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

all pipes of brake line NW 10

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
23 Energy delivery Circuit 3 52 Return connection Circuit 2

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 2 Pressure Switch 441 014 055 0
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
9 • Brake Actuators 19
10 20

10 6
WABCO
 HPB - Diagram
dual-circuit 2
Diagram: 841 300 331 0

all pipes of brake line NW 10

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
23 Energy delivery Circuit 3 52 Return connection Circuit 2

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 2 Pressure Switch 441 014 055 0
3 1 Shut-Off Valve 477 397 . . . 0 13 1 Pressure Switch 441 014 . . . 0
4 1 Brake Valve 467 406 . . . 0 14 4 Test connection
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
8 1 Tank 18 • Accumulator 458 501 . . . 0
9 • Brake Actuators 19
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

all pipes of brake line NW 10

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
23 Energy delivery Circuit 3 52 Return connection Circuit 2

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 2 Pressure Switch 441 014 055 0
3 1 Shut-Off Valve 477 397 . . . 0 13 1 Pressure Switch 441 014 . . . 0
4 1 Brake Valve 467 406 . . . 0 14 4 Test connection
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
8 1 Tank 18 • 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
with quick-release facility
without quick-release facility
14
Spring Brake Actuator
Purpose:
The spring brake actuator serves to
generate the braking force for the wheel
brake in secondary and parking braking
systems.
Operation:
Ready Position
In the driving condition, the pressure
from the hand brake valve is acting
directly on Port 1 of the Spring Brake
Actuator. The secondary or parking
brake is released.
Braking Position
When the hand brake valve is actuated,
the hydraulic pressure is reduced as a
function of the angular position of the
hand brake lever.
As the pressure in the hydraulic portion
(A) of the Spring Brake Actuator is
reduced, the force of the releasing
Compression Spring (B) makes Piston
Rod (C) retract in the direction of the
Actuator’s axis, thus actuating the wheel
brake. The Spring Brake Actuator’s
maximum brake force is reached when
the pressure falls to zero.
9
Quick Release Facility
Some variants are available with a quick-
release facility.
This permits, in the event of the pressure
in the hydraulic portion (A) failing, the
wheel brake to be released by applying a
blow in the direction of the arrow (F),
using a hammer, thus severing the
frictional connection established
between Compression Spring (B) and
Piston Rod (C) and actuating the quick-
release facility (D).
As the pressure in the hydraulic portion
(A) builds up again, the connection
between Compression Spring (B) and
Piston Rod (C) is established once more
and the Spring Brake Actuator is fully
operative again.
Emergency Release Facility
If Spring Brake Actuators without a quick-
release facility are used, the parking
brake can still be released should the
hydraulic pressure fail. To do so, the
Hexagon Nut (6) on Piston Rod (K) is
taken off Yoke (C1). An open-jawed
spanner (jaw size 13) is applied to
Section (L) on Piston Rod (K). Piston Rod
(K) is then turned in such a way that Yoke
(C1) is displaced towards the brake
lever.
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:
The enclosed portion of the
actuator is spring-loaded !
Replacing the Bellows
Remove clamps (2; 3 or H) from the
bellows, replace as necessary when
fitting the new bellows. Pull off the faulty
bellows (1), push on new bellows and
fasten with clamps (2; 3 or H).
piston rod. The new Yoke (5) is screwed
into the piston rod up to the point where
the original piston rod length is once
again achieved (see outline drawing:
distance from centre yoke hole to end
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
Installation Requirements:
The connecting lines must be installed in
such a way as to permit proper bleeding.
The actuator should be mounted at a
slight angle, its piston rod pointing
downwards.
Maintenance:
No maintenance beyond the legal
requirements is necessary.
When using high-pressure cleaners on
the vehicle, please make sure that the
water jet is not aimed directly at the
Spring Brake Actuator (to prevent
damaging the bellows).
WABCO
427 001
3
Repair Work:
When working on the braking
system, always make sure that
there is absolutely no pressure
in the system. Even when the
engine is switched off there will
be some residual pressure in the
system!
When doing repair work, make
sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
using plugs!
9 17
3 441 014 Pressure Switch

Purpose: braking system or directly on one of its

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

Make Contact / Circuit Closer

The Pressure Switch can be fitted in the
braking system or directly on one of its
components. The system pressure acts
on an absorption area within the switch,
making an electrical contact as the
pressure on that area is increased. The
resulting current is used to activate a
warning facility, for instance.
Break Contact / Circuit Breaker
Break Contact Make Contact The Pressure Switch can be fitted in the
Installation Requirements:
No special measures need to be taken.
Maintenance:
No special maintenance beyond the legal
requirements is necessary.
When using high-pressure cleaners on
the vehicle, please make sure that the
water jet is not directed at the Pressure
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
Installation dimensions:

Repair Work:
When working on the braking
system, always make sure that
there is absolutely no pressure
in the system. Even when the
engine is switched off there will
be some residual pressure in the
system!
When doing repair work, make
sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
using plugs!

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
two contact plugs can be set to the
desired value within a certain range. For
adjusting range, please refer to the table
"Technical Data" on the previous page.
After making the adjustment, the
adjusting screw should be secured using
wax or a similar material.

WABCO 9 19
3 458 501 Hydraulic Accumulator

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

Fluids are practically incompressible and
are thus incapable of accumulating
pressure energy. In hydropneumatic
accumulators, the compressibility of a
gas is utilized to accumulate fluid. The
compressible medium used in the
accumulators is nitrogen.
In braking systems, the purpose of the
accumulators is to store the energy
supplied by the hydrailc pump. They are
also used as an energy reserve when the
pump is not working, as a compensator
for any losses through leakage, and as
oscillation dampers.
element. The fluid portion (A) is
connected to the hydraulic circuit,
causing the diaphragm accumulator to
be filled and the gas volume to be
compressed as the pressure rises. When
the pressure falls, the compressed gas
volume will expand, thus displacing the
accumulated pressure fluid into the
circuit.
The diaphragm bottom contains a valve
disk (D) which, if the diaphragm
accumulator is completely empty, closes
the hydraulic outlet, thus preventing
damage to the diaphragm.

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

Installation Requirements:
Performance testing and
checking of the Accumulator:
A = ball valve for shutting off pump flow
B = ball valve for reducing pressure
S = safety valve: set to 180 bar max.
M = pressure gauge
H = hydraulic accumulator
WABCO
Hydraulic Accumulator
The accumulators can be fitted in the
hydraulic circuit, directly on a component
or in blocks on suitable consoles.
They should be fitted in as cool a location
as possible.
Installation can be in any position.
Maintenance:
No special maintenance beyond the legal
requirements is necessary.
The accumulator should be checked
annually. It should be replaced if the
initial gas pressure has fallen by more
than 30% (please refer to "Performance
The accumulator is gradually pressurized
via the test pump; until the initial gas
pressure is reached, the hydraulic
pressure in the accumulator will rise
abruputly. This is apparent from gauge
"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
repeated, wait for intervals of 3 minutes
between the individual tests. Any
accumulator whose initial gas pressure is
insufficient must be scrapped following
the instructions under "Disposal of the
Accumulator".
The amount of initial gas pressure can
also be checked from the vehicle.Start
the vehicle’s engine. The pump will now
supply oil to the accumulators. Until the
initial gas pressure is reached, the
hydraulic pressure in the accumulator will
rise abruputly. This is apparent from the
gauge in the cab. If the initial gas
pressure is more than 30% below the
prescribed value, that initial pressure lies
outside the permissible range for at least
one of the accumulators fitted in the
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.
458 501
3
testing and checking of the
Accumulator").
Disposal of the Accumulator:
Before the accumulator is scrapped, its
gas filling pressure must be reduced. For
this purpose, drill a hole through Gas
Chamber (B) using a drill approx. 3 mm in
diameter. The gas chamber is located on
the side opposite the threaded port
above the welding seam around the
centre of the accumulator.
Wear safety goggles when doing this
job!
individually tested. The accumulator
whose initial gas pressure is insufficient
must be replaced and scrapped following
the instructions under "Disposal of the
Accumulator".
Repair Work:
When working on the braking
system, always make sure that
there is absolutely no pressure
in the system. Even when the
engine is switched off there will
be some residual pressure in the
system!
When doing repair work, make
sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
using plugs!
12 21
3 467 406 Brake Valve
for single circuit braking system
Purpose:
The purpose of the Brake Valve is to
sensitively increase and decrease the
braking pressure when the brake pedal
(or the actuating lever) is actuated.
Operation:
Ready Position
When the braking system is ready for
operation, its accumulator pressure acts
directly on Port 1 of the Brake Valve. A
connection is established between Ports
2 and 5 so that the wheel brake (Port 2)
is pressureless via the return (Port 5).
Partial Braking
When the Brake Valve is actuated, an
amount of hydraulic pressure is output as
a ratio of the foot force applied.
he Spring Assembly (A) beneath Base
Plate (E) is designed in such a way that
the braking pressure changes depending
on the angle. In the lower braking
pressure range, the vehicle can be
467 406 1 .. 0 slowed sensitively.
When the braking process is
commenced, Slide (C) is mechanically
actuated via Spring Assembly (A). As
Slide (C) moves downward, it will first
467 406 108 0
22 13
close Return 5 via the control edge, thus
establishing a connection between
Accumulator Port 1 and Port 2 for the
wheel brake cylinders. The foot force
applied now determines the output
braking pressure. Control Slide (C) is
held in the control position by the force
applied (spring assembly) and the
hydraulic pressure below Slide (C)
(balance of forces). After output of the
braking pressure, Slide (C) is in a partial
braking position, causing Ports 1 and 5 to
close and holding the pressure in Port 2.
Full Braking Position
When Pedal (B) is fully actuated, an end
position of the brakes is reached and a
connection established between
Accumulator Port 1 and Brake Cylinder
Port 2. Return 5 is closed at this point.
When the braking process is ended, a
connection is once again established
between Brake Cylinder Port 2 and
Return Port 5, closing Accumulator Port
1.
Limiting the Braking Pressure
Pedal Restriction Screw (D) on Base
Plate (E) below Pedal (B) is used to limit
the braking pressure. This will cause the
accumulator pressure building up in the
braking system to be limited.
WABCO
 Brake Valve
for single circuit braking system
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

Installation dimensions:

showing: 467 406 108 0

Thread of pipe connections:

M 14x1.5 - 12 deep

Port connections:
1 = Energy supply
21 = Energy delivery
51 = Return connection

WABCO 14 23
 3 467 406 Brake Valve
for single circuit braking system

Installation dimensions:

showing: 467 406 102 0

Thread of pipe connections:

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
21 = Energy delivery
51 = Return connection

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

No special maintenance beyond the legal
requirements is necessary.
When using high-pressure cleaners on
the vehicle, please make sure that the
water jet is not aimed directly at the
Brake Valve (to prevent damaging the
bellows).
Replacing the Pedal Cover
Pedal Cover (1) is simply pulled off by
Replacing the complete Actuating
Mechanism
Carefully clamp the unit vertically in a
fixture. The actuating mechanism can be
removed by taking out the four Screws
(H) below Base Plate (E). Make sure that
Spring Assembly (A) does not fall out.
When installing the new actuating
mechanism, make sure that Spring
Assembly (A) is fitted in the right order.
Tighten the four Screws (H).

24 15
WABCO
 Brake Valve
for single circuit braking system
Replacing the Bellows
To change Bellows (3) it is advisable to
remove Pedal (B). For this purpose,
loosen Retaining Ring (L) and knock out
Bolt (M) using a mandril. When knocking
out the bolt, make sure that the mandril is
applied to the side of the bolt without a
knurl. Remove Pedal (B) and Bellows (3).
Now fit the new Bellows (3) and proceed
in reverse order as described above. The
upper portion of Bellows (3) is fastened to
Piston (N), its lower portion to Base Plate
(E).
Replacing the Grooved Ring
Carefully clamp the unit vertically in a
fixture. Unscrew Screw Plug (P) and pull
Slide (C) out downwards. Check the slide
for damage. If it is found to be damaged,
the whole Brake Valve needs to be
replaced. (Pairs of slides and housings
467 406
3
are matched in manufacturing.) If the
slide is not damaged in any way, remove
the whole actuating mechanism as
described above. Remove Spring
Assembly (A) and Grooved Ring (4) and
put in a new greased grooved ring with its
lips pointing downwards. Install both the
spring assembly as shown in the
drawing, and the pedal. Carefully re-
insert Slide (C) into the housing from
below, turning it slightly. Put in Spring (R)
and close the unit with Screw Plug (P).
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
Slide (C). If this is not the case, change
the setting by removing or adding
distance washers (5) in the upper spring
plate of the spring assembly. Check the
distance between the lower edge of the
hole and the control edge of Slide (C)
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
system, always make sure that
there is absolutely no pressure
in the system. Even when the
engine is switched off there will
be some residual pressure in the
system!
When doing repair work, make
sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
using plugs!

WABCO 16 25
3 467 406 Brake Valve
for dual circuit braking system
Purpose:
The purpose of the Brake Valve is to
sensitively increase and decrease the
braking pressure when the brake pedal
(or the actuating lever) is actuated.
Operation:
Ready Position
When the braking system is ready for
operation, its accumulator pressure acts
directly on Port 11/12 of the Brake Valve.
A connection is established between
Ports 21/22 and Ports 51/52 so that the
wheel brakes (Ports 21/22) are
pressureless via the returns (Ports 51/
52).
Partial Braking
When the Brake Valve is actuated, an
amount of hydraulic pressure is output as
a ratio of the foot force applied.
The Spring Assembly (A) beneath Base
Plate (E) is designed in such a way that
the braking pressure changes depending
on the angle. In the lower braking
pressure range, the vehicle can be
slowed sensitively.
When the braking process is
commenced, the upper Slide (C1) is
mechanically actuated via Spring
Assembly (A), and the lower Slide (C2) is
actuated hydraulically by Slide (C1). As
Slides (C1 and C2) move downward,
26 17
they will first close Returns 51/52 via the
control edges, thus establishing a
connection between Accumulator Ports
11/12 and Ports 21/22 for the wheel
brake cylinders. The foot force applied
now determines the output braking
pressure. The Control Slides (C1 and
C2)) are held in the control position by
the force applied (spring assembly)
above the slides and the hydraulic
pressure below the slides (balance of
forces). After output of the braking
pressure, Slides (C1 and C2) are in a
partial braking position, causing Ports 11/
12 and 51/52 to close and holding the
pressure in Ports 21/22.
Full Braking Position
When Pedal (B) is fully actuated, an end
position of the brakes is reached and a
connection established between
Accumulator Ports 11/12 and Brake
Cylinder Ports 21/22. Returns 51/52 are
closed at this point.
When the braking process is ended, a
connection is once again established
between Brake Cylinder Ports 21/22 and
Return Ports 51/52, closing Accumulator
Ports 11/12.
The arrangement of slides in the valve
ensures that even if one braking circuit
fails the other remains fully operational.
This is achieved by means of the
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).
WABCO
 Brake Valve
for dual circuit braking system
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
3 467 406 Brake Valve
for dual circuit braking system

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

Installation dimensions:

showing: 467 406 227 0

Thread of pipe connections:

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
for dual circuit braking system
467 406
3
Installation dimensions:

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
 3 467 406 Brake Valve
for dual circuit braking system

Installation Requirements:
Return Lines 51/52 must be connected
directly to the tank.
The connecting lines must be installed in
such a way as to permit proper bleeding.
Maintenance of the Brake Valve
No special maintenance beyond the legal
requirements is necessary.
When using high-pressure cleaners on
the vehicle, please make sure that the
water jet is not aimed directly at the
Brake Valve (to prevent damaging the
bellows).
Replacing the Pedal Cover
Pedal Cover (1) is simply pulled off by
hand. The new pedal cover is pushed
over Pedal (B) and tightened manually.
Fasten the bellows with the strap
retainers.
Replacing the complete Actuating
Mechanism
Carefully clamp the unit vertically in a
fixture. The actuating mechanism can be
removed by taking out the four Screws
(H) below Base Plate (E). Make sure that
Spring Assembly (A) does not fall out.
When installing the new actuating
mechanism, make sure that Spring
Assembly (A) is fitted in the right order.
Tighten the four Screws (H).
Replacing the Bellows
To change Bellows (3) it is advisable to
remove Pedal (B). For this purpose,
loosen Retaining Ring (L) and knock out
Bolt (M) using a mandril. When knocking
out the bolt, make sure that the mandril is
applied to the side of the bolt without a
knurl. Remove Pedal (B) and Bellows (3).
Now fit the new Bellows (3) and proceed
in reverse order as described above. The
upper portion of Bellows (3) is fastened to
Piston (N), its lower portion to Base Plate
(E). Secure the bellows using clamps.
Replacing the Grooved Ring
Carefully clamp the unit vertically in a
fixture. Unscrew Screw Plug (P) and pull
Slides (C1 and C2) out downwards.
Check the slides for damage. If they are
found to be damaged, the whole Brake
Valve needs to be replaced. (Pairs of
slides and housings are matched in
manufacturing.) If the slides are not
damaged in any way, remove the whole
actuating mechanism as described
above. Remove Spring Assembly (A)
and Grooved Ring (4) and put in a new
greased grooved ring with its lips pointing
downwards. Install both the spring
assembly as shown in the drawing, and
the pedal. Put in Spring (R1), followed by
Slide (C2), using a slight turning motion if
possible. Insert Spring (R2) and close the
unit with Screw Plug (P). 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 Slide (C1). If this
is not the case, change the setting by
removing or adding Distance Washers
(5) in the upper spring plate. Check the
distance between the lower edge of the
hole at Port 51 and the control edge of
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
system, always make sure that
there is absolutely no pressure
in the system. Even when the
engine is switched off there will
be some residual pressure in the
system!
When doing repair work, make
sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
using plugs!

30 18
WABCO
 Hand Brake Valve
Purpose:
The purpose of the Hand Brake Valve is
to sensitively increase and decrease the
braking pressure when the hand brake
lever is actuated.
Operation:
Ready Position
When the braking system is ready for
operation, its accumulator pressure acts
directly on Port 1 of the Hand Brake
Valve. A connection is established
between Ports 1 and 21 so that the
vehicle's hand brake is released.
Secondary Braking System
When the Hand Brake Valve is actuated,
the hydraulic release pressure is
increased or decreased as a function of
the hand brake lever's pivoting angle.
Spring Assembly (A) below Cam Plate
(B) permits a sensitive braking process
for the vehicle.
When the secondary braking process is
(Locked position = pressure reduced)
commenced, Slide (C) is mechanically
actuated via Spring Assembly (A). s Slide
(C) moves upwards, it first closes
Accumulator Port 1 via the control edge
and then establishes a connection
Installation Requirements:
Return Line 5 must be connected directly
to the tank
The connecting lines must be installed in
such a way as to permit proper bleeding.
The Hand Brake Valve should be
installed in a position where it cannot be
accidentally actuated by the driver's foot.
Maintenance of the Brake Valve
No special maintenance beyond the legal
requirements is necessary.
When using high-pressure cleaners on
the vehicle, please make sure that the
water jet is not aimed directly at the Hand
Brake Valve (to prevent damaging the
bellows).
WABCO
467 410
3
between Brake Cylinder Port 2 and
Return 5. The pivoting angle of the hand
brake lever will now determine the
pressure in the spring brake actuator
(Port 2). Slide (C) is held in the control
position by the force (spring assembly)
above the slide and by the hydraulic
pressure below the slide (balance of
forces). Slide C is in a partial braking
position, causing Ports 1 and 5 to close
and to hold the pressure in Port 2.
In the range of partial brake application,
the hand lever will automatically return to
the driving position when the braking
process is ended.
Parking Brake
When the lever is fully actuated, an end
position of the brake is reached and a
connection is established between
Return 5 and Brake Cylinder Port 2.
Accumulator Port 1 is closed and the
lever is locked in position.
When the parking brake is released, a
connection between Brake Cylinder Port
2 and Accumulator Port 1 is once more
established, and Return Port 5 is closed.
Once released from its locked position,
the hand brake lever will automatically
return to the driving position.
Repair Work:
When working on the braking
system, always make sure that
there is absolutely no pressure
in the system. Even when the
engine is switched off there will
be some residual pressure in the
system!
When doing repair work, make
sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
using plugs!
Replacing the 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)..
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
467 410 012 0 125 bar pressure reducing
467 410 013 0 125 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 #)
467 410 018 0 60 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.

Installation dimensions:

showing: 467 410 012 0

Thread of pipe connections:

1,21, 5 = M16 x 1.5 - 10 deep
25 = M 12 x 1.5 - 10 deep

Port connections:
1 = Energy supply
21 = Energy delivery
24 = Pressure switch connection
5 = Return connection

32 20
WABCO
 Double Check Valve
Purpose:
The purpose of the Double Check Valve
is to permit alternate actuation of the
braking circuits. It permits a hydraulic
braking circuit to be actuated by two
actuating valves.
Operation:
When the control pressure is built up, the
control pressure is passed unrestrictedly
from Port 11 or 12, depending on the type
476 399
478 399 3
of actuation of the valve, to Port 2. A ball
seat valve arrangement ensures that as
the foot brake valve is actuated, Port 12
remains pressureless when the pressure
is increased at Port 11, and vice versa.
The ball seat also prevents the control
pressure being reduced through the part
of the line which is not being utilized.
Note:
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

Installation dimensions:

Thread of pipe connections:

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
such a way as to permit proper bleeding.
The Double Check Valve can be
mounted in any position.
Maintenance of the Double Check
Valve
No special maintenance beyond the legal
requirements is necessary.
Repair Work:
When working on the braking
system, always make sure that
there is absolutely no pressure
in the system. Even when the
engine is switched off there will
be some residual pressure in the
system!
When doing repair work, make
sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
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
control the pressure level in the
accumulators.
Operation:
Ready Position
When the braking system is ready for
operation (i.e. the accumulators are
charged) the pump stream is present at
Port 1 of the Shut-Off Valve. A
connection is established between Ports
1 and 5 so that the pump stream can,
with a small difference in pressures, be
returned directly to the reservoir or other
consumers. The rear of Main Slide (A) is
pressureless. The pressure within the
braking system will hold Control Slide
(B ) in its locked position (E1) in which the
rear of Main Slide (A) is directly
connected to Return 5 via Hole (G).
Check Valve (C) in the hole to Port 2
secures the accumulator pressures.
As the accumulator pressure falls to the
preset value, Control Slide (B) will,
through the force of Spring Assembly
(D), overcome its locked position (E1)
and move to another locked position
(E2). Via Orifice (F) and through
Connecting Hole (H), an oil stream flows
to the rear of Main Slide (A). The
pressure building up at the rear of Main
Slide (A) and the pressure present below
Main Slide (A) put Main Slide (A) in a
floating position, permitting a partial
stream to continue to reach Port 5 and
the remaining stream to flow to Port 2 via
Check Valve (C) until the pressure at Port
2 is approx. 150 bar. Control Slide (B) will
then once again move to Locked Position
(E1) in which a connection is established
between Ports 1 and 5 and the whole of
the pump stream once again flows to the
reservoir. Check Valve (C) once again
secures the accumulator pressures.

Technical Data:
Part Number 477 397 001 0 477 397 011 0 477 397 031 0
Operating pressure 200 bar max.
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

Installation dimensions:
showing: 477 397 001 0
Thread of pipe connections:
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
5 = Return connection
Installation Requirements:
WABCO
Shut-Off Valve
for Single Circuit Systems
The connecting lines must be installed in
such a way as to permit proper bleeding.
Maintenance of the Shut-Off Valve
No special maintenance beyond the legal
requirements is necessary.
For safety reasons the whole of the Shut-off Valve must be
replaced if damaged.
477 397
3
Repair Work:
When working on the braking
system, always make sure that
there is absolutely no pressure
in the system. Even when the
engine is switched off there will
be some residual pressure in the
system!
When doing repair work, make
sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
using plugs!
25 35
 3 477 397 Shut-Off Valve
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
connection is established between Ports
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
connection is established between Ports
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

Operating pressure 200 bar max.
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
Operating temperature range –40°C to +80°C
Weight 3.8 kg

36 26
WABCO

Installation dimensions:
showing: 477 397 015 0
Thread of pipe connections:
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
21,23 = Service brake
27 = Hydraulic accumulator
28 = Pressure switch
5 = Return connection
Installation Requirements:
WABCO
Shut-Off Valve
for Dual Circuit Systems
View X
The connecting lines must be installed in
such a way as to permit proper bleeding.
Maintenance of the Shut-Off Valve
No special maintenance beyond the legal
requirements is necessary.
For safety reasons the whole of the Shut-off Valve must be
replaced if damaged.
477 397
3
Repair Work:
When working on the braking
system, always make sure that
there is absolutely no pressure
in the system. Even when the
engine is switched off there will
be some residual pressure in the
system!
When doing repair work, make
sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
using plugs!
9 37
3 477 397 Shut-Off Valve
for Triple Circuit Systems
Purpose:
The purpose of the Shut-Off Valve is to
control the pressure level in the
accumulators.
Operation:
Ready Position
When the braking system is ready for
operation (i.e. the accumulators are
charged) the pump stream is present at
Port 1 of the Shut-Off Valve. A
connection is established between Ports
1 and 5 so that the pump stream is, with
a small difference in pressures, returned
directly to the reservoir. The rear of Main
Slide (A) is pressureless. The pressure
within the braking system will hold
Control Slide (B ) in its locked position
(E1) in which the rear of Main Slide (A) is
directly connected to Return 5 via Hole
(G). Check Valve (D) in the hole to Port
27 secures the accumulator pressure of
Variant 014 the operating accumulator. This is
available as an additional braking volume
for the braking system, preventing
excessively frequent actuation of the
Variant 007
38
Shut-Off Valve in the event of a leakage.
Shuttle Valves (H) additionally secure
each braking circuit against pressure
losses in the event of a broken pipe.
Charging Process
As the accumulator pressure falls to the
preset value, Control Slide (B) will,
through the force of Spring Assembly
(C), overcome its locked position (E1)
and move to another locked position
(E2). Via Orifice (F) an oil stream flows to
the rear of Main Slide (A). The pressure
building up at the rear of Main Slide (A)
and the pressure present below Main
Slide (A) put Main Slide (A) in a floating
position, permitting a partial stream to
continue to reach Port 5 and the
remaining stream to flow to Ports 21//22/
23 via Check Valve (D) until the pressure
within the braking system is approx. 150
bar. Control Slide (B) will then once again
move to Locked Position (E1) in which a
connection is established between Ports
1 and 5. The whole of the pump stream
once again flows to the reservoir via Port
5. Check Valve (D) again secures the
accumulator pressures.
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
Operating temperature range –30°C to +80°C
Weight 3.8 kg

Installation dimensions:

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
5 = Return connection

Installation Requirements: The connecting lines must be installed in Repair Work:

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

When doing repair work, make

sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
using plugs!

For safety reasons the whole of the Shut-off Valve must be

replaced if damaged.

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
Operating pressure 160 bar max.
Pressure limiting 180 +10 bar
Permissible Medium mineral oil: 1940 to 10 mm² /s
Operating temperature range –40°C to +80°C
Flow rate 0.7 to 16 l /min

40 28
WABCO

Installation dimensions:
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
5 = Return connection
Installation Requirements:
WABCO
Check Valve
The connecting lines must be installed in
such a way as to permit proper bleeding.
The Check Valve can be mounted in any
position.
Maintenance of the Check Valve
No special maintenance beyond the legal
requirements is necessary.
For safety reasons the whole of the Check Valve must
be replaced if damaged.
477 399
3
Repair Work:
When working on the braking
system, always make sure that
there is absolutely no pressure
in the system. Even when the
engine is switched off there will
be some residual pressure in the
system!
When doing repair work, make
sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
using plugs!
29 41
3 477 411 Relay Valve
Purpose:
The purpose of the Relay Valve is to
rapidly transfer large volumes to the
wheel brake. It offers the benefit of being
able to operate with a small actuating
volume.
Operation:
Ready Position
When the braking system is ready for
operation, the accumulator pressure is
present at Port 1 of the Relay Valve. A
connection is established between Ports
2 and 5 so that the wheel brake cylinders
of the vehicle are released.
Braking Position
When the foot brake valve is actuated, a
hydraulic braking pressure builds up at
Port 2 as a function of the input pressure
at Port 4.
Technical Data:
Part Number
Operating pressure
Control volume
Permissible Medium
Operating temperature range
Transmission ratio
42
When the braking process is
commenced, Slide (A) is actuated via
Control Port 4 and moves into the braking
position against the force of Spring (B).
The slide will first close Return Port 5 via
the control edge and then, via another
control edge, connect Accumulator Port
1 with Port 2. Via a hole, the oil stream
now flows from Port 1 to Port 2 through
Hollow Slide (A), moving it to its final
braking position. In this process, the
output braking pressure at Port 2 is equal
to the control pressure of the foot brake
valve at Port 4.
Release Position
As the control pressure at Port 4 is
reduced, Hollow Slide (A) returns to its
initial position. The connection between
Ports 1 and 2 is closed once again by the
control edges. The second control edge
will then open the connection between
Port 1 and Return Port 5.
477 411 000 0
165 bar max.
0.58 cm³
mineral oil: 2000 to 10 mm² /s
–40°C to +80°C
1:1
WABCO
 Relay Valve
Installation dimension:
Installation Requirements: The return line must be connected
directly to the tank.
The connecting lines must be installed in
such a way as to permit proper bleeding.
The Relay Valve should be mounted in
the vicinity of the wheel brake.
Maintenance of the Relay Valve
No special maintenance beyond the legal
requirements is necessary.
For safety reasons the whole of the Relay Valve must be
replaced if damaged.
WABCO
477 411
3
Repair Work:
When working on the braking
system, always make sure that
there is absolutely no pressure
in the system. Even when the
engine is switched off there will
be some residual pressure in the
system!
When doing repair work, make
sure your environment is very
clean.
Immediately close all open ports
on the components and on pipes
using plugs!
30 43
 4

General Comments

WABCO 10 45
 Information for Installation
General Comments a) All pipes in the braking system must
have a nominal width of at least 10
mm.
b) The pipes should be installed in such
a way as to permit proper bleeding,
i.e. so that no air cushions can de-
velop. If you detect noises when com-
mencing the braking process, this is
an indication of poor bleeding.
c) When fitting the pipes, make sure that
there are no areas of friction.
d) The return lines of the individual com-
ponents of the braking system must
not be combined in one return line to
the tank.
e) Do not use a pipe for the return lines
of the dual circuit brake valve to com-
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
4
f) Look for visible leaks in lines and
pipes. Leaks are an indication that
the system is not properly sealed.
Check the level of the brake fluid.
Stop leakage.
g) When using high-pressure cleaners,
do not aim the nozzle directly at the
bellows. (This may cause damage to
the bellows.)
h) When working on the braking system,
always make the sure that the system
is completely pressureless!
i) Make sure that everything is spotles-
sly clean!
j) Immediately close all open ports on
the components and on pipes using
plug.
11 47
4 Information for Installation
Information for Installation It is particularly important that the com-
ponents all have their separate return li-
nes since otherwise the return pressure
can be present in the wheel brake in the
form of residual pressure. This leads to
unnecessary wear of the brake linings
and excessive temperatures at the wheel
brake and can thus result in hardening of
the linings, and in a failure of the seals on
the wheel brake cylinders.
When combining the returns of the dual
circuit foot brake valve, please make
sure that hoses are used for connecting
the return ports. Using a pipe to connect
the two circuits can cause functional de-
fects through distortions in installation.
For very long vehicles with large cylinder
volumes, the installation of relay valves
can be very helpful, reducing response
and pressure build-up times to a mini-
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-
tors must be designed according to the
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
ke valve only actuates the relay valves.
The input volume of the relay valves is
approx. 1 cm³.
If shut-off valves with an integrated check
valve are used, an additional accumula-
tor of 0.7 litres needs to be screwed into
the component. That additional accumu-
lator is primarily used to monitor the actu-
al pressure of the other three
accumulators and to report them to the
shut-off valve. The accumulators can be
emptied when the brakes are operated,
without being re-charged since all circuits
are secured from each other by the check
valves. The additional accumulator will
also prevent activation of the shut-off val-
ve as a consequence of small leakages
and thus a fall in pressure in the connec-
tion established between the check val-
ves even though the pressure in the
accumulators of the braking circuit is still
higher than 120 bar.
For this purpose we require the following
information from you:
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