Service Manual of Wheel Loader

Contents
5 Brake system ......................................................................................................................................... 1
51 Service brake system .................................................................................................................................. 3
511 Composition of service brake system ................................................................................................ 3
512 Maintenance of foot brake valve ....................................................................................................... 3
513Assembling and disassembling of booster.......................................................................................... 6
514Air tank ................................................................................................................................................. 9
515 oil-water separator .............................................................................................................................11
516 Brake caliper ..................................................................................................................................... 14
517 Exhaustion method of brake system ............................................................................................... 15
52 Parking brake system ............................................................................................................................... 16
521 Introduction of parking brake system ............................................................................................ 16
522 Replacement of parking brake chamber ........................................................................................ 16
523 parking brake solenoid valve ........................................................................................................... 17
53 Common faults of brake system .............................................................................................................. 18

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 Service Manual of Wheel Loader

5 Brake system
The brake system of the loader includes service brake system and parking brake system. The
Manual mainly introduces the dual-circuit dry brake. As the working principle of the single-circuit
brake is the same with that of the dual-circuit brake, it will not be repeated here.

To power slot of To air compressor

variable speed pilot
valve

Fig. 5-1 Layout of Service Brake System

1. Foot brake valve; 2. Booster; 3. Air tank; 4. Rear axle brake tube; 5. Front axle brake tube; 6.
Oil-water separator

Fig. 5-2 Schematic Diagram of Service Brake

1. Booster; 2. Power stop valve; 3. Foot brake valve; 4. Air tank; 5. Oil-water separator; 6. Air
compressor

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Fig. 5-3 Layout of Parking Brake System

1. Parking brake chamber; 2. Parking brake solenoid valve; 3. Air tank

Fig. 5-4 Schematic Diagram of Parking Brake

1. Parking brake chamber; 2. Parking brake solenoid valve; 3.Air tank

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Fig. 5-5 Connection Dimension of
Foot Brake Valve
Opening A: to air tank interface
M22×1.5
Openings B&D: to booster interface
M22×1.5
Opening C: interface of brake tail
lamp switch NPT1/8
51 Service brake system
511 Composition of service brake system
The air-over-oil caliper disc dry brake is mainly
composed of air compressor, dryer (equipped), booster,
brake caliper, foot brake valve, air tank and pipelines,
etc.
512 Maintenance of foot brake valve
Main technical parameters
Rated working air pressure: 784kpa;
Operating temperature range: -30℃~+80℃;
Sealing requirements: off working state ≤10kpa,
working state ≤20kpa.
Disassembling of foot brake valve assembly
1. Place the machine at the maintenance position.
2. Turn on the drain valve of the air tank to unload the
brake system.
3. Disconnect the connectors of the stop lamp switch
of the brake valve.
4. Disconnect the brake valve to the booster and air
pipe of air tank.
5. Disconnect the brake valve to the air pipe of
variable speed pilot valve.
6. Disconnect the intake pipe of brake valve.
7. Disassemble the four bolts connected to the foot
brake valve assembly and the cab and remove the
foot brake valve.
Assembling of foot brake valve assembly
1. Place the foot brake valve assembly in the cab and
fasten the four bolts of foot brake valve connected
to the cab.
2. After applying an appropriate amount of sealant
545 on the elbow connection, T-junction and stop
lamp switch and then fasten them to the brake
valve. The bent end of the elbow connection is
towards the back downwards, basically with a 45°
angle to the horizontal plane.
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Fig. 5-6 Brake performance test
Note:
1) Wipe clean the foreign matters of the threads.
2) Apply an appropriate amount of sealant on the ends
of the straight joint and stop lamp switch. When
doing so, start to apply sealant on the second
buckle at the end of the external thread and fill the
third to fifth buckles of the thread with glue
solutions.
3) After the completion of assembling, there should
be one complete circle of glue line at the edge of
the external thread and the threaded hole. During
the assembling, the glue should be timely applied.
The threads should be manually fastened. The
setting time should be at least over 30min after the
assembling.
AT545 sealant
T-junction/elbow connection: 60±10Nm
Air pipe: 57±7.5Nm
3. Connect the foot brake valve to the booster hose
and the intake hose.
4. Connect the harness of the stop lamp switch.
5. The disassembling steps of different vehicles
equipped with dual-foot brake valve are the same
with those equipped with the one-foot brake valve.
Carry out the disassembling by reference
accordingly.
Common fault diagnosis and troubleshooting of foot
brake valve
The working performance of the foot brake valve will
directly affect the braking effects and the safety of the
loader during the driving. Generally, it is not allowed to
arbitrarily disassemble the foot brake valve. However,
the common faults in the foot brake valve should be
mastered so as to quickly solve the problems.
1. Detection of the brake performance of foot brake
valve
 In the event of any doubt about the performance of
the air brake valve, there is no need to remove the
air brake valve. When inflating the air inlet with
about 800kPa air pressure, immerse the air outlet of
the valve into the water.
 If there is no bubble coming out of the water, it
indicates that the non-brake performance of the air
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brake valve is normal;
 When there is bubble coming out of the water, in
indicates that the brake valve leaks air in the
non-brake state;

2. Balance assembly
The balance spring that becomes less resilient is likely
to slow down or deactivate the brake.

Fig. 5-7 Balance spring

1. Balance spring assembly

3. Piston and return spring

The piston return spring that becomes less resilient or is
broken will result in excessive brake; if the stuck piston
assembly fails to effectively push down the intake valve
core to open the air inlet, it will cause the reduction of
braking torque.

Fig. 5-8
1. Piston return spring
2. Piston

4. Intake valve assembly

When the rubber valve aperture on the top of the intake
valve is damaged or has sundries, part of the air will
leak from the intake valve. The valve return spring that
becomes less resilient, rusted or broken will lead to poor
sealing;
The poor sealing caused by worn O-ring will result in
air leakage from the air outlet during the brake, thus
causing slow brake. During the maintenance, paper pad
or copper sheet can be added in the groove installed
with seal rings to enhance the sealing. When the seal

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Fig. 5-9 Intake Valve Assembly rings are severely damaged, become less elastic or
broken, they should be replaced by new ones.
1.Rubber valve aperture
2. Valve return spring
3. O-ring
4. O-ring

513Assembling and disassembling of

booster
Detection of booster pressure
1. There is doubt about the performance of the
booster, remove the fittings of the oil outlet of the
booster and install one hydraulic pressure indicator
(0-25MPa, accuracy: not less than level 0.4) at the oil
outlet. Press the air brake valve pedal and observe the
pressure values of the barometer and the hydraulic
Fig. 5-10 Detection of booster pressure indicator of the oil outlet:
pressure  when the ratio of the pressure values of hydraulic
pressure indicator and barometer reaches 90% of
the supercharge ratio, it indicates that the
performance of the booster is normal; when such
ratio is less than 90% of the supercharge ratio, it
indicates that the performance of the booster
attenuates;
 When the hydraulic pressure indicator has no
pressure value, it indicates that the piston is stuck;
 When the pressure values of the hydraulic pressure
indicator and barometer synchronously reduce, it
indicates that air chamber leaks air;
 When the pressure value of the barometer does not
decrease, while the pressure value of the hydraulic
pressure indicator reduces, it indicates that the
hydraulic chamber of the booster leaks oil.

Note: The pressure measuring openings vary with

different boosters. The actual object shall prevail.

Disassembling of booster assembly

1. Place the vehicle at the service position.
2. Remove the pressure of the air tank.
3. Disconnect the booster to the front and rear axle
brake hoses and collect the discharged brake fluid with a
clean container.
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4. Disconnect the intake hose and steel pipe of the
booster.
5. Disassemble the fixed bolts of the booster and
remove the booster.

Note: The booster should be assembled according

to the reverse steps of those as mentioned above.

Fig. 5-11 Assembling of Piston Ring

Cup
1. Push rod piston assembly
2. Air piston ring cup
Disassembling of booster
1. During the disassembling and the reassembling,
please note not to damage each finished surface
and rubber parts of the products. In the event of
damaged rubber parts, replace them with new parts
and ensure that the assembling environment and
the components are clean.

Fig. 5-12 Assembling of Push Rod

Piston Assembly
2. Assemble air piston ring cup and push rod piston
1. Push rod piston assembly assembly and then set the seal ring in the piston
groove with the tools. Note the installation
direction. The installation method is similar to that
of the belt. Be sure not to damage the seal ring and
the piston.

Note: Please use blunt wrench during the

installation and do not damage the seal ring.

Fig. 5-13 Assembling of Connection

Cover
1. Connection cover assembly

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3. After applying one layer of #2 lithium-based grease

on the inner wall of the cylinder and on the surface
of the seal ring, be sure to place the push rod piston
assembly in the cylinder assembly.

Note: The rubber parts of the air chamber should

not contact such oil liquid as brake fluid; otherwise, it
will cause corroded rubber.

Fig. 5-14 Assembling of Cylinder

Assembly and Connection Cover
Assembly
1. Cylinder assembly
2. Connection cover assembly
4. Assemble the scraper seal, liner and Y-ring to the
connection cover and assemble them into the
connection cover assembly.

Note: Please use blunt wrench during the

installation. Do not damage the scraper seal, liner and
Y-ring.

Fig. 5-15 Assembling of Piston

Assembly
1. Hydraulic piston
2. Cup

5. Connect the cylinder assembly and the connection

cover assembly and fasten them with bolts, nuts
and washers.

Fig. 5-16 Assembling of Piston

Assembly

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6. Assemble the cup and the hydraulic piston into
hydraulic piston assembly.

Note: Please use blunt wrench during the

installation. Do not damage the cup.

7. After the air enters the air chamber, push out the air
piston. Assemble the push rod seat assembly and
Fig. 5-17 Assembling of Hydraulic the hydraulic piston assembly with the retainer
Cylinder ring.
1. Assembling of hydraulic cylinder 8. Assemble the hydraulic cylinder and the
connection cover with the bolts and spring washers.
9. The inner structures of the booster of different
models and manufacturers will vary slightly. The
actual object shall prevail.
10. The booster should be disassembled according to
the reverse steps of those as mentioned above.

514Air tank
A B Function
The air tank installed on the left side of the middle part
of the loader, mainly used to:
(1) Store compressed air to provide brake air source
for the brake system;
C
D (2) When the air compressor is not working, ensure the
E brake air for certain times;
F (3) Install carriers for safety valve, brake pressures
switch and drain valve;
(4) When the driver presses the foot brake pedal, the
G compressed air enters the brake or the braking
chamber through the control valve to achieve
service brake;
Fig. 5-18 Air tank
1. A- Air inlet Note: The appearances and structures of air tanks
2. B- Tire inflation inlet of different models vary. This introduction shall be only
3. C-Air outlet for reference.

4. D- Preformed opening Compositions

5. E- Interface of brake pressure Brake pressure switch

switch Provide pressure values for the barometer to enable the
6. F- Interface of air pressure sensor driver to correctly determine the brake state according to
the readings of the barometer and determine whether the
7. G- Drain valve
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performance of the air channel is good.
Emergency brake switch
When the air tank pressure is excessively low or the
brake system leaks air, the emergency brake switch
functions to interrupt the power transmission and
control the parking brake solenoid valve to achieve the
parking brake.
Safety valve
When the safety control valve of the oil-water separator
combination valve fails, it protects the safety of the
brake system. The set pressure is 0.85-0.9Mpa. When
the pressures is excessively high, switch on the safety
valve to exhaust air.
Inflation valve
The inflation valve is used to inflate the tire.
Use and maintenance of air tank
Harm of accumulated water in the air tank
When the water is accumulated to certain extent, if it is
not discharged timely, the water, rust and impurities will
enter the foot brake valve and the inner part of the
booster along the pipelines during the braking, thus
causing contaminated foot brake valve and inner part of
the booster and resulting in such faults in reduced
lubricity, rust, worn sealing elements and stuck piston,
etc.

Note: The accumulated water in air tank is the

main reason to cause fault in brake elements. Users
should discharge the water regularly according to the
requirements of the operation and maintenance manual
during the use!
Disassembling of air tank assembly
1. Place the vehicle at the service position.
2. Remove the pressure of the air tank.
3. Disassemble the bolts of the air tank hood and
remove the hood.
4. Disconnect the air tank to the brake valve hose.
5. Remove the emergency brake switch and the
pressure switch.
6. Disconnect the air inlet and parking brake air pipe
of air tank.
7. Disassemble the fixed bolts of air tank and remove
the air tank。
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Assembling of air tank assembly
8. Fasten the air tank assembly to the frame.
9. Connect the intake pipe and parking brake air pipe
of air tank, and
Intake pipe: 80±10N·m
Parking brake air pip: 40-50N·m
10. Install the emergency brake switch, pressure switch
and air tank to the brake valve hose.
Emergency brake switch: 30±5N·m
Pressure switch: 35±5N·m
Connection: 80±10N·m
Hose: 57±7.5N·m
11. Install air tank hood.

Note: The volume and the tire inflation inlets of

different air tanks might be different. The actual object
shall prevail.

515 oil-water separator

Usage
A combination valve for oil-water separator is a
combination valve consisting of an oil-water separator
and an air pressure regulator. It provides the functions
below:
(1) Automatically regulate the operating pressure of the
brake system air source, ensuring the safety of the
loader brake system;
(2) Separate such impurities as oil and water in the
compressed air, and automatically drain such impurities
through the unloading mechanism;
(3) Inflate the pneumatic tyre when its win nut has been
removed.

Figure 5-19 Oil-water separator

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Composition
1 The air pressure regulator of a combination valve for
12
2
oil-water separator mainly consists of control piston,
regulating valve, adjusting spring, and tympan.
3
11 The gas-liquid drain valve mainly consists of air bleed
4 piston assembly, oil collector, and valve seat;
10
5

6 9

7 8

Figure 5-20
1. Adjusting spring 2. Control
piston
3. Tympan 4. Regulating
valve
5. Valve seat 6 Return spring
7. Oil collector 8. Plug screw
9. Filter element assembly 10.
Check valve
11. Spring 12. Relief valve assembly

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1 2 Usage notes
Such key parts as air pressure adjusting screws and relief valve
assemblies have been adjusted by the manufacturer when
delivered from the factory. For these parts, change without
permission which may endanger the whole brake system and
then driving safety is usually prohibited. In case an adjustment is
really required, be sure to adjust first the relief valve assembly
and then the air pressure adjusting screws, so that the pressure of
the adjusted system will not rise too much. Then, screw off the
wing nut (as shown in the figure) and connect the inflation pipe.
The filtered compressed air can be used to inflate the pneumatic
tyre.

Figure 5-21
1. Air pressure adjusting screw
2. Relief valve assembly
3. Wing nut

5
4 Common faults

3 6
1) When the seal ring of the bleed valve below the
exhaust piston is damaged or stuck by sundries, the
valve may fail to be closed tightly and air leakage may
be caused;
2) When the return spring of air bleed piston fails or the
air bleed piston is stuck, the valve may fail to be closed
tightly and air leakage may be caused;
2 3) When the air hole (towards atmosphere) of the upper
1 shell is blocked, the air bleed piston may fail to return
effectively. Then, the valve may fail to be closed tightly
and air leakage may be caused;
4) After the tympan cracks, the pressure may drop and
the compressed air may leak from the air breather of the
Figure 5-22 upper cover;
1. Bleed valve 2. Return spring 5) When the pressure adjusting spring has a smaller elastic force
of air bleed piston due to long-time work, the system pressure will drop, too;
3. Air breather 4. Tympan
5. Pressure adjusting spring 6.
Orifice

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6) When the orifice from cavity C to cavity D is blocked and at

D the same time the pressure adjusting spring and the piston
assembly are stuck, the air pressure regulator may lose some of
its functions. When the air pressure exceeds 0.784Mpa, the
compressed air will act on the relief valve and jack it open, and
discharge air into the relief valve.

516 Brake caliper

Replacement
Check whether the groove in the middle of the friction
plate is ground flush. If so, it indicates that the friction
plate is severely worn and it should be replaced. (If the
braking force is inadequate, check the worn conditions
of the friction plates and have them replaced timely).
The caliper disc type brake caliper is an integral
structure. Such structure has good strength and rigidity.
Friction plate that can slide along the guiding shaft is
installed between the brake disc and the piston;
The brake caliper is an integral structure. The brake
caliper should be removed as a whole for the
maintenance after having the friction plate replaced.

Disassembling of brake caliper

1. Disassemble the fixed cotter pins of the connection
pin shaft of the friction plate; remove the
connection pin shaft and the brake friction plate.

Fig. 5-20

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2. Dismantle the connection bolts and the washers of
the inner and outer calipers. Separate the inner and
outer calipers and remove the O-rings between
them.

Fig. 5-21

3. Disassemble the collar and dust cover of the inner

caliper and disassemble the piston and rectangular
seals. The assembling should be conducted
according to the reverse steps of disassembling.

Fig. 5-22

517 Exhaustion method of brake system

1. Place the machine at the service position.
2. Fill the oil cup of booster with the brake fluid.
3. Loosen the air vent screws of the booster. After an
entire stream of liquid flows out, tighten the
bleeder screws.
4. Start the engine. After the air pressure rises to the
specified value, press the brake valve pedal for
several times to enable the brake pipelines and the
brake caliper to be filled with brake fluid. When
the brake pedal is pressed, loosen the air vent
screws of the brake caliper to discharge the air and
quickly fasten the bleeder screws. Repeat the
operations till no bubble comes out of the brake
caliper and an entire stream of brake fluid flows
out. Stop the exhaust and tighten the bleeder
screws.
5. During the air bleeding, brake fluid should be
continually filled in the brake oil cup, so as to
prevent the air from entering again.

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6. After the air is discharged completely, add the
brake fluid in the oil cup to over two thirds and
screw the oil cup cap.

52 Parking brake system

521 Introduction of parking brake system
Parking brake mainly consists of: parking brake
chamber, solenoid valve, bracket and parking brake
switch, etc.
522 Replacement of parking brake
chamber
Disassembling of parking brake chamber
1. Place the vehicle at the service position.
2. Place the key at the “ON” position and screw the
parking brake button.

Note: This act aims at relieving the parking

brake to enable the air chamber to be released, so as to
disconnect from the parking brake.
3. Disconnect the air chamber from the parking brake.

Note: After disconnecting the air chamber from

the parking brake, press the parking brake button and
place the key at the “OFF” position.
4. Remove the pressure of the air tank.
5. Remove the air pressure signal lamp switch.
6. Disconnect the intake pipe of the parking brake
chamber and remove the tee pieces.
7. Dismantle the fixed nut of the air chamber and
remove the air chamber.

Assembling of parking brake chamber

1. Place the air chamber on the fixed bracket and
fasten it with fixed nuts.
2. Install the tee pieces and the air pressure signal
lamp switch.
3. Connect the intake pipe of the air chamber.
4. Start and idle run the machine. After the air
pressure reaches the requirements and remains
stable, shut down the engine and place the key at
the “ON” position. Screw the parking brake switch.
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Note: This act aims at relieving the parking brake

to enable the air chamber to be released, so as to
facilitate the connection between the air chamber and
the parking brake.
5. Connect the air chamber to the parking brake with
the pin shaft.

Note: To connect the air chamber and the parking

brake, the engine must be shut down.

523 parking brake solenoid valve

Specifications
Rated air pressure: 0.784Mpa
Resistance: 26.3Ω
Operating mode: Power-off brake
Method to determine whether there is a failure: Use a
multimeter to measure the resistance of the solenoid
valve. If the resistance is about 26.3Ω, it indicates that
the internal coil of the solenoid valve is normal.
When the internal valve element of the brake solenoid valve
operates, you will hear a sound. If no sound is heard, it indicates
the valve element is stuck.
Fig. 5-23parking brake solenoid valve

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53 Common faults of brake system

1. Fault: braking drag of loader
1) Definition of braking drag: when the brake is
relieved, the brake caliper cannot be separated,
which causes the brake caliper in the non-brake
state to still transmit part of the braking torque.
2) Judgment:
① If the air enters the brake system and the pipeline is
mixed with air, during the brake, the braking effect lags
behind as the volume of the compressed air becomes
smaller. After the brake is released, the volume of the
compressed air in the pipeline increases, causing the
stagnation due to the incomplete backflow of the brake
fluid.
② The brake caliper is in fault. The rectangular oil seal
is damaged. The brake caliper cannot return smoothly or
the inner piston is rusted.
③ The foot brake valve is in fault. The movement of
the inner piston suffers from clamping stagnation.
④ The booster is in fault. The booster chamber piston
of the booster is abnormally worn and its return is
subjected to clamping stagnation.
2. Fault: “no brake” suddenly
Judgment:
“No brake” suddenly occurs when the pressure in the air
tank and the trapped fuel in the oil cup of the booster are
within the specified range, check the following reasons:
① The chamber ring cup of the booster suddenly
spreads rims or is damaged and the compressed air
jumps into the low-pressure chamber through the
sealing elements;
② The master cylinder cup of the booster suddenly
spreads rims or is damaged and the brake fluid of the
high-pressure chamber jumps into the low-pressure
chamber;
③ The piston assembly of the air brake valve suddenly
get stuck and the intake valve cannot be effectively
pushed down to open the air inlet;
3. Fault: The loader is off the track during the
braking.
Judgment:
The direct reason for the off tracking is the unequal
braking torques of wheels on left and right sides.
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When the brake caliper on one side of the wheel is
“locked” and it is hard to be released in the process of
running, usually, it is because the rectangular seal rings
in the brake caliper that play the role of returning are
damaged. After pressing the foot brake pedal, the brake
caliper on one side brakes; while on the other side, the
brake fluid cannot enter the brake caliper due to the
inner leakage, blocked oil way or rusted brake caliper,
thus causing off tracking resulting from unequal braking
torques.
4. Fault: The loader slides during the parking brake.
Judgment:
The fractional resistance between the brake disc and the
brake pad is small.
① The greasy dirt between the brake disc and the brake
pad reduces the friction coefficient. In such case, clean
up the greasy dirt between the brake disc and the brake
pad with gasoline.
② The flexible operating shaft is not properly adjusted.
Readjust the pin shaft moving stroke of the control
handle. The direct contact area of the brake pad and the
brake disc is small.

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