Braking system, description

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L120F Volvo

The machine has a hydraulic brake system, divided into two circuits, one for the front axle and one for the rear axle.
The hydraulic brake system consists of a foot brake valve and an accumulator block with three accumulators. One accumulator is for
the front circuit, one accumulator is for the rear circuit and one accumulator is in common.
The accumulators are precharged with nitrogen gas and their purpose is to store pressure and to make sure that the braking capacity
is safeguarded.
The brake system is supplied via the central valve with hydraulic oil from Pump 3 (P3) or Pump 2 (P2).
P3 supplies the radiator fan and ensures that the brakes are charged during transport operation. P2 supplies the brake system
passively when the working hydraulics is used when P2 is not supplying the steering system with oil.
The front and rear axles are equipped with wet disc brakes. Brake cooling is achieved in that each brake disc is equipped with pump
impeller, which works as a circulation pump for the axle oil.
The cooling system and the brake system have many components in common, see Cooling fan, description.
See also Wiring diagram 501 and Hydraulic diagram, complete.
Figure 1

1 Pump 3 10 Priority spool

2 Central valve 11 Pump 2
3 MA5502 Brake pressure charging 12 Foot brake valve
4 PWM2601 Control, cooling fan 13 SE5205
5 Pressure reducing valve, brake 14 SE5218
6 Brake accumulator block SW3801 Keyboard
7 Cooling fan motor SW9143 Attachment locking
8 Hydraulic oil cooler * Atmospheric pressure sensor
9 Filter

Pump 2 (P2), hydraulic (passive) brake pressure charging

P2 feeds the central valve and from there primarily supplies the steering with oil. When the steering is "saturated" with oil, the priority
spool in the central valve shifts to supplying brake pressure charging, servo system and working hydraulics. When the working
hydraulics is used and the pressure exceeds the system pressure existing in the brake circuit, the brake accumulators will be
passively charged via the pressure-reducing valve for brake pressure.
Pump 3 (P3), electrically controlled brake pressure charging
When the pressure in the working hydraulics is insufficient, the brake system is instead charged by P3. P3 supplies oil to port (PF) on
the central valve and from there to the cooling fan motor via port (PFF).
The flow from P3 is conducted into the central valve via connection PF and is conducted on to the cooling fan via MA5502 and
connection PFF. The pressure from the pump is also supplied to PWM2601 via a restriction. PWM2601 can, if the current is
increased, close the connection to tank, and thereby create a higher LS-pressure. The flow from P3 varies with the LS-pressure and
thereby also the cooling fan speed. The function is proportional. Through feed-back from the fan revolution sensor SE2601 the V-
ECU receives information about whether the signal to PWM2601 has resulted in the correct fan speed.
When V-ECU registers a too low pressure from SE5218, brake pressure charging is initiated. The current to PWM2601 increases. At
the same time MA5502 closes. The hydraulic oil flow to the fan is then limited by a restriction.
When the brake pressure has increased sufficiently, brake pressure charging is interrupted. The V-ECU reduces the current to
proportional valve PWM2601, MA5502 opens and the cooling fan returns to the rpm it had before brake pressure charging started.
If the requirement for cooling is great, the cooling fan motor receives a large flow of oil producing a high pressure in the circuit. If the
pressure exceeds the existing system pressure in the brake circuit, the brake accumulators will be charged passively.
If the pressure in the brake accumulators is too low, sensor SE5218 warns of this, via the instruments.
Braking
When the brake pedal is pressed down, the connection to the axles is opened. The hydraulic oil can then flow from the pumps via the
central valve and the accumulator block for the brakes to the axles where the brakes are applied.
The foot brake valve is of the proportional type, which means that the output brake pressure is proportional to the pedal angle. The
valve is divided into two circuits. One circuit acts on the front axle brakes and the other on the rear axle brakes. The maximum brake
pressure out to the axles is reduced compared with the pressure that is delivered to the foot brake valve. Adjustment of the reduced
brake pressure is performed on the underside of the valve by increasing or decreasing the pedal stroke.
Brake test
With the aid of the operator display unit it is possible to carry out a simple test of the brakes, see Information display, service.
Instructions for the procedure is shown on the display unit.
The bake test calculates the retarding ability of the machine to gain information about the condition of the brakes. The measuring
result and the average value of the brake pressure is shown on the display unit. If the measuring is not approved, no measuring
results will be shown on the display unit.
When the speed exceeds 10 km/h (6 mph) after completed test, the measuring result disappears until a new test is carried out. The
three latest approved measuring results are saved for presentation on the display unit under the service menu.
Software

Brake pressure, monitoring (accumulator)

Input signals Conditions for output functions Output functions

¡ Brake pressure low ¡ Brake pressure low True ¡ Warning

True/False Engine Off Low brake pressure
¡ Engine On/Off Machine moving On
¡ Machine moving On/
 Off
¡ Brake pressure low True
Engine On

The following applies in case of incorrect input signals:

Input signal Assumed value in case of a fault

Brake pressure, low True
Engine On/Off Off
Machine moving On

Brake pressure (accumulator), reference

Input signals Conditions for output functions Output functions
General conditions for the function
¡ Brake pressure,
SE5218 ¡ The output functions become input signals for brake pressure charging

¡ Brake pressure up to 9 MPa (1305 psi) ¡ Brake pressure low True

¡ Brake pressure above 9 MPa (1305 psi) ¡ Brake pressure low False

¡ Brake pressure up to 12.5 MPa (1813 psi) ¡ Brake pressure charging low
True

¡ Brake pressure above 14.5 MPa (2105 psi) ¡ Brake pressure charging low
False
NOTE!
If the brake pressure is rising the limit value is 14.5 MPa (2103
psi). If the brake pressure is dropping the limit value is 12.5
MPa (1813 psi).

Monitoring, SE5218 See Diagnostics

¡ Check Brake system failure

Brake pressure charging

Input signals Conditions for output functions Output functions

¡ Brake pressure low ¡ Brake pressure low True for 10 seconds ¡ Brake pressure charging
True/False ¡ Engine On requested
¡ Brake pressure
charging low True/
False ¡ Brake pressure charging low True
¡ Engine On/Off ¡ Engine On

¡ Brake pressure charging low True for 60 seconds ¡ Warning

¡ Engine On Brake system failure

¡ Brake pressure charging low False ¡ Brake pressure charging

¡ Engine On requested
¡ Brake pressure low True ¡ Warning
Brake system failure
The following applies in case of incorrect input signals:

Input signal Assumed value in case of a fault

Brake pressure charging, low Brake pressure charging requested
Engine On/Off On
Brake pressure, low False

Auxiliary brake (engine braking)[T1]i

Input signals Conditions for output functions Output functions

¡ Maximum cooling ¡ Engine speed above 1400 rpm ¡ Requested cooling fan
fan speed speed with auxiliary brake =
¡ Directional status Maximum cooling fan speed
¡ Gear selector
position
¡ Engine speed, ¡ Engine speed below 1400 rpm ¡ Requested cooling fan
SE2701 speed with auxiliary brake =
0

[T1]The function prevents upshifting when the machine is driven downhill.

In case of a fault with any of the input signals, requested cooling fan speed with auxiliary brake will be = 0.

Brake pedal applied

Input signals Conditions for output functions Output functions

¡ Output brake ¡ Output brake pressure below 0.5 MPa ¡ Brake pedal applied Off
pressure, SE5205

¡ Output brake pressure from 0.5 MPa (73 psi) and ¡ Brake pedal applied On
upwards

Monitoring, SE5205 See Diagnostics

¡ Check Brake system failure

Stop lights
Input signals Conditions for output functions Output functions

¡ Brake pedal applied ¡ Brake pedal applied Off ¡ Brake pedal applied Off
On/Off

¡ Brake pedal applied On ¡ Brake pedal applied On

¡ Stop lights, LA5201 and
LA5202 light up

Brake test
Input signals Conditions for output functions Output functions

¡ Speed, SE4307 ¡ Brake test activated On (via the display unit). ¡ Brake test started On
¡ Output brake ¡ Speed above 20 km/h (12.4 mph).
pressure, SE5205
¡ Clock
¡ Brake test activated ¡ Speed 15 km/h (9.3 mph) at the time of the ¡ The time (clock) and output
On/Off deceleration. brake pressure is stored.
 ¡ Speed 5 km/h (3.1 mph) at the time of the deceleration.

¡ Completed brake test. ¡ Brake test information is

shown on the display unit
within 0.5 seconds.

Monitoring, SE4307 See Diagnostics

¡ Check Transmission failure

Monitoring, SE5205
¡ Check Brake system failure

In case of faulty input signals for speed, output brake pressure or clock (time) the output signals are considered to be faulty.
In case of faulty input signal for Brake test activated, it is considered to be Off.