Informations de Service

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Brake cooling system, 523 Informations de Service 10/05/2022
description
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A40F Volvo SN 11001-99999

Brake cooling system, description

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A40F Volvo SN 11001-99999

Introduction
The function of the brake cooling oil is to cool away the heat that is generated between the brake discs in the hub reduction
when the brake is applied. It also lubricates the hub reduction.
The brake cooling oil circulates in the brake cooling oil system that, by way of a hydraulically driven brake cooling oil pump,
is supplied with control pressure from the hydraulic system, see Hydraulic diagram, complete, and is cooled in a heat
exchanger.

Figure 1

Function description
Temperature measurement
The cooling oil temperature is measured at four points in order to enable control of brake cooling oil circulation:

 temperature sensor SE5215 is located on front axle in the distribution block for brake cooling oil (distributes brake
cooling oil out to the hubs on the axle)
 temperature sensor SE5216 is located on front bogie axle in the distribution block for brake cooling oil
 temperature sensor SE5217 is located on rear bogie axle in the distribution block for brake cooling oil
 temperature sensor SE5207 is located in the brake cooling oil tank
Figure 2
Frame with axles and hose routing for brake cooling oil

1. Temperature sensor SE5207

2. Pump unit
3. Temperature sensor SE5215
4. Temperature sensor SE5216
5. Temperature sensor SE5217

Brake cooling oil's flow

There is always a circulation of a basic flow through the brake cooling oil system. The brake cooling oil flow is controlled
indirectly by an actuator (PWM5201) which is a part of the hydraulic oil system. The flow that the actuator gives (basic flow
or, when brake cooling needs to be increased, max. flow) drives a hydraulic oil motor located on the pump unit for brake
cooling oil. This pump unit consists of the hydraulic oil motor, two brake cooling oil pumps (one for the tractor's brake
cooling oil circuit and one for the trailer's brake cooling oil circuit), and a coolant pump. The hydraulic motor drives the
pump unit and when the actuator gives flow to the hydraulic motor, the pumps on the pump unit are driven and thus
circulate the brake cooling oil in both brake cooling oil circuits and coolant in the cooling circuit. The flow to the hydraulic
oil motor is supplied with pressure from hydraulic pump P6 which also supplies the brake system with control pressure.
When the brake pressure drops a solenoid valve changes over to brake pressure charging. When the brake system is
pressurized again, the solenoid valve lets over pump pressure to provide the brake cooling system with flow.

Figure 3
Pump unit

1. Hydraulic oil motor

2. Rpm sensor SE2607
3. Brake cooling oil pump (trailer's brake cooling oil circuit)
4. Brake cooling oil pump (tractor's brake cooling oil circuit)
5. Coolant pump
6. Actuator PWM5201
7. Solenoid valve MA5503
Figure 4
Cooling performance as function of temperature of brake cooling oil

A. Actuator SE5201, basic flow

B. Actuator SE5201, max. flow
C. Cooling fan cooling system 0 — 100%

Application of brakes
When brakes are applied and brake cooling needs to increase (at least one of the temperature sensors send signal if the
temperature is above 80 °C (176 °C)) a signal is sent to the actuator (PWM5201) to supply max. flow of brake cooling oil. At
the same time a signal is sent to increase rpm of the cooling fan which cools the coolant from the heat exchanger where the
brake cooling oil is cooled. The signal increases in linear manner from 0 % at 80 °C (176 °F), which gives min. rpm for the
cooling fan, to 100% at 100 °C (212 °F), which gives max. rpm for the cooling fan. When the actuator (PWM5201) supplies
max. flow and the cooling fan's rpm increases, the rpm for the pump unit also increases (see also Hydraulic system,
description).
Then when the temperature of the brake cooling oil drops below 80 °C (176 °F) the cooling fan returns to min. rpm, on the
condition that request for increased cooling fan rpm is not generated from the engine cooling system or the transmission's
cooling circuit, see Cooling unit, description. When the brake cooling oil temperature is below 77 °C (171 °F) the actuator
(PWM5201) returns to supplying basic flow.
Pump unit's rpm
To ensure cooling of the brakes, there is a control function in the machine's software.
If the machine's engine is on and the pump unit's rpm (measured by rpm sensor SE2607) is below 100 rpm for at least 5
seconds (continuously), then a signal is sent to increase the cooling fan's rpm to 35% of the span between min. and max.
rpm. A signal is also sent to the actuator for control of the hydraulic motor in the pump unit, about max. flow.
Other functions that affect the brake cooling oil system
The coolant system that cools the brake cooling oil in the heat exchanger also circulates through the heat exchanger where
the oil for the transmission is cooled, see Cooling unit, description. The circulation pump for the coolant system for brakes
and transmission is the coolant pump that is located in the pump unit described above. If the temperature in the
transmission exceeds 90 °C (194 °F) (measured by sensor in oil sump), a signal is sent to the actuator for control of the
hydraulic motor in the pump unit (PWM5201) to supply max. flow.
Same request from several sub-functions

 If any of the above sub-functions in the software send a signal to the actuator for control of the hydraulic motor for
the pump unit (PWM5201) about max. flow, then max. flow shall be requested.
 If several of above sub-functions send a signal to increase cooling fan rpm, the highest value shall be that which is
requested, unless the max. rpm is not exceeded, see above under heading Pump unit's rpm.

Regardless of the request for increasing the flow, basic flow is always set on the pump unit if brake charging is requested.
Control lights and alarms on the operator's panel
  If the temperature of the brake cooling oil becomes too high, control lights are activated on the operator's panel as
follows:

– if the machine's engine is on and any, or some of the temperature sensors for the brake cooling
oil shows that the temperature exceeds 120 °C (248 °F) for at least 5 seconds, then orange
central warning is activated on the operator's panel. The control light turns off when the brake
cooling oil temperature has dropped below 118 °C (244 °F).
– if the machine's engine is on and the brake cooling oil temperature reaches above 130 °C (266 °
F) for at least 5 seconds, then red central warning is activated on the operator's display, at the
same time as a buzzer sounds. The control light turns off and the buzzer shuts off when the
brake cooling oil temperature has dropped below 128 °C (262 °F).

 If the machine's engine is running and the pump unit's rpm is below 100 rpm for 15 seconds, then red central
warning is activated.
 In case of too low level of brake cooling oil in the tank, red central warningis activated on the operator's display.
The oil level in the brake cooling oil tank is monitored using a level monitor (SE5214). Sensing of the oil level shall
show below the warning level for at least 3 seconds in order for red central warning light to be activated on the
operator's display. This is to avoid incorrect sensing due to oil sloshing around in the tank when operating.

Software description

Input signal Reaction to incorrect input signal

Engine On/Off Engine Off assumed.
SE2607, Sensor, rpm brake cooling oil pump Set condition for output signal to incorrect.
0 rpm is assumed.
SE4202, Sensor, oil temperature transmission Temperature is set to 95°.
SE5207, Sensor, cooling oil temperature tank Control temperature is set to 80°.
SE5214, Monitor, cooling oil level tank Normal level assumed.
Level indicator in display invalidated.
SE5215, Sensor, cooling oil temperature, front axle Control temperature is set to 80°.
SE5216, Sensor, cooling oil temperature, front bogie axle Control temperature is set to 80°.
SE5217, Sensor, cooling oil temperature, rear bogie axle Control temperature is set to 80°.

Conditions for output signal Output function

Highest temperature from temperature sensors is used. Control temperature
Request for radiator fan is based on control temperature according Request radiator fan in percent
to the following:

 At temperature <= 80°, request is set to 0%

 At temperatures between 80° < 100°, corresponding cooling
fan speed is requested linearly between 0% — 100%
 At temperature >= 100°, request is set to 100%

Request for brake cooling oil circulation is based on control Request brake cooling oil circulation
temperature with hysteresis according to the following:

 At temperature > 80°, request is set to 2,500 rpm

 At temperature <= 77°, request is set to basic flow

With engine On basic flow is set to 750 rpm, and goes to 480 rpm
after 60 seconds.

Alarm conditions Warning display

Amber central warning
 Engine On
  Brake cooling oil pump < 100 rpm for more than 15 Check
seconds Brake cooling oil pump

Amber central warning

 Cooling oil level tank Low for more than 3 seconds
Check
Brake cooling oil, low level
Red central warning
 Control temperature < 120° for more than 5 seconds
Warning
Alarm level is set to normal when control temperature drops below High brake cooling oil temperature
118°.
Red central warning with buzzer
 Control temperature < 130° for more than 5 seconds.
Warning
Alarm level Red central warning without buzzer is activated when the High brake cooling oil temperature
temperature drops below 128°.

Supplementary information
For more information on speed (rpm) sensor SE2607, see SE2607, description and measuring.
For more information on actuator PWM5201, see PWM5201, description and measuring.
For more information on temperature sensor SE5207, see SE5207, description and measuring.
For more information on level sensor SE5214, see SE5214, description and measuring.
For more information on temperature sensors SE5216–SE5217, see SE5215-SE5217, description and measuring.