without any air bubbles.
Afterwards change over to the second winch and repeat the procedure.

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An emergency release pump for the parking brake (e.g. for towing purpose) is located on top
of the gantry frame.
To release the parking brake by hand the plunger of the switching valves has to be pushed
in.
The pipe has to be removed from the clamps and inserted into the pump.
With moving the pipe up and down the pressure will rise and the parking brake will be
opened. The pressure from the hand pump to the parking brake is limited to 180bar by a
pressure relief valve.
If the plunger at the switching valves is pulled out to its original position the parking brake
will close again.

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An emergency release pump for the parking brake (e.g. for towing purpose) is located on top
of the gantry frame.
To release the parking brake by hand the lever at the ball valves has to be turned 90 degrees
as shown.
The pipe has to be removed from the clamps and inserted into the pump.
With moving the pipe up and down the pressure will rise and the parking brake will be
opened. The pressure from the hand pump to the parking brake is limited by a pressure relief
valve (models from 2008 up).
If the lever at the ball valves is put back to its original position the parking brake will close
again.

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At the sectional drawing of the wet disk brake is shown how the springs of the parking brake
pushes the parking brake piston against the operating brake piston. The operating brake
piston transfers the spring force to the brake disks. This way the parking brake is applied.

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The parking brake piston pushes the springs together whenever the piston area is
pressurized. This allows the operating brake piston also to move over and release gaps at
the brake disks. The parking brake is released.
The operating brake piston is pushing the brake disks together whenever the piston area of
the operating brake is pressurized, the force on the disks (=brake force) is depending on the
pressure at the operating brake piston.

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The control hole for the abrasive wear of the wet disks is located at the bottom area of the
wheel gear drive.
The drive motor has to be removed and the brake cooling lines have to be disconnected and
plugged.

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At the control hole the depths from the wheel gear housing to the piston surface has to be
measured while the operating brake is not applied (pressure-less) and the parking brake is
opened (pressurized).
Make a note of the measuring result.

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Repeat the depths measurement from the wheel gear housing to the piston surface while the
operating brake is fully applied (pressurized) and the parking brake is closed (pressure-less).
This measurement is also used for the abrasive wear determination.
Make also a note of this measuring result.
The differential of both measurements is the actual air gap.
The value of the air gap of a new set of wet disks is 3mm +0.5 / -0.1.

Determination of the abrasive wear

The original depth measurement of the new set of wet disks is stamped into the wheel gear
housing next to the control hole. Whenever the set of wet disks has been replaced the new
depth measurement has to be stamped into the wheel gear housing.
The maximum acceptable abrasive wear is 1.2mm.
So is an original depth of 60.5mm is stamped into the wheel gear drive the set of wet disks
have to be changed by a measured depth of 61.7mm.

Note: With increasing wear of the disks, the tension of the parking brake springs will
decrease and consequently the torque of the parking brake.

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Important notes:
The diesel engine has to be off!
The parking brake has to be closed!
The spreader has to be lowered onto capable stands / to the ground!
Only check the winch brakes one at the time!

The winch brake has to be pressurized at the port (A) to open the winch brake (mind. 55 bar
max. 160 bar).
The plug at the manual release opening (B) has to be removed and the depth to the piston
surface has to be measured (approx. 40mm).

Release the pressure at the port (A) now to close the winch brake and repeat the depth
measurement at the opening (B).

The set of wet disks has to be replaced if the difference between the two measured values
exceeds 5.5mm.

After successful measuring close the opening with the plug.

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