Service Information

Document Title: Function Group: Information Type: Date:

Brake, description 500 Service Information 2014/3/11
Profile:
CWL, L45B [GB]

Brake, description
The service brake on machines L40B, SN 192 and L45B, SN 195 is a pump accumulator brake system operated via the inch
brake pedal with hydraulic activation of the disc brake on the front axle.
The parking brake acts by mechanical activation of the disc brake on the front axle.
Machines L40B, SN 191 and L45B, SN 194 have two brake pedals. The inch brake pedal on the left is a pump accumulator
brake system with hydraulically activated oil bath multiple disc brake on the rear axle.
The right brake pedal is a pump accumulator brake system with hydraulically activated oil bath multiple disc brake on the
rear axle.
The parking brake acts by mechanical activation of the disc brake on the front axle.
If the accumulated pressure in the brake system falls below 9.5 MPa (95 bar), the indicator light (6) flashes.
With the parking brake applied, the indicator light (6) lights. If the travelling switch or multifunction lever is used to preselect
a direction of travel (forward/reverse) while the parking brake is applied, the indicator light (6) flashes and a warning buzzer
sounds.

Figure 1
Indicator light, parking brake accumulated pressure, braking system
 Service Information

Document Title: Function Group: Information Type: Date:

Brake system, component 500 Service Information 2014/3/11
Profile:
CWL, L45B [GB]

Brake system, component

Position of components, machine L40B, SN 192 / L45B, SN 195

Figure 1

1. Inch brake pedal

2. Parking brake
3. Hydraulic pump
4. Hydraulic oil tank
5. Inch brake valve
6. Brake disc
7. Parking brake caliper
8. Service brake caliper
9. Accumulator charge valve

Position of components, machine L40, SN 191 / L45B, SN 194

Figure 2

1. Inch brake pedal

2. Brake pedal
3. Parking brake
4. Hydraulic pump
5. Hydraulic oil tank
6. Inch brake valve
7. Brake valve
8. Brake disc
9. Parking brake caliper
10. Accumulator charge valve
11. Multiple disc brake, rear axle
 Service Information

Document Title: Function Group: Information Type: Date:

Hydraulic diagram, brake 500 Service Information 2014/3/11
system, dry brakes
Profile:
CWL, L45B [GB]

Hydraulic diagram, brake system, dry brakes

Figure 1

1. Inch brake valve

2. Brake light switch (5 bar / 73 psi)
3. Pressure switch control pressure (8.5 bar / 123 psi)
4. Warning switch, low brake pressure (95 bar / 1378 psi)
5. Accumulator charge valve
6. Steering pump with priority valve
7. Hydraulic adjustment pump (control pressure)
8. Parking brake caliper
9. Service brake caliper

N Connection for hydraulic fan

EF Excess Flow
CF Priority Flow
LS Load Sensing Signal
T Tank
SP2 Accumulator
SP1 Brake pressure pedal
M1 Test brake pressure
M2 Test accumulator charge
 Service Information

Document Title: Function Group: Information Type: Date:

Hydraulic diagram, brake 500 Service Information 2014/3/11
system, wet brakes
Profile:
CWL, L45B [GB]

Hydraulic diagram, brake system, wet brakes

Figure 1
 1. Inch brake valve
2. Brake valve
3. Brake light switch (5 bar / 73 psi)
4. Warning emitter, low brake pressure (95 bar / 1378 psi)
5. Accumulator charge valve
6. Steering pump with priority valve
7. Hydraulic adjustment pump (control pressure)
8. Oil bath multiple disc brake, rear axle

N Connection for hydraulic fan

EF Excess Flow
CF Priority Flow
LS Load Sensing Signal
T Tank
SP2 Accumulator
SP1 Brake pressure pedal
M1 Test brake pressure
M2 Test accumulator charge
M3 Test brake pressure
 Service Information

Document Title: Function Group: Information Type: Date:

Brake linings, checking 510 Service Information 2014/3/11
wear
Profile:
CWL, L45B [GB]

Brake linings, checking wear

Op nbr 517-001

A brake lining wear measurement gives information on the overall condition of the brake disc set without disassembling the
final drive.
This is required above all on modified braking behaviour such as:

 Braking noise
 change in deceleration
 change in brake fluid level
 change in brake pressure

NOTE!
The wear measurement must be performed on both sides of the final drive and should be tested at least once a year.

Multi disc brake lining's wear measurement

Limiting value of the piston stroke

Axle model Number of inner discs Allowed piston Normal piston stroke
stroke
AP-R745 4 5 mm (0.20 in) 2,5 - 2,9 (0,10 - 0,11 in.)

NOTE!
The number of inner discs is punch-marked on the rating plate.

Measurement

1. Turn the final drive until the screw plug is in top position. (12 o'clock)

Figure 1
Final drive position

2. Remove the screw plug, and apply the brake pressure, minimum 40 bar (580 psi).

3. Screw in the measuring screw (M16 x 1.5).

NOTE!
Tightening torque: 10 Nm (7.4 lbf ft)
 4. Measure the dimension 'X'.

Figure 2
Measuring, dimension X

5. Remove the brake pressure, and screw in the measuring screw (M16 x 1.5).
NOTE!
Tightening torque: 10 Nm (7.4 lbf ft)

6. Measure the dimension 'Y'.

7. Calculate the difference between X and Y.

Dimension 'X' - Dimension 'Y' = Piston stroke

8. Compare this piston stroke with the table 'Limiting value of the piston stroke'.
NOTE!
If the measured piston stroke exceeds the allowed value, the lining discs have to be replaced on both sides of the
final drives.

Figure 3
Measuring, dimension Y

NOTE!
To repair the multiple disc brake, see Service Manual Components ZF Axles AP-B 745 / AP-R 745.
 Service Information

Document Title: Function Group: Information Type: Date:

Brake disc, replacing one 511 Service Information 2014/3/11
Profile:
CWL, L45B [GB]

Brake disc, replacing one

Op nbr 511-002

Remove brake disc

Figure 1

1. Remove universal shaft (1) on front axle.

2. Withdraw ES bolt (2) and remove handbrake cable (3) from lever.

3. Unscrew both fixing bolts on brake caliper (4), unscrew parking brake and remove from brake carrier.

4. Pull brake disc (5) off universal shaft flange.

5. Install brake disc

Push brake disc (5) onto universal shaft flange.

6. Fit brake caliper (4), parking brake onto brake carrier. Screw in fixing bolt and tighten with a torque of 300 Nm
 (221 lbf ft).

7. Connect handbrake cable to lever and secure with ES bolt.

8. Fit universal shaft and tighten fixing bolt with a torque of 72 Nm (53 lbf ft).

9. Check brake system for function.

 Service Information

Document Title: Function Group: Information Type: Date:

Brake calliper removed, 511 Service Information 2014/3/11
reconditioning
Profile:
CWL, L45B [GB]

Brake calliper removed, reconditioning

Brake caliper, parking brake

Op nbr 511-081

Figure 1
Parking brake caliper

1. Brake caliper
2. Shaft seal
3. Coil spring
4. Operating lever
5. Washer
6. Twistlock
7. Fixing bolt
8. Ring cage
9. Balls
10. Rotor assembly
11. Insert
12. Plastic cover
13. Brake lining

1. Remove brake pad (13)

2. Release twist lock (6) and unscrew fixing bolt (7).

3. Remove twist lock (6), disc (5), control lever (4) and coil spring (3).

4. Unscrew rotor assembly (10) from caliper.

NOTE!
The ring cage and three balls may fall out with the rotor assembly.

5. Remove the three balls (9) and ring cage (8).

6. Using a sharp knife, make several cuts on the outside of the plastic cover (12). Break off the plastic cover and
remove insert (11).

7. Press out shaft seal ring (2) from caliper using a pressing mandrel.

8. Clean all parts of the caliper thoroughly with methanol and blow dry with compressed air.
NOTE!
Do not use any cleaning agents containing mineral oil.

9. Press in new shaft seal ring (2) into caliper from the outside until it engages in a groove.

10. Coat one side of the new insert (11) with lubricant and insert plastic cover, then coat the other side of the insert
with lubricant.

11. Engage brake pad in plastic cover (12).

12. Insert plastic cover (12) on rotor and compress in the vice until the plastic cover engages.

13. Remove brake pad from plastic cover again.

14. Coat ball guide in caliper with lubricant.

15. Insert balls (9) and ring cage (8) in caliper.

16. Insert rotor assembly (10) and position ball guide against balls.

17. Place coil spring (3) on caliper and mount control lever (4) in base position.
NOTE!
The coil spring must be guided outside the four pins on the control lever.

18. Fit washer (5) and twist lock (6) so that the tabs engage in the lower bore of the control lever. Screw in control lever
(7) and tighten with a torque of 15 Nm (11 lbf ft).

19. Fit brake pad in brake caliper.

 Service Information

Document Title: Function Group: Information Type: Date:

Brake disc, replacing one Service Information 2014/3/11
Profile:
CWL, L45B [GB]

Brake disc, replacing one

Remove brake disc

Op nbr 511-002

Figure 1

1. Remove universal shaft (1) on front axle.

2. Withdraw ES bolt (2) and remove handbrake cable (3) from lever.

3. Unscrew both fixing bolts on brake caliper (5), unscrew parking brake and remove from brake carrier.

4. Unscrew brake line (4) at screw nozzle.

5. Unscrew both fixing bolts on brake caliper (6), unscrew service brake and remove from brake carrier.

6. Pull brake disc (7) off universal shaft flange.

Install brake disc

 7. Push brake disc (7) onto universal shaft flange.

8. Fit brake caliper (5), parking brake and brake caliper (6), service brake on brake carrier. Screw in fixing bolt and
tighten with a torque of 300 Nm (221 lbf ft).

9. Connect handbrake cable to lever and secure with ES bolt.

10. Screw brake line onto screw nozzle and tighten with a torque of 30 Nm (22 lbf ft).

11. Fit universal shaft and tighten fixing bolt with a torque of 72 Nm (53 lbf ft).

12. Bleed brake system and check for leaks and function.
 Service Information

Document Title: Function Group: Information Type: Date:

Brake calliper removed, Service Information 2014/3/11
reconditioning
Profile:
CWL, L45B [GB]

Brake calliper removed, reconditioning

Brake caliper, service brake

Op nbr 511-081

Figure 1
Service brake caliper

1. Brake caliper
2. Bleed valve
3. Sealing ring
4. Piston
5. Dust caps
6. Damper plate
7. Brake lining
8. Accessories kit

1. Remove brake pad (7)

2. Remove dust-tight cap (5) from caliper using a rounded tool.

3. Using a screw clamp and a wooden shim approx. 8 mm thick, fix the piston in one brake caliper half yoke.

4. Press out the opposite piston (4) from the caliper using compressed air.
NOTE!
 10 bar (1 MPa) (145 psi) pressure gives a piston force of up to 6000 N.

5. Close the open cylinder bore using a sealing plate you have made.

6. Remove the screw clamp and wooden shim, and press the piston out of the brake caliper using compressed air.

7. Using a rounded plastic needle, press the sealing ring (3) out of the cylinder groove.

8. Clean all parts of the caliper thoroughly with methanol and blow dry with compressed air.
NOTE!
Do not use any cleaning agents containing mineral oil.

9. Check cylinder bore and piston body carefully for damage, replace complete caliper if necessary.

10. Moisten cylinder bore and groove, piston and sealing rings with assembly fluid.

11. Insert sealing rings (3) carefully in the corresponding cylinder groove.

12. Using a commercial piston return device, insert the pistons straight in the bores.

13. Push dust-tight caps (5) over the piston ends and press into the corresponding grooves of the caliper.
 Service Information

Document Title: Function Group: Information Type: Date:

Brake system, checking 520 Service Information 2014/3/11
function, hydraulic
Profile:
CWL, L45B [GB]

Brake system, checking function, hydraulic

NOTE!
The brake system should be tested according to STVZO § 29 and Appendix VIII to the STVZO.

Op nbr 520-001

11666020 Pressure gauge

11666037 Hose

1. Run the machine until a hydraulic oil temperature of 55 + 5°C (131 + 41°F) is reached.

Figure 1

2. Turn off engine and apply parking brake.

3. Evacuate the brake system by pressing the brake pedal repeatedly.

4. Connect pressure gauge to measurement point “M2”.

NOTE!
On L40B, SN 191 and L45B, SN 194 connect to measurement point “M3”.
 Figure 2

5. Turn ignition key to position “I”, the warning light (parking brake — accumulated pressure brake system) must now
flash.

Figure 3
Warning light parking brake accumulated pressure, braking system

6. Start engine. If the pressure (at measuring point “M2”) shows 95 bar (1378 psi), the warning light must come on
(with parking brake applied).

7. Fill brake system until the accumulator charge valve closes. Pressure display at “M2” Nominal:150 bar (2176 psi).
NOTE!
At full engine speed, the accumulator fill time should not exceed 30 seconds.

8. Turn off engine.

9. Turn on ignition and activate brake pedal four times.

NOTE!
A regeneration time of one minute must be left between each activation.

10. After the fourth activation, the warning light should no longer flash (residual pressure minimum 95 bar / 1378 psi).
NOTE!
If after checking the pressure reading at “M2”, Nominal: 150 bar (2176 psi) shut off pressure is not reached, the
accumulator charge valve must be set accordingly.

11. Release nut (1) on accumulator charge valve. To increase the pressure, turn the adjustment screw clockwise, or to
reduce the pressure anticlockwise, until the nominal value is displayed.

12. Screw on new nut and tighten with a torque of 40 Nm (29.5 lbf ft).
NOTE!
The triggering pressure cannot be changed, it changes with the shutdown pressure (difference 30 bar / 432 psi).
 Service Information

Document Title: Function Group: Information Type: Date:

Accumulators, checking in 527 Service Information 2014/3/11
machine
Profile:
CWL, L45B [GB]

Accumulators, checking in machine

Op nbr 527-003

11666135 Gas filling kit

WARNING
Charging the accumulator with nitrogen only. Do not use oxygen or compressed air. Danger of explosion

NOTE!
Test only at room temperature of 20°C (68°F)

1. Release pressure in brake system.

2. Screw filler and tester (gas filler kit 11666135) to accumulator.

3. Open accumulator fill valve. Read pressure display on filler and tester: nominal 60 bar (870 psi).

4. If the value shown is not correct, connect the nitrogen cylinder to the filler and tester and fill until the specified gas
fill pressure is achieved.
NOTE!
The gas fill pressure should be tested at least once a year. Replace the accumulators if the gas pressure has fallen
by more than 30%.
 Service Information

Document Title: Function Group: Information Type: Date:

Accumulator, checking 527 Service Information 2014/3/11
(removed)
Profile:
CWL, L45B [GB]

Accumulator, checking (removed)

Op nbr 52701

11666019 Pressure gauge 0–6 MPa (0–60 bar) (0–870 psi)

11666041 Pump
11666037 Hose
E 1234 Nipple
E 1281 Nipple

NOTE!
All work on the brake system must be conducted in the cleanest possible conditions. Wipe clean all pipe and hose
connections before they are disconnected. Plug all pipes and hoses immediately after disconnecting.

If the functional check of the brake system indicates that one or more accumulator has insufficient precharge pressure or
lacks precharge pressure, check each accumulator as follows:
Removing

1. WARNING
An accumulated pressure remains in the brake system even if the engine has been stopped. If the system is
opened without first releasing the pressure, oil under high pressure will jet out.

Release the brake system pressure by depressing the brake pedal repeatedly (30–40 times).

2. Carefully remove the connection pipes to the accumulators and plug the connections.

NOTICE
There may be a residual pressure in the brake system.

3. Remove the accumulators.

4. Pressure test
Test the accumulators one at a time.
 Figure 1
Checking removed accumulator

A. Accumulator

1. 11666041
2. 11666037
3. E 1234
4. 11666019
5. Included in 11 666 037
6. E 1281

5. Pump oil into the accumulator.

After a few pump strokes, the pressure will increase rapidly to the precharge pressure and will continue to increase
slowly.
Precharge pressure: min. 3.5 MPa (507.5 psi)
If the precharge pressure is below 3.5 MPa (507.5 psi), the accumulator must be discarded, see Discarded
accumulators.

Installing

6. Install the accumulators.

7. Start the engine and let it run at increased rpm until the shutoff pressure is 13.4–14.0 MPa (134–140 bar) (1943–
2030 psi)
 Service Information

Document Title: Function Group: Information Type: Date:

Discarded accumulators 527 Service Information 2014/3/11
Profile:
CWL, L45B [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 (0.118 in) drill.

Figure 1
Accumulator

A. Drill here with a Ø3 mm (0.118 in) drill

1. Nitrogen gas space

2. Rubber diaphragm
3. Connection for oil
 Many thanks for your purchase.
Happy every day.

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