HPB Hydraulic Power Braking System: General Comments, Diagrams and Description of Components

HPB Hydraulic Power
Braking System
General Comments,
Diagrams and
Description of Components
2001 Edition
4. revised edition
The amendments are marked
 Copyright WABCO 2001
WABCO
Vehicle Control Systems

An American Standard Company
The right of amendment is reserved

Table of Contens
1. General Comments ........................................................................................... 5
2. Diagrams of HPB Systems ............................................................................... 7

841 300 329 0 single - circuit................................................................ 9
841 300 314 0 dual - circuit ................................................................ 10
841 300 331 0 dual - circuit ................................................................ 11
841 300 332 0 dual - circut with relay valves...................................... 12
3. Description of Components ........................................................................... 13

427 001 Spring Brake Actuator ................................................................ 14
441 014 Pressure Switch.......................................................................... 18
458 501 Hydraulic Accumulator................................................................ 20
467 406 Brake Valve ................................................................................ 22
467 410 Hand Brake Valve....................................................................... 30
47. 399 Double Check Valve ................................................................... 32
477 397 Shut-Off Valve ............................................................................ 34
477 399 Check Valve ............................................................................... 40
477 411 Relay Valve ................................................................................ 42
4. General Comments ......................................................................................... 45

Information for Installation................................................................................. 47
Capacity of Accumulators ................................................................................. 48
5. Legal Requirements
ECE Regulation 13 - Annex 7C - ...................................................................... 50
WABCO 1 3
1
General Comments
WABCO 2 5
1 General Comments
HPB Hydraulic Power At present the majority of special- The legal requirements for the HPB
Braking System purpose vehicles, particularly con- with regard to the size of its energy
struction vehicles up to a dead accumulators, the performance of its
weight of approx. 7 tonnes, are energy source and the properties of
equipped with hydraulic muscular the alarm devices are defined in ECE
power braking systems. Vehicles - Regulation No. 13, Annex 7c.
with a higher dead weight usualy (Please refer to our manual "Legal
have compressed-air braking sys- Requirements", 2000 Edition, Pages
tems. 325 to 327) or page 50 to this bro-
chure.
Since wet inboard disk brakes are
being increasingly used in European The HPB system is not really suitable
construction vehicles, WABCO has for operating a trailer braking system.
developed a Hydraulic Power Brak- This requires a system for supplying
ing System (HPB) which takes into compressed air with a hydraulically
account the special requirements for operated Trailer Control Valve (470
construction vehicles. 015 ... 0) to be installed. The hand
brake facility for the trailer can then
The components of the hydraulic be operated, for instance, via a hydro
braking system are suitable for fluids pressure switch, a solenoid valve
on the basis of mineral oils and some and a relay valve (pneumatic).
bio-fluids which means that the fluids
present in the construction vehicle's
hydraulics can be used as the energy In order to take into account the trend
transmitter for the braking system. towards dual circuit service braking
systems, we recommend that vehi-
The cross-sections of the compo- cles > 25 k.p.h. are fitted with a dual
nents have been designed to ac- circuit HPB system although accord-
count for the higher viscosity of such ing to the German Motor Vehicle
fluids rather than conventional brake Construction and Use Regulation
fluid. construction vehicles merely require
a single circuit system.
The components are particularly ro-
bust to ensure that they are capable
of withstanding the tough conditions
of everyday operation.
IMPORTANT!
If the brake volume is greater than 75

cm³, at least the first (top circuit) of
the pedal brake valve must be
equipped with a relay valve.
The response and threshold times

must be checked in all cases. If nec-
essary, both circuits of the service
brake system must be equipped with
relay valves.
6 2
WABCO
2
HPB - Diagrams
WABCO 4 7
HPB - Diagram
single-circuit 2
Diagram: 841 300 329 0
all pipes of brake line NW 10
Port connections:
0 Suction
1 Energy supply
2 Energy delivery
5 Return connection
No. Qty. Description Part Number No. Qty. Description Part Number
1 1 Pump 11 1 Pressure Switch 441 014 049 0
2 1 Filter 12 1 Pressure Switch 441 014 055 0
3 1 Shut-Off Valve 477 397 . . . 0 13
4 14 2 Test connection
5 15
6 1 Brake valve 467 406 1. . 0 16
7 17 • Accumulator 458 501 . . . 0
8 1 Tank 18
9 • Brake Actuators 19
10 20
WABCO 5 9
2 HPB - Diagram
dual-circuit
Diagram: 841 300 314 0
Port connections:
0 Suction 24, 25 Hydraulic accumulator for Brake Valve:
1 Energy supply 26, 27 Hydraulic accumulator 24 Test connection (manometric switch)
11 Energy supply Circuit 1 28 Pressure switch 25 Test connection (manometric switch)
12 Energy supply Circuit 2
2 Energy delivery 4 Pilot connection
21 Energy delivery Circuit 1 5 Return connection
22 Energy delivery Circuit 2 51 Return connection Circuit 1
3 1 Shut-Off Valve 477 397 015 0 13
4 1 Brake Valve 467 406 . . . 0 14 3 Test connection
5 15
6 16
7 17 • Accumulator 458 501 . . . 0
8 1 Tank 18 • Accumulator 458 501 . . . 0
10 20
10 6
WABCO
HPB - Diagram
dual-circuit 2
Diagram: 841 300 331 0
Port connections:
3 1 Shut-Off Valve 477 397 . . . 0 13 1 Pressure Switch 441 014 . . . 0
5 1 Hand Brake Valve 467 410 . . . 0 15 1 Accumulator 458 501 071 0
6 16 • Accumulator 458 501 . . . 0
7 17 • Accumulator 458 501 . . . 0
10 1 Spring Brake Actuator 427 001 . . . 0 20
WABCO 7 11
2 HPB - Diagram
dual-circut with relay valves
Diagram: 841 300 332 0
Port connections:
3 1 Shut-Off Valve 477 397 . . . 0 13 1 Pressure Switch 441 014 . . . 0
5 1 Hand Brake Valve 467 410 . . . 0 15 1 Accumulator 458 501 071 0
6 16 • Accumulator 458 501 . . . 0
7 2 Relay Valve 477 411 . . . 0 17 • Accumulator 458 501 . . . 0
9 • Brake Actuators 19 1 Accumulator 458 501 071 0
10 1 Spring Brake Actuator 427 001 . . . 0 20 1 Accumulator 458 501 071 0
12 8
WABCO
3
Description of Components
WABCO 9 13
3 427 001 Spring Brake Actuator
Purpose: Quick Release Facility

Some variants are available with a quick-
The spring brake actuator serves to release facility.
generate the braking force for the wheel
brake in secondary and parking braking This permits, in the event of the pressure
systems. in the hydraulic portion (A) failing, the
wheel brake to be released by applying a
Operation: blow in the direction of the arrow (F),
using a hammer, thus severing the
Ready Position frictional connection established
In the driving condition, the pressure between Compression Spring (B) and
from the hand brake valve is acting Piston Rod (C) and actuating the quick-
directly on Port 1 of the Spring Brake release facility (D).
Actuator. The secondary or parking
brake is released. As the pressure in the hydraulic portion
(A) builds up again, the connection
Braking Position between Compression Spring (B) and
When the hand brake valve is actuated, Piston Rod (C) is established once more
the hydraulic pressure is reduced as a and the Spring Brake Actuator is fully
function of the angular position of the operative again.
hand brake lever.
Emergency Release Facility
If Spring Brake Actuators without a quick-
As the pressure in the hydraulic portion
with quick-release facility release facility are used, the parking
(A) of the Spring Brake Actuator is
brake can still be released should the
reduced, the force of the releasing
hydraulic pressure fail. To do so, the
Compression Spring (B) makes Piston
Hexagon Nut (6) on Piston Rod (K) is
Rod (C) retract in the direction of the
taken off Yoke (C1). An open-jawed
Actuator’s axis, thus actuating the wheel
spanner (jaw size 13) is applied to
brake. The Spring Brake Actuator’s
Section (L) on Piston Rod (K). Piston Rod
maximum brake force is reached when
without quick-release facility (K) is then turned in such a way that Yoke
the pressure falls to zero.
(C1) is displaced towards the brake
lever.
14 9
WABCO
Spring Brake Actuator 427 001
3
Technical Data:
427 001 006 0

Part Number 427 001 002 0 427 001 005 0 427 001 007 0 427 001 008 0
427 001 009 0
Operating pressure 150 bar max.
Stroke 80 ± 3 mm
Release pressure 87 ± 4 bar 60 -4 bar 40 ± 4 bar 95 +6 bar 60 -4 bar
Operating temperature range –30°C to +80°C
Medium mineral oil 10 to 2000 mm2/s
Output force at 0 mm stroke 2.75 kN 2.3 kN 1.5 kN 3.0 kN 2.3 kN
Output force at 80 mm stroke 4.32 kN 3.25 kN 2.2 kN 5.0 kN 3.25 kN
Piston rod deflection 3° on all sides
Emergency release facility NO NO NO YES YES
Yoke NO YES YES YES YES
Bellows YES YES YES YES YES
Weight 6.5 kg 6.8 kg 8.0 kg
Spare parts: Description No. Part Number Variant of Actuator

Bellows 1 897 753 560 4 002, 005, 006
Bellows 1 897 753 931 4 007, 008
Clamp 2/G 893 511 670 4 002, 005, 006, 007, 008
Clamp H 893 511 650 4 007, 008
Clamp 3 894 325 278 4 002, 005, 006
Yoke 5 895 801 870 4 005, 006
Yoke 5 895 801 513 2 009
Hexagon nut 6 810 306 018 4 005, 006
For safety reasons the whole of the Spring Brake Actuator must
be replaced if parts other than those listed above are damaged.
Caution: Replacing the Bellows piston rod. The new Yoke (5) is screwed
The enclosed portion of the Remove clamps (2; 3 or H) from the into the piston rod up to the point where
bellows, replace as necessary when the original piston rod length is once
actuator is spring-loaded ! again achieved (see outline drawing:
fitting the new bellows. Pull off the faulty
bellows (1), push on new bellows and distance from centre yoke hole to end
fasten with clamps (2; 3 or H). face of Port 1). Secure piston rod by
means of hexagon nut.
Replacing the Yoke

When replacing the Yoke (5) on
actuators without a quick-release facility,
immobilize the piston rod by applying a
spanner (jaw size 13). Remove Hexagon
Nut (6) and unscrew Yoke (5) from the
WABCO 9 15
3 427 001 Spring Brake Actuator
Installation dimensions:
quick-release facility:
showing: 427 001 007 0 actuation by applying a blow to the
flange
Thread of pipe connections:

M 16x1.5 - 16 deep
Variant 002
showing: 427 001 005 0
16 WABCO
Spring Brake Actuator 427 001
3
Installation Requirements: Repair Work:
The connecting lines must be installed in When working on the braking
such a way as to permit proper bleeding. system, always make sure that
The actuator should be mounted at a there is absolutely no pressure
slight angle, its piston rod pointing in the system. Even when the
downwards. engine is switched off there will
be some residual pressure in the
Maintenance: system!
No maintenance beyond the legal When doing repair work, make

requirements is necessary. sure your environment is very
clean.
When using high-pressure cleaners on Immediately close all open ports
the vehicle, please make sure that the on the components and on pipes
water jet is not aimed directly at the using plugs!
Spring Brake Actuator (to prevent
damaging the bellows).
WABCO 9 17
3 441 014 Pressure Switch
Purpose: braking system or directly on one of its

components. The system pressure acts
The Pressure Switches are used to on an absorption area within the switch,
visually or audibly warn the driver of the breaking an electrical contact as the
pressure within the system. pressure on that area is increased. The
current is now broken, e.g. to deactivate
Operation: a warning facility.
Make Contact / Circuit Closer

Installation Requirements:
The Pressure Switch can be fitted in the
braking system or directly on one of its No special measures need to be taken.
components. The system pressure acts
on an absorption area within the switch, Maintenance:
making an electrical contact as the
No special maintenance beyond the legal
pressure on that area is increased. The
requirements is necessary.
resulting current is used to activate a
warning facility, for instance.
When using high-pressure cleaners on
the vehicle, please make sure that the
Break Contact / Circuit Breaker water jet is not directed at the Pressure
Break Contact Make Contact The Pressure Switch can be fitted in the Switch (corrosion of contacts).
Technical Data:
Adjusting Actuating
H1 H2 Voltage
Part Number Medium G range pressure
(mm) (mm) in V
in bar in bar
Break Contact
441 014 043 0 mineral oil M 12x1.5 55 9 20 - 50 21 ± 2 42

441 014 044 0 mineral oil M 12x1.5 55 9 10 - 20 17 ± 1 42
441 014 049 0 mineral oil M 12x1.5 55 9 50 - 150 100 ± 10 42
441 014 051 0 mineral oil M 12x1.5 55 9 20 - 50 37 ± 2 42
441 014 057 0 mineral oil M10x1 tapered 55 9 10 - 20 10 - 20 42
441 014 059 0 mineral oil M 12x1.5 55 9 1 - 10 3 ± 0,5 42
441 014 076 0 mineral oil M 12x1.5 60 9 – 21 ± 2 42
441 014 077 0 mineral oil M 12x1.5 60 9 – 100 ± 5 42
441 014 078 0 mineral oil M 12x1.5 60 9 – 85 ± 5 42
441 014 079 0 mineral oil M 12x1.5 55 9 – 6±1 42
Make Contact
441 014 048 0 mineral oil M 12x1 tapered 43 9 3-6 3-6 42

441 014 052 0 mineral oil M 12x1.5 55 9 20 - 50 37 ± 2 42
441 014 055 0 mineral oil M 12x1.5 55 9 1 - 10 1 - 10 42
441 014 058 0 mineral oil M 10x1 tapered 55 9 20 - 50 20 - 50 42
441 014 070 0 mineral oil M 12 x 1,5 55 9 50 - 150 54 ± 5 42
441 014 071 0 mineral oil M 10x1 tapered 55 9 1 -10 1 -10 42
441 014 074 0 mineral oil M 12 x 1,5 60 9 – 21 ± 2 42
441 014 075 0 mineral oil M 12 x 1,5 60 9 – 4 ± 0,5 42
Breaking capacity of all pressure switches 100 Voltampere resistive load Boot for Pressure Switch: Part Number 897 750 342 4
18 10
WABCO
Pressure Switch 441 014
3
Repair Work:
When working on the braking When doing repair work, make
system, always make sure that sure your environment is very
there is absolutely no pressure clean.
in the system. Even when the Immediately close all open ports
engine is switched off there will on the components and on pipes
be some residual pressure in the using plugs!
system!
For safety reasons the Pressure Switch needs to be

replaced as a whole if damaged.
Adjusting and testing the

Pressure Switch:
The adjusting screw located between the After making the adjustment, the
two contact plugs can be set to the adjusting screw should be secured using
desired value within a certain range. For wax or a similar material.
adjusting range, please refer to the table
"Technical Data" on the previous page.
WABCO 9 19
3 458 501 Hydraulic Accumulator
Purpose: diaphragm (C) as a gas-tight dividing

element. The fluid portion (A) is
Fluids are practically incompressible and connected to the hydraulic circuit,
are thus incapable of accumulating causing the diaphragm accumulator to
pressure energy. In hydropneumatic be filled and the gas volume to be
accumulators, the compressibility of a compressed as the pressure rises. When
gas is utilized to accumulate fluid. The the pressure falls, the compressed gas
compressible medium used in the volume will expand, thus displacing the
accumulators is nitrogen. accumulated pressure fluid into the
circuit.
In braking systems, the purpose of the
accumulators is to store the energy The diaphragm bottom contains a valve
supplied by the hydrailc pump. They are disk (D) which, if the diaphragm
also used as an energy reserve when the accumulator is completely empty, closes
pump is not working, as a compensator the hydraulic outlet, thus preventing
for any losses through leakage, and as damage to the diaphragm.
oscillation dampers.
Operation:
The accumulator consists of a fluid
portion (A) and a gas portion (B) with a
Technical Data:
Part Number 458 501 071 0 458 501 075 0 458 501 101 0
Diameter 121 mm 117 mm 136 mm
Mounting height 146 mm 141 mm 160 mm
Nominal volume 0.75 dm³ 0.75 dm³ 1.0 dm³
Priming pressure 50 bar 7 bar 50 bar
Operating medium mineral oil
Operating pressure 180 bar max. 50 bar max. 200 bar max.
Thread M 18x1.5 M18x1.5 M 22x1.5
Operating temperature range – 30°C to + 80°C
mounting position optional
Priming gas nitrogen
20 11
WABCO
Hydraulic Accumulator 458 501
3
Installation Requirements: The accumulators can be fitted in the testing and checking of the
hydraulic circuit, directly on a component Accumulator").
or in blocks on suitable consoles.
Disposal of the Accumulator:
They should be fitted in as cool a location
as possible. Before the accumulator is scrapped, its
Installation can be in any position. gas filling pressure must be reduced. For
this purpose, drill a hole through Gas
Chamber (B) using a drill approx. 3 mm in
Maintenance: diameter. The gas chamber is located on
No special maintenance beyond the legal the side opposite the threaded port
requirements is necessary. above the welding seam around the
centre of the accumulator.
The accumulator should be checked Wear safety goggles when doing this
annually. It should be replaced if the job!
initial gas pressure has fallen by more
than 30% (please refer to "Performance
Performance testing and The accumulator is gradually pressurized individually tested. The accumulator
checking of the Accumulator: via the test pump; until the initial gas whose initial gas pressure is insufficient
pressure is reached, the hydraulic must be replaced and scrapped following
pressure in the accumulator will rise the instructions under "Disposal of the
abruputly. This is apparent from gauge Accumulator".
"M". If the initial gas pressure is more
than 30% below the prescribed value, the
accumulator needs to be replaced. If the
measuring process needs to be Repair Work:
repeated, wait for intervals of 3 minutes
between the individual tests. Any When working on the braking
accumulator whose initial gas pressure is system, always make sure that
insufficient must be scrapped following there is absolutely no pressure
the instructions under "Disposal of the in the system. Even when the
Accumulator". engine is switched off there will
The amount of initial gas pressure can system!
also be checked from the vehicle.Start
the vehicle’s engine. The pump will now
supply oil to the accumulators. Until the When doing repair work, make
initial gas pressure is reached, the sure your environment is very
hydraulic pressure in the accumulator will clean.
A = ball valve for shutting off pump flow rise abruputly. This is apparent from the Immediately close all open ports
gauge in the cab. If the initial gas on the components and on pipes
B = ball valve for reducing pressure pressure is more than 30% below the using plugs!
S = safety valve: set to 180 bar max. prescribed value, that initial pressure lies
outside the permissible range for at least
M = pressure gauge one of the accumulators fitted in the
H = hydraulic accumulator vehicle. This accumulator can be traced
only by using the method described
above, i.e. all accumulators have to be
For safety reasons the Accumulators need to be

replaced as a whole if damaged.
WABCO 12 21
3 467 406 Brake Valve
for single circuit braking system
Purpose: close Return 5 via the control edge, thus

establishing a connection between
The purpose of the Brake Valve is to Accumulator Port 1 and Port 2 for the
sensitively increase and decrease the wheel brake cylinders. The foot force
braking pressure when the brake pedal applied now determines the output
(or the actuating lever) is actuated. braking pressure. Control Slide (C) is
held in the control position by the force
Operation: applied (spring assembly) and the
hydraulic pressure below Slide (C)
Ready Position (balance of forces). After output of the
When the braking system is ready for braking pressure, Slide (C) is in a partial
operation, its accumulator pressure acts braking position, causing Ports 1 and 5 to
directly on Port 1 of the Brake Valve. A close and holding the pressure in Port 2.
connection is established between Ports
2 and 5 so that the wheel brake (Port 2) Full Braking Position
is pressureless via the return (Port 5). When Pedal (B) is fully actuated, an end
position of the brakes is reached and a
Partial Braking connection established between
When the Brake Valve is actuated, an Accumulator Port 1 and Brake Cylinder
amount of hydraulic pressure is output as Port 2. Return 5 is closed at this point.
a ratio of the foot force applied.
When the braking process is ended, a
he Spring Assembly (A) beneath Base connection is once again established
Plate (E) is designed in such a way that between Brake Cylinder Port 2 and
the braking pressure changes depending Return Port 5, closing Accumulator Port
on the angle. In the lower braking 1.
pressure range, the vehicle can be
467 406 1 .. 0 slowed sensitively. Limiting the Braking Pressure
Pedal Restriction Screw (D) on Base
When the braking process is Plate (E) below Pedal (B) is used to limit
commenced, Slide (C) is mechanically the braking pressure. This will cause the
actuated via Spring Assembly (A). As accumulator pressure building up in the
Slide (C) moves downward, it will first braking system to be limited.
467 406 108 0
22 13
WABCO
Brake Valve
467 406
3
Technical Data:
Part Number Pedal Angle Actuating path Brake Pressure Actuating Force
467 406 100 0 45° 130 ± 10 mm 150 bar 360 N
+10
467 406 101 0 45° 90 ± 10 mm 100 bar 280 N
467 406 102 0 45° 90 ± 10 mm 80 +10 bar 240 N
+10
467 406 103 0 45° 85 ± 10 mm 100 bar 240 N
+10
467 406 105 0 40° 90 mm 40 bar 280 N
467 406 108 0 Lever – 150 bar 875 N
+10
467 406 111 0 45° 90 ± 10 mm 80 bar 240 N
+5
467 406 112 0 40° 85 ± 5 mm 65 bar 350 N
467 406 115 0 45° 65 mm 40 +10 bar 240 N
+10
467 406 117 0 45° 90 ± 10 mm 100 bar 240 N
+10
467 406 119 0 45° 67,3 ± 10 mm 70 bar 220 N
467 406 121 0 50° 28° 100 +10 bar 280 N
467 406 122 0 Lever 18° 80 bar 520 N
+8
467 406 124 0 40° 22° 60 bar 360 N
467 406 125 0 Plunger 14 mm 150 bar 2400 N
+10 +7
467 406 304 0 50° 40 mm 50 bar 175 N
467 406 404 0 50° 50 +10 mm 50 +7 bar 175 N
Operating temperature range for all variants –40°C to +80°C / Operating Pressure: 150 bar
showing: 467 406 108 0

M 14x1.5 - 12 deep
Port connections:
1 = Energy supply
21 = Energy delivery
51 = Return connection
WABCO 14 23
showing: 467 406 102 0
Variant 1, 21, and 51 24

100 M 14x1.5 -12 deep M 12x1.5
101, 102,
M 14x1,5 -12 deep –
108, 122
125 M 14x1.5 -14 deep –
111, 117,
M 16x1.5 -12 deep M 10x1 **)
119
105, 115,
122, 124, M 16x1.5 -12 deep M 12x1.5
304, 404
121 M 16x1.5 -12 deep M 10x1
**) closed withplug
Port connections:
1 = Energy supply
Installation Requirements: Return Line 51 must be connected hand. The new pedal cover is pushed
directly to the tank.The connecting lines over Pedal (B) and tightened manually.
must be installed in such a way as to Fasten the bellows with the strap
permit proper bleeding. retainers.
Maintenance of the Brake Valve

Replacing the complete Actuating
Mechanism
Carefully clamp the unit vertically in a
When using high-pressure cleaners on fixture. The actuating mechanism can be
the vehicle, please make sure that the removed by taking out the four Screws
water jet is not aimed directly at the (H) below Base Plate (E). Make sure that
Brake Valve (to prevent damaging the Spring Assembly (A) does not fall out.
bellows). When installing the new actuating
mechanism, make sure that Spring
Replacing the Pedal Cover Assembly (A) is fitted in the right order.
Pedal Cover (1) is simply pulled off by Tighten the four Screws (H).
24 15
WABCO
Brake Valve
467 406
3
Replacing the Bellows are matched in manufacturing.) If the
To change Bellows (3) it is advisable to slide is not damaged in any way, remove
remove Pedal (B). For this purpose, the whole actuating mechanism as
loosen Retaining Ring (L) and knock out described above. Remove Spring
Bolt (M) using a mandril. When knocking Assembly (A) and Grooved Ring (4) and
out the bolt, make sure that the mandril is put in a new greased grooved ring with its
applied to the side of the bolt without a lips pointing downwards. Install both the
knurl. Remove Pedal (B) and Bellows (3). spring assembly as shown in the
Now fit the new Bellows (3) and proceed drawing, and the pedal. Carefully re-
in reverse order as described above. The insert Slide (C) into the housing from
upper portion of Bellows (3) is fastened to below, turning it slightly. Put in Spring (R)
Piston (N), its lower portion to Base Plate and close the unit with Screw Plug (P).
(E). Check Return Port 51 to see if there is a
gap of approx. 2 mm between the lower
edge of the hole and the control edge of
Replacing the Grooved Ring Slide (C). If this is not the case, change
Carefully clamp the unit vertically in a the setting by removing or adding
fixture. Unscrew Screw Plug (P) and pull distance washers (5) in the upper spring
Slide (C) out downwards. Check the slide plate of the spring assembly. Check the
for damage. If it is found to be damaged, distance between the lower edge of the
the whole Brake Valve needs to be hole and the control edge of Slide (C)
replaced. (Pairs of slides and housings again.
Spare parts:
Description No. Part Number Variant of Brake Valve
Pedal Cover 100, 101, 102, 103, 105, 107,
1 897 730 022 4 108, 111, 112, 115, 117, 119
121, 124, 404
2 467 406 781 2 100
complete 2 467 406 782 2 101, 102, 103, 111, 115, 117
Actuating 2 467 406 783 2 108
Mechanism
2 467 406 789 2 121, 122, 304, 404
2 467 406 791 2 105, 107, 112, 124
2 467 901 783 2 119
100, 101, 102, 103, 111, 115,
3 897 754 860 4
Bellows 117, 125
105, 107, 112, 119, 121, 124,
3 897 754 865 4
304, 404
4 897 161 557 4 122, 304, 404
Grooved Ring 4 897 162 000 4 105, 107, 112, 115, 124
100, 101, 102, 103, 108, 111,
4 897 162 080 4
117, 119, 121, 125
Washer 5 895 121 420 4 121
100, 101, 102, 103, 105, 107,
5 895 151 420 4 108, 111, 112, 115, 117, 119,
122, 124, 125, 404
For safety reasons the whole of the Brake Valve must be replaced
if parts other than those listed above are damaged.
Repair Work: When working on the braking When doing repair work, make
system!
WABCO 16 25
for dual circuit braking system
Purpose: they will first close Returns 51/52 via the

control edges, thus establishing a
The purpose of the Brake Valve is to
connection between Accumulator Ports
sensitively increase and decrease the
11/12 and Ports 21/22 for the wheel
braking pressure when the brake pedal
brake cylinders. The foot force applied
(or the actuating lever) is actuated.
now determines the output braking
pressure. The Control Slides (C1 and
Operation: C2)) are held in the control position by
Ready Position the force applied (spring assembly)
When the braking system is ready for above the slides and the hydraulic
operation, its accumulator pressure acts pressure below the slides (balance of
directly on Port 11/12 of the Brake Valve. forces). After output of the braking
A connection is established between pressure, Slides (C1 and C2) are in a
Ports 21/22 and Ports 51/52 so that the partial braking position, causing Ports 11/
wheel brakes (Ports 21/22) are 12 and 51/52 to close and holding the
pressureless via the returns (Ports 51/ pressure in Ports 21/22.
52).
Full Braking Position
Partial Braking When Pedal (B) is fully actuated, an end
When the Brake Valve is actuated, an position of the brakes is reached and a
amount of hydraulic pressure is output as connection established between
a ratio of the foot force applied. Accumulator Ports 11/12 and Brake
Cylinder Ports 21/22. Returns 51/52 are
The Spring Assembly (A) beneath Base closed at this point.
Plate (E) is designed in such a way that
the braking pressure changes depending When the braking process is ended, a
on the angle. In the lower braking connection is once again established
pressure range, the vehicle can be between Brake Cylinder Ports 21/22 and
slowed sensitively. Return Ports 51/52, closing Accumulator
Ports 11/12.
When the braking process is
commenced, the upper Slide (C1) is The arrangement of slides in the valve
mechanically actuated via Spring ensures that even if one braking circuit
Assembly (A), and the lower Slide (C2) is fails the other remains fully operational.
actuated hydraulically by Slide (C1). As This is achieved by means of the
Slides (C1 and C2) move downward, mechanical actuation of both slides and
requires slightly more pedal travel.
Limiting the Braking Pressure

Pedal Restriction Screw (D) on Base
Plate (E) below Pedal (B) is used to limit
the braking pressure.
Failure of a Circuit
In the event of the lower circuit failing, the
upper circuit will remain operational.
Spring Assembly (A) will mechanically
actuate Slide (C1). In the event of the
upper circuit failing, the lower circuit will
remain operational since the lower Slide
(C2) is mechanically actuated by Spring
Assembly (A) and Slice (C1).
26 17
WABCO
Brake Valve
467 406
3
Technical Data:
Operating
Part Number Pedal Angle Brake Pressure Actuating Force Comments
Pressure
467 406 202 0 40° 150 bar 63 + 7 bar 320 N
467 406 208 0 Lever 150 bar 110 bar 800 N
+ 10
467 406 216 0 40° 150 bar 110 bar 300 N
467 406 218 0 40° 150 bar 110 + 10 bar 380 N
+ 10
467 406 220 0 40° 150 bar 72 bar 220 N
467 406 227 0 25° 150 bar 150 bar 320 N
467 406 233 0 25° 150 bar 150 bar 400 N
467 406 234 0 35° 150 bar 150 bar 400 N
467 406 235 0 Plunger 150 bar 150 bar 2500 N
+7
467 406 301 0 45° 150 bar 55 bar 290 N
467 406 305 0 Plunger 150 bar 150 bar 5000 N
467 406 307 0 50° 150 bar 40 + 10 bar 220 N
+8
467 406 401 0 45° 150 bar 70 bar 300 N
+7
467 406 408 0 45° 150 bar 63 bar 240 N *)
467 406 411 0 45° 150 bar 90 bar 350 N with pedal locking device *)
467 406 414 0 50° 150 bar 50 + 7 bar 175 N with hydr. actuation
+ 10
467 406 507 0 35° 200 bar 128 bar 520 N
+ 10
467 406 508 0 35° 200 bar 128 bar 400 N
with electrical actuation of
467 406 509 0 35° 150 bar 70 bar 250 N
the retarder
467 406 510 0 45° 250 bar 128 + 10 bar 450 N
+ 10
467 406 511 0 45° 250 bar 175 bar 450 N
Operating temperature range for all Variants –30°C to +80°C
*) Port 51 closed with plug
Spare parts:
Description No. Part Number Variant of Brake Valve
Pedal Cover 202, 216, 218, 220, 227, 233, 234, 301, 307, 401, 407,
1 897 730 022 4
408, 411, 414, 507, 508, 509, 510, 511
2 467 406 782 2 218
2 467 406 784 2 408
2 467 406 786 2 507
2 467 406 789 2 307
2 467 406 791 2 202, 234
complete 2 467 406 792 2 208
Actuating 2 467 406 795 2 235, 305
Mechanism 2 467 406 798 2 233
2 467 406 799 2 216, 220, 401
2 467 901 780 2 407, 410, 414
2 467 901 781 2 211
2 467 901 784 2 508
2 467 901 785 2 509
2 467 901 787 2 411
WABCO 9 27
Spare parts: Description No. Part Number Variant of Brake Valve

complete 2 467 901 790 2 227
Actuating 510, 511
Mechanism 2 467 901 792 2
3 897 752 270 4 218
Bellows 3 897 752 670 4 208
202, 216, 220, 227, 233, 235, 305, 307, 401, 407, 408,
3 897 754 865 4
410, 411, 414, 507, 508, 509, 510, 511
4 897 161 557 4 401, 407, 408, 410, 411, 414
Grooved Ring 4 897 162 000 4 202, 305, 307
4 897 162 040 4 510, 511
4 897 162 080 4 208, 216, 218, 220, 227, 233, 234, 235, 507, 508, 509
Washer 5 895 105 870 4 234, 401
5 895 107 710 4 507
202, 208, 216, 218, 220, 233, 235, 305, 408, 508, 509,
5 895 151 420 4
510
showing: 467 406 227 0
Variant 11, 12, 21, 22,

24, 25
51, 52
208, 211, 216,
218, 220, 227,
M 16x1.5 M 10x1
233, 234, 235,
-12 deep - 8 deep
238, 507, 508,
509, 510, 511
301, 305,
M 16x1.5 M 11x1.5
307, 400,
-12 deep - 10 deep
401, 408
411, 414 M 16x1.5 M 12x1.5
-12 deep - 8 deep
Port connections:
11, 12 = Hydraulic accumulator
21, 22 = Service brake
24, 25 = Test connection
51, 52 = Return connection
28 9
WABCO
Brake Valve
467 406
3
showing: 467 406 202 0
Port connections:
11, 12 = Hydraulic accumulator
21, 22 = Service brake
24, 25 = Test connection
51, 52 = Return connection
showing: 467 406 208 0
WABCO 9 29
Installation Requirements: Return Lines 51/52 must be connected Bolt (M) using a mandril. When knocking
directly to the tank. out the bolt, make sure that the mandril is
The connecting lines must be installed in applied to the side of the bolt without a
such a way as to permit proper bleeding. knurl. Remove Pedal (B) and Bellows (3).
Now fit the new Bellows (3) and proceed
Maintenance of the Brake Valve in reverse order as described above. The
No special maintenance beyond the legal upper portion of Bellows (3) is fastened to
requirements is necessary. Piston (N), its lower portion to Base Plate
(E). Secure the bellows using clamps.
When using high-pressure cleaners on
the vehicle, please make sure that the Replacing the Grooved Ring
water jet is not aimed directly at the Carefully clamp the unit vertically in a
Brake Valve (to prevent damaging the fixture. Unscrew Screw Plug (P) and pull
bellows). Slides (C1 and C2) out downwards.
Check the slides for damage. If they are
Replacing the Pedal Cover found to be damaged, the whole Brake
Pedal Cover (1) is simply pulled off by Valve needs to be replaced. (Pairs of
hand. The new pedal cover is pushed slides and housings are matched in
over Pedal (B) and tightened manually. manufacturing.) If the slides are not
Fasten the bellows with the strap damaged in any way, remove the whole
retainers. actuating mechanism as described
above. Remove Spring Assembly (A)
and Grooved Ring (4) and put in a new
Replacing the complete Actuating
greased grooved ring with its lips pointing
Mechanism downwards. Install both the spring
Carefully clamp the unit vertically in a assembly as shown in the drawing, and
fixture. The actuating mechanism can be the pedal. Put in Spring (R1), followed by
removed by taking out the four Screws Slide (C2), using a slight turning motion if
(H) below Base Plate (E). Make sure that possible. Insert Spring (R2) and close the
Spring Assembly (A) does not fall out. unit with Screw Plug (P). Check Return
When installing the new actuating Port 51 to see if there is a gap of approx.
mechanism, make sure that Spring 2 mm between the lower edge of the hole
Assembly (A) is fitted in the right order. and the control edge of Slide (C1). If this
Tighten the four Screws (H). is not the case, change the setting by
removing or adding Distance Washers
Replacing the Bellows (5) in the upper spring plate. Check the
To change Bellows (3) it is advisable to distance between the lower edge of the
remove Pedal (B). For this purpose, hole at Port 51 and the control edge of
loosen Retaining Ring (L) and knock out Slide (C1) again.
For safety reasons the whole of the Brake Valve must be replaced
if parts other than those listed above are damaged.
Repair Work: When working on the braking When doing repair work, make
system!
30 18
WABCO
Hand Brake Valve 467 410
3
Purpose: between Brake Cylinder Port 2 and
Return 5. The pivoting angle of the hand
The purpose of the Hand Brake Valve is brake lever will now determine the
to sensitively increase and decrease the pressure in the spring brake actuator
braking pressure when the hand brake (Port 2). Slide (C) is held in the control
lever is actuated. position by the force (spring assembly)
above the slide and by the hydraulic
Operation: pressure below the slide (balance of
forces). Slide C is in a partial braking
Ready Position position, causing Ports 1 and 5 to close
When the braking system is ready for and to hold the pressure in Port 2.
operation, its accumulator pressure acts
directly on Port 1 of the Hand Brake In the range of partial brake application,
Valve. A connection is established the hand lever will automatically return to
between Ports 1 and 21 so that the the driving position when the braking
vehicle's hand brake is released. process is ended.
Secondary Braking System Parking Brake

When the Hand Brake Valve is actuated, When the lever is fully actuated, an end
the hydraulic release pressure is position of the brake is reached and a
increased or decreased as a function of connection is established between
the hand brake lever's pivoting angle. Return 5 and Brake Cylinder Port 2.
Accumulator Port 1 is closed and the
Spring Assembly (A) below Cam Plate lever is locked in position.
(B) permits a sensitive braking process
for the vehicle. When the parking brake is released, a
connection between Brake Cylinder Port
When the secondary braking process is 2 and Accumulator Port 1 is once more
(Locked position = pressure reduced)
commenced, Slide (C) is mechanically established, and Return Port 5 is closed.
actuated via Spring Assembly (A). s Slide
(C) moves upwards, it first closes Once released from its locked position,
Accumulator Port 1 via the control edge the hand brake lever will automatically
and then establishes a connection return to the driving position.
Installation Requirements: Repair Work:

Return Line 5 must be connected directly
to the tank When working on the braking
The connecting lines must be installed in system, always make sure that
such a way as to permit proper bleeding. there is absolutely no pressure
The Hand Brake Valve should be in the system. Even when the
installed in a position where it cannot be engine is switched off there will
accidentally actuated by the driver's foot. be some residual pressure in the
system!
Maintenance of the Brake Valve
When doing repair work, make
No special maintenance beyond the legal sure your environment is very
clean.
Immediately close all open ports
When using high-pressure cleaners on on the components and on pipes
the vehicle, please make sure that the using plugs!
water jet is not aimed directly at the Hand
Brake Valve (to prevent damaging the Replacing the Bellows
bellows).
To change Bellows (D), remove
Actuating Button (E) from Lever (F). To
do this, push out the two Retaining Pins
(G). The Bellows (D) can now be pulled
off and the new ones installed. Push
Actuating Button (E) back onto Lever (F),
securing it with Retaining Pins (G)..
WABCO 19 31
3 467 410 Hand Brake Valve
Technical Data:
Operating Working Permissible Operating temperature

Part Number in locked position
pressure pressure Medium range
467 410 011 0 50 bar pressure reducing
467 410 015 0 150 bar 50 bar mineral oil –40°C to+80°C pressure reducing
467 410 016 0 100 bar pressure increasing
467 410 017 0 50 bar pressure reducing #)
#) Hand Brake Valve 467 410 017 0 has a red actuating button
Spare parts: Description Part Number Variant of Hand Brake Valve

Bellows 897 754 190 4 011, 012, 013, 015, 016, 017, 018
For safety reasons the whole of the Hand Brake Valve must be
replaced if parts other than the bellows are damaged.
showing: 467 410 012 0

1,21, 5 = M16 x 1.5 - 10 deep
25 = M 12 x 1.5 - 10 deep
Port connections:
1 = Energy supply
24 = Pressure switch connection
32 20
WABCO
Double Check Valve 476 399
478 399 3
Purpose: of actuation of the valve, to Port 2. A ball
seat valve arrangement ensures that as
The purpose of the Double Check Valve
the foot brake valve is actuated, Port 12
is to permit alternate actuation of the
remains pressureless when the pressure
braking circuits. It permits a hydraulic
is increased at Port 11, and vice versa.
braking circuit to be actuated by two
The ball seat also prevents the control
actuating valves.
pressure being reduced through the part
of the line which is not being utilized.
Operation:
When the control pressure is built up, the Note:
control pressure is passed unrestrictedly
from Port 11 or 12, depending on the type Do not use for planning new projects
Technical Data:
Part Number 476 399 001 0 478 399 002 0

Operating pressure 200 bar max., 2 bar min.
Permissible Medium mineral oil
brake fluid
10 mm²/s to 1936 mm²/s
Operating temperature range – 40°C to +80°C
Rate of flow max. 12 dm³ / min
Weight 0.42 kg

M 14 x 1.5 DIN 74 235
Port connections:
11, 12 = Energy supply
2 = Energy delivery
Installation Requirements: The connecting lines must be installed in system, always make sure that
such a way as to permit proper bleeding. there is absolutely no pressure
The Double Check Valve can be in the system. Even when the
mounted in any position. engine is switched off there will
Maintenance of the Double Check system!
Valve
No special maintenance beyond the legal When doing repair work, make
sure your environment is very
clean.
Repair Work: Immediately close all open ports
on the components and on pipes
When working on the braking using plugs!
For safety reasons the whole of the Double Check Valve

must be replaced if damaged.
WABCO 21 33
3 477 397 Shut-Off Valve
for Single Circuit Systems
Purpose: Charging Process

The purpose of the Shut-Off Valve is to As the accumulator pressure falls to the
control the pressure level in the preset value, Control Slide (B) will,
accumulators. through the force of Spring Assembly
(D), overcome its locked position (E1)
Operation: and move to another locked position
(E2). Via Orifice (F) and through
Ready Position
Connecting Hole (H), an oil stream flows
When the braking system is ready for
to the rear of Main Slide (A). The
operation (i.e. the accumulators are
pressure building up at the rear of Main
charged) the pump stream is present at
Slide (A) and the pressure present below
Port 1 of the Shut-Off Valve. A
connection is established between Ports Main Slide (A) put Main Slide (A) in a
1 and 5 so that the pump stream can, floating position, permitting a partial
with a small difference in pressures, be stream to continue to reach Port 5 and
returned directly to the reservoir or other the remaining stream to flow to Port 2 via
consumers. The rear of Main Slide (A) is Check Valve (C) until the pressure at Port
pressureless. The pressure within the 2 is approx. 150 bar. Control Slide (B) will
braking system will hold Control Slide then once again move to Locked Position
(B ) in its locked position (E1) in which the (E1) in which a connection is established
rear of Main Slide (A) is directly between Ports 1 and 5 and the whole of
connected to Return 5 via Hole (G). the pump stream once again flows to the
Check Valve (C) in the hole to Port 2 reservoir. Check Valve (C) once again
secures the accumulator pressures. secures the accumulator pressures.
Technical Data:
Part Number 477 397 001 0 477 397 011 0 477 397 031 0
Pressure at port 5 150 bar max. 110 bar max. 50 bar max.
Cut-in pressure 130 -10 bar 110 +10 bar 120 +10 bar
Cut-off pressure 150 -10 bar 140 -10 bar 150 -10 bar
Flow rate from 1 Þ 2 = 3 l /min from 1Þ 2 = 12 l /min
max. 16 l /min
from 1 Þ 5 = 45 l /min from 1 Þ 5 = 45 l /min
Permissible Medium mineral oil: 10 . . . 1940 mm² /s
Switching range 20 +10 bar
Operating tempera-
–30°C to +80°C
ture range
Weight 2.4 kg
34 22
WABCO
Shut-Off Valve
for Single Circuit Systems
477 397
3
showing: 477 397 001 0

1, 5 = M 18x1.5 -14 deep (M = 50 ± 5 Nm)
2 = M 16x1.5 -14 deep (M = 40 ± 5 Nm)
Port connections:
1 = Energy supply
2 = Service brake
Installation Requirements: The connecting lines must be installed in Repair Work:

such a way as to permit proper bleeding.
When working on the braking
Maintenance of the Shut-Off Valve system, always make sure that
No special maintenance beyond the legal there is absolutely no pressure
requirements is necessary. in the system. Even when the
engine is switched off there will
system!

clean.
using plugs!
For safety reasons the whole of the Shut-off Valve must be

replaced if damaged.
WABCO 25 35
for Dual Circuit Systems
Purpose: Charging Process

As the accumulator pressure falls to the
The purpose of the Shut-Off Valve is to
preset value, Control Slide (B) will,
control the pressure level in the
through the force of Spring Assembly
accumulators.
(C), overcome its locked position (E1)
and move to another locked position
Operation: (E2). Via Orifice (F) an oil stream flows to
Ready Position the rear of Main Slide (A). The pressure
building up at the rear of Main Slide (A)
When the braking system is ready for
and the pressure present below Main
operation (i.e. the accumulators are
Slide (A) put Main Slide (A) in a floating
charged) the pump stream is present at
position, permitting a partial stream to
Port 1 of the Shut-Off Valve. A
continue to reach Port 5 and the
remaining stream to flow to Ports 21/23
1 and 5 so that the pump stream is, with
via Check Valve (D) until the pressure
a small difference in pressures, returned
within the braking system is approx. 150
directly to the reservoir. The rear of Main
bar. Control Slide (B) will then once again
Slide (A) is pressureless.
move to Locked Position (E1) in which a
The pressure within the braking system
1 and 5. The whole of the pump stream
will hold Control Slide (B ) in its locked
once again flows to the reservoir via Port
position (E1) in which the rear of Main
5. Check Valve (D) once again secures
Slide (A) is directly connected to Return
the accumulator pressures.
5 via Hole (G). Check Valve (D) in the
hole to Ports 21 and 23 secures the
accumulator pressures. Shuttle Valve (H)
causes the accumulator with the lowest
pressure to operate the Shut-Off Valve
whilst securing the circuit in the event of
a broken pipe.
Technical Data: Part Number 477 397 015 0

Pressure limiting 180 -10 bar
Cut-in pressure 120 +8 bar
Cut-off pressure 150 -8 bar
Flow rate max. 45 l /min
Permissible Medium mineral oil: 2000 to 10 mm² /s
VAI 6 to 12
Switching range 20 +10 bar
Weight 3.8 kg
36 26
WABCO
Shut-Off Valve
for Dual Circuit Systems
477 397
3
showing: 477 397 015 0

1, 5 = M18 x 1.5 -12 deep
(M = 50 ± 5 Nm)
21, 23
27 = M16x1.5 -12 deep
(M = 40 ± 5 Nm)
28 = M12x1.5 -12 deep
(M = 28 ± 3 Nm)
Port connections:
1 = Energy supply View X
21,23 = Service brake
27 = Hydraulic accumulator
28 = Pressure switch

system!

clean.
using plugs!

WABCO 9 37
for Triple Circuit Systems
Purpose: Shut-Off Valve in the event of a leakage.

Shuttle Valves (H) additionally secure
The purpose of the Shut-Off Valve is to each braking circuit against pressure
control the pressure level in the losses in the event of a broken pipe.
accumulators.
Charging Process
Operation: As the accumulator pressure falls to the
preset value, Control Slide (B) will,
Ready Position through the force of Spring Assembly
When the braking system is ready for (C), overcome its locked position (E1)
operation (i.e. the accumulators are and move to another locked position
charged) the pump stream is present at (E2). Via Orifice (F) an oil stream flows to
Port 1 of the Shut-Off Valve. A the rear of Main Slide (A). The pressure
connection is established between Ports building up at the rear of Main Slide (A)
1 and 5 so that the pump stream is, with and the pressure present below Main
a small difference in pressures, returned Slide (A) put Main Slide (A) in a floating
directly to the reservoir. The rear of Main position, permitting a partial stream to
Slide (A) is pressureless. The pressure continue to reach Port 5 and the
within the braking system will hold remaining stream to flow to Ports 21//22/
Control Slide (B ) in its locked position 23 via Check Valve (D) until the pressure
(E1) in which the rear of Main Slide (A) is within the braking system is approx. 150
directly connected to Return 5 via Hole bar. Control Slide (B) will then once again
(G). Check Valve (D) in the hole to Port move to Locked Position (E1) in which a
27 secures the accumulator pressure of connection is established between Ports
Variant 014 the operating accumulator. This is 1 and 5. The whole of the pump stream
available as an additional braking volume once again flows to the reservoir via Port
for the braking system, preventing 5. Check Valve (D) again secures the
excessively frequent actuation of the accumulator pressures.
Variant 007
38 WABCO
Shut-Off Valve
for Triple Circuit Systems
477 397
3
Technical Data: Part Number 477 397 007 0 477 397 014 0
Pressure at port 5 – 200 bar max.
Pressure limiting 170 + 30 bar without
Cut-in pressure 120 + 8 bar
Cut-off pressure 150 - 8 bar
Flow rate max. 16 l /min 45 l /min
Flow rate to braking circuit 3 + 1 l /min 3 + 1 l /min
Permissible Medium mineral oil 10 ... 2000 mm² /s
Weight 3.8 kg
showing: 477 397 014 0
Thraed of pipe connections:

1, 5 = M18 x 1.5 -12 deep
(M = 50 ± 5 Nm)
21, 22
23, 27= M16 x 1.5 -12 deep
(M = 40 ± 5 Nm)
28 = M12 x 1.5 -12 deep
(M = 28 ± 3 Nm)
View X
Port connections:
1 = Energy supply
21,22,23 = Service brake
27 = Hydraulic accumulator
28 = pressure switch

system!

clean.
using plugs!

WABCO 27 39
3 477 399 Check Valve
Purpose: Ready Position

When the pressure at Port 1 is reduced,
The purpose of the Check Valve is to
return flow of the oil is prevented by
secure the pressure in the intact braking
closing of Check Valves (A), thus
circuits of a triple circuit braking system in
securing the pressure in the hydraulic
the event of one circuit failing.
accumulators. As the pressure is
increased, Check Valves (A) are opened
Operation: once again, permitting the pressures in
Filling Position the cirucits to be balanced.
After Check Valves (A) have opened, the
oil stream from Port 1 will reach the Pressure Limiting Facility
downstream accumulators of the brake A Pressure Limiting Valve (B) integrated
valves via Ports 21 and 22 and flows via in the Check Valve limits the output
Port 23 to the accumulator for the hand pressure to a maximum of 180 bar.
brake valve. Pressure gauges or
manometric switches can be connected
at Ports 24, 25 and 26 to check the
braking pressure.
Technical Data:
Part Number 477 399 300 0
Pressure limiting 180 +10 bar
Flow rate 0.7 to 16 l /min
40 28
WABCO
Check Valve 477 399
3
Thraed of pipe connections:

1, 5, 21
22, 23 = M14x1.5 DIN 74 235
24, 25
26 = M14x1.5 -12 deep
Port connections:
1 = Energy supply
21 – 26 = Energy delivery

The Check Valve can be mounted in any When working on the braking
position. system, always make sure that
there is absolutely no pressure
Maintenance of the Check Valve in the system. Even when the
system!

clean.
using plugs!
For safety reasons the whole of the Check Valve must

be replaced if damaged.
WABCO 29 41
3 477 411 Relay Valve
Purpose: When the braking process is

commenced, Slide (A) is actuated via
The purpose of the Relay Valve is to Control Port 4 and moves into the braking
rapidly transfer large volumes to the position against the force of Spring (B).
wheel brake. It offers the benefit of being The slide will first close Return Port 5 via
able to operate with a small actuating the control edge and then, via another
volume. control edge, connect Accumulator Port
1 with Port 2. Via a hole, the oil stream
Operation: now flows from Port 1 to Port 2 through
Hollow Slide (A), moving it to its final
Ready Position
braking position. In this process, the
When the braking system is ready for output braking pressure at Port 2 is equal
operation, the accumulator pressure is to the control pressure of the foot brake
present at Port 1 of the Relay Valve. A valve at Port 4.
2 and 5 so that the wheel brake cylinders
Release Position
of the vehicle are released.
As the control pressure at Port 4 is
reduced, Hollow Slide (A) returns to its
Braking Position initial position. The connection between
When the foot brake valve is actuated, a Ports 1 and 2 is closed once again by the
hydraulic braking pressure builds up at control edges. The second control edge
Port 2 as a function of the input pressure will then open the connection between
at Port 4. Port 1 and Return Port 5.
Technical Data:
Part Number 477 411 000 0
Control volume 0.58 cm³
Transmission ratio 1:1
42 WABCO
Relay Valve 477 411
3
Installation dimension:
Installation Requirements: The return line must be connected Repair Work:

directly to the tank.
The connecting lines must be installed in When working on the braking
such a way as to permit proper bleeding. system, always make sure that
The Relay Valve should be mounted in there is absolutely no pressure
the vicinity of the wheel brake. in the system. Even when the
Maintenance of the Relay Valve be some residual pressure in the
system!
requirements is necessary. When doing repair work, make
clean.
using plugs!
For safety reasons the whole of the Relay Valve must be

WABCO 30 43
4
General Comments
WABCO 10 45
Information for Installation
4
General Comments a) All pipes in the braking system must f) Look for visible leaks in lines and
have a nominal width of at least 10 pipes. Leaks are an indication that
mm. the system is not properly sealed.
Check the level of the brake fluid.
b) The pipes should be installed in such Stop leakage.
a way as to permit proper bleeding,
i.e. so that no air cushions can de- g) When using high-pressure cleaners,
velop. If you detect noises when com- do not aim the nozzle directly at the
mencing the braking process, this is bellows. (This may cause damage to
an indication of poor bleeding. the bellows.)
c) When fitting the pipes, make sure that h) When working on the braking system,
there are no areas of friction. always make the sure that the system
is completely pressureless!
d) The return lines of the individual com-
ponents of the braking system must i) Make sure that everything is spotles-
not be combined in one return line to sly clean!
the tank.
j) Immediately close all open ports on
e) Do not use a pipe for the return lines the components and on pipes using
of the dual circuit brake valve to com- plug.
bine them in one return line. (This is
possible only if Ports 5.1 and 5.2 are
connected by means of hoses and
combined to form one return line.)
PLEASE NOTE:
Even when the engine is switched off or the

pump is not running, the system pressure
will be maintained!
WABCO 11 47
4 Information for Installation
Information for Installation It is particularly important that the com- ke valve only actuates the relay valves.
ponents all have their separate return li- The input volume of the relay valves is
nes since otherwise the return pressure approx. 1 cm³.
can be present in the wheel brake in the
form of residual pressure. This leads to If shut-off valves with an integrated check
unnecessary wear of the brake linings valve are used, an additional accumula-
and excessive temperatures at the wheel tor of 0.7 litres needs to be screwed into
brake and can thus result in hardening of the component. That additional accumu-
the linings, and in a failure of the seals on lator is primarily used to monitor the actu-
the wheel brake cylinders. al pressure of the other three
accumulators and to report them to the
When combining the returns of the dual shut-off valve. The accumulators can be
circuit foot brake valve, please make emptied when the brakes are operated,
sure that hoses are used for connecting without being re-charged since all circuits
the return ports. Using a pipe to connect are secured from each other by the check
the two circuits can cause functional de- valves. The additional accumulator will
fects through distortions in installation. also prevent activation of the shut-off val-
ve as a consequence of small leakages
and thus a fall in pressure in the connec-
For very long vehicles with large cylinder
tion established between the check val-
volumes, the installation of relay valves
ves even though the pressure in the
can be very helpful, reducing response
accumulators of the braking circuit is still
and pressure build-up times to a mini-
higher than 120 bar.
mum. The relay valve should be fitted as
close to the wheel brake cylinders as
possible. Thus the lengths of the lines
from the accumulator to the wheel brake
cylinders are reduced since the foot bra-
Capacity of Accumulators The capacity of the hydraulic accumula- For this purpose we require the following
tors must be designed according to the information from you:
legal provisions for the HPB with regard
to the size of energy accumulators.
We support our customers, free of char-

ge, in designing the accumulators.
48 12
WABCO
Information for Installation
4
Date:
Company:
Person to contact:
Telephone number:
Fax number:
Type of vehicle:
excavator, wheel loader,
........
Type designation:
Speed: k.p.h.
Wheel brake data:
Axle manufacturer:
Wheel brake manufacturer:
Wheel brake type:
Input volume of wheel brake cylinders per axle for actuation of service braking system
front axle rear axle
V min cm³ cm³
V max cm³ cm³
Input volume of wheel brake cylinders per axle for actuation of secondary braking system
front axle rear axle
V min cm³ cm³
V max cm³ cm³
Input volume of
spring brake actuator cm³
braking pressures
Pressure for secondary braking system bar
Pressure for service braking system bar
It would further assist us if you could

send us the data sheet for the wheel
brake.
WABCO 10 49
5 Legal Requirements
ECE Regulation 13 C. HYDRAULIC BRAKING SYSTEMS WITH STORED ENERGY

- Annex 7C -
1. CAPACITY OF ENERGY STORAGE DEVICES
(ENERGY ACCUMULATORS).
1.1. General
1.1.1. Vehicles on which operation of the braking system requires the use of
stored energy provided by hydraulic fluid under pressure shall be equipped
with energy storage devices (energy accumulators) of a capacity meeting
the requirements of paragraph 1.2. of this annex (Part C).
1.1.2. However, the energy storage devices shall not be required to be of a

prescribed capacity if the braking system is such that in the absence of any
energy reserve it is possible with the service braking system control to
achieve a braking performance at least equal to that prescribed for the
secondary braking system.
1.1.3. In verifying compliance with the requirements of paragraphs 1.2.1., 1.2.2.

and 2.1. of this annex, the brakes shall be adjusted as closely as possible
and, for paragraph 1.2.1., the rate of full-stroke actuations must be such as
to provide an interval of at least 60 seconds between each actuation.
1.2. Power-Driven Vehicles
1.2.1. Power-driven vehicles equipped with a hydraulic braking system with

stored energy shall meet the following requirements:
1.2.1.1. After eight full-stroke actuations of the service braking system control, it
shall still be possible to achieve, on the ninth application, the performance
prescribed for the secondary braking system.
1.2.1.2. Testing shall be performed in conformity with the following requirements:
1.2.1.2.1. Testing shall commence at a pressure that may be specified by the

manufacturer but is not higher than the cut-in pressure.
1.2.1.2.2. The energy storage device(s) shall not be fed; in addition, any energy
storage device(s) for auxiliary equipment shall be isolated.
1.2.2. Power-driven vehicles equipped with a hydraulic braking system with

stored energy which cannot meet the requirements of paragraph 5.2.1.5.1.
of this Regulation shall be deemed to satisfy that paragraph if the following
requirements are met:
1.2.2.1. After any single transmission failure it shall still be possible after eight full-
stroke actuations of the service braking system control, to achieve, at the
ninth application, at least the performance prescribed for the secondary
braking system or, where secondary performance requiring the use of
stored energy is achieved by a separate control, it shall still be possible
after eight full-stroke actuations to achieve, at the ninth application, the
residual performance prescribed in paragraph 5.2.1.4. of this Regulation.
1.2.2.2. Testing shall be performed in conformity with the following requirements:
1.2.2.2.1. With the energy source stationary or operating at a speed corresponding to

the engine idling speed, any transmission failure may be induced. Before
inducing such a failure, the energy storage device(s) shall be at a pressure
that may be specified by the manufacturer but not exceeding the cut-in
pressure.
50 10
WABCO
Legal Requirements
5
ECE Regulation 13 1.2.2.2.2. The auxiliary equipment and its energy storage devices, if any, shall be
- Annex 7C - isolated.
2. CAPACITY OF HYDRAULlC FLUID ENERGY SOURCES
2.1. The energy sources shall meet the requirements set out in the following
paragraphs:
2.1.1. Definitions
2.1.1.1. "p1" represents the maximum system operational pressure (cut-out

pressure) in the energy storage device(s) specified by the manufacturer.
2.1.1.2. "p2" represents the pressure after four full-stroke actuations with the service
brake control, starting at p1, without having fed the energy storage
device(s).
2.1.1.3. "t" represents the time required for the pressure to rise from p2 to p1 in the
energy storage device(s) without application of the service braking system
control.
2.1.2. Conditions of Measurement
2.1.2.1. During the test to determine the time t, the feed rate of the energy source
shall be that obtained when the engine is running at the speed
corresponding to its maximum power or at the speed allowed by the over-
speed governor.
2.1.2.2. During the test to determine the time t, energy storage device(s) for
auxiliary equipment shall not be isolated other than automatically.
2.1.3. Interpretation of Results
2.1.3.1. In the case of all vehicles except those of categories M3, N2 and N3, the
time t shall not exceed 20 seconds.
2.1.3.2. In the case of vehicles of categories M3, N2 and N3, the time t shall not
exceed 30 seconds.
3. CHARACTERISTICS OF WARNING DEVICES
With the engine stationary and commencing at a pressure that may be

specified by the manufacturer but does not exceed the cut-in pressure, the
warning device shall not operate following two full-stroke actuations of the
service braking system control.
WABCO 51

HPB Hydraulic Power Braking System: General Comments, Diagrams and Description of Components

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HPB Hydraulic Power

The amendments are marked

 Copyright WABCO 2001

Vehicle Control Systems

The right of amendment is reserved

1. General Comments ........................................................................................... 5

2. Diagrams of HPB Systems ............................................................................... 7

3. Description of Components ........................................................................... 13

4. General Comments ......................................................................................... 45

If the brake volume is greater than 75

The response and threshold times

all pipes of brake line NW 10

Diagram: 841 300 314 0

all pipes of brake line NW 10

all pipes of brake line NW 10

Diagram: 841 300 332 0

all pipes of brake line NW 10

Purpose: Quick Release Facility

427 001 006 0

Spare parts: Description No. Part Number Variant of Actuator

Replacing the Yoke

Thread of pipe connections:

showing: 427 001 005 0

No maintenance beyond the legal When doing repair work, make

Purpose: braking system or directly on one of its

Make Contact / Circuit Closer

441 014 043 0 mineral oil M 12x1.5 55 9 20 - 50 21 ± 2 42

441 014 048 0 mineral oil M 12x1 tapered 43 9 3-6 3-6 42

For safety reasons the Pressure Switch needs to be

Adjusting and testing the

Purpose: diaphragm (C) as a gas-tight dividing

For safety reasons the Accumulators need to be

Purpose: close Return 5 via the control edge, thus

467 406 108 0

showing: 467 406 108 0

Thread of pipe connections:

showing: 467 406 102 0

Thread of pipe connections:

Variant 1, 21, and 51 24

**) closed withplug

Maintenance of the Brake Valve

Purpose: they will first close Returns 51/52 via the

Limiting the Braking Pressure

*) Port 51 closed with plug

Spare parts: Description No. Part Number Variant of Brake Valve

showing: 467 406 227 0

Thread of pipe connections:

Variant 11, 12, 21, 22,

showing: 467 406 202 0

showing: 467 406 208 0

Secondary Braking System Parking Brake

Installation Requirements: Repair Work:

Operating Working Permissible Operating temperature

Spare parts: Description Part Number Variant of Hand Brake Valve

showing: 467 410 012 0

Thread of pipe connections:

Part Number 476 399 001 0 478 399 002 0

Thread of pipe connections:

For safety reasons the whole of the Double Check Valve