Wbco Full Hydraulic Power Brake

FPB – FULL
HYDRAULIC POWER BRAKE

FPB
Full Hydraulic Power Brake
Edition 5
This publication is not subject to an updating service.

You will find the current version at
http://www.wabco.info/8150100443
© 2013 WABCO Europe BVBA - All rights reserved
Subject to change without notice

Version 2/09.2013(en)
8150200443 815 010 044 3
Contents
Disclaimer ...........................................................................................................4
More Information................................................................................................4
1 Introduction ........................................................................................................5
2 System proposal ................................................................................................6

841 300 329 0 single-circuit...................................................................6
841 300 314 0 dual-circuit .....................................................................7
841 300 331 0 dual-circuit with secondary braking system ...................8
841 300 332 0 dual-circuit with relay valves..........................................9
841 300 276 0 Compact valve with brake valve and
pump control valve ......................................................10
3 Device description ...........................................................................................11

427 001 Spring brake actuator ..................................................................12
441 014 Pressure switch ...........................................................................16
458 501 Hydraulic accumulator.................................................................18
467 406 Brake valve..................................................................................20
467 410 Park brake valve..........................................................................31
467 415 Compact valve.............................................................................33
477 397 Cutoff valve .................................................................................34
477 399 Check valve.................................................................................40
477 411 Relay valve..................................................................................42
4 Annex ................................................................................................................45
General notes ....................................................................................................45
Installation instructions.......................................................................................46
Capacity of accumulators...................................................................................46
Application Data Sheet for Full Hydraulic Power Brake Systems ......................47
Legal requirements for Europe –

Directive 98/12/EC – Section C – Annex IV (excerpt)........................................48
Further references .............................................................................................50
Testing the WABCO Full Hydraulic Power Brake (FPB) ....................................51
1 3
Disclaimer
Disclaimer We assume no liability for the Text and graphics are subject to our right
correctness, completeness or up-to- of use, copying or distribution in any form
dateness of the information in this requires our approval.
document. All technical information,
descriptions and images apply for the Any brand markings, even if not indicated
date printing this document or respective as such, are subject to the rules of the
supplements. We retain the right to any labelling rights. If legal disputes arise
changes as a result of continuous further from the utilisation of the information in
development. this document, these are exclusively to
be handled under the regulations of
national law.
The content of this document provides no
guarantees nor warranted characteristics In so far as components or individual
nor can it be construed as such. Liability formulations of this applicable legal
for damage is strictly excluded unless it is status documentation are no longer or
based upon intent or gross negligence on not fully relevant, the remaining parts of
our part or unless this contradicts other the documentation remain unaffected
mandatory statuary regulations. thereby in their content and validity.
Further information Technical documents can be found on You will find available repair kits and
the Internet by entering an index word in spare parts on the Internet by entering
the WABCO Online Product Catalogue the device product number in the
INFORM: WABCO Online Product Catalogue
http://www.wabco-auto.com INFORM:
=> INFORM => Index http://www.wabco-auto.com
=> INFORM
=> Product number
=> Repair
4
Introduction
1
FPB – Full Hydraulic Power At present, the majority of special The legal requirements for the FPB with
Braking System vehicles, construction machines of up to regard to the size of its energy
approx. 10 t dead weight are equipped accumulators, output of its energy source
with a hydraulic manual braking system. and the properties of the warning system
Vehicles with a greater dead weight are defined in the EC directive 98 / 12 /
usually have Full Hydraulic Power EC, Annex IV in Section C (see
Braking Systems. paperback "Legal Requirements" 2004
edition" or chapter "Legal requirements
For wet inboard disc brakes, the WABCO in Europe" in this document).
Full Hydraulic Power Braking System is a
good choice because it explicitly takes
The FPB system is not really suitable for
into account the requirements of
construction machines. operating a trailer braking system. This
requires the installation of a system for
supplying compressed air with a
The components of the Full Hydraulic
hydraulically operated Trailer Control
Power Braking System are suitable for
Valve (470 015 ... 0). The hand brake
fluids on the basis of mineral oils and
facility for the trailer may then be
some bio-fluids which means that the
operated via a hydro pressure switch, a
fluids present in the construction
vehicle's hydraulic system can be used solenoid valve and a relay valve
as the energy transmitter for the braking (pneumatic).
system.
In order to take into account the trend
All devices have been designed to towards dual circuit service braking
account for the higher viscosity of such systems, we recommend that > 25 km/
fluids as compared to the brake fluid. h.vehicles be fitted with a dual circuit FPB
system.
The components are particularly robust A single circuit system would already
to ensure that they are capable of satisfy the German road traffic
withstanding the severe strain of regulations for construction machines
everyday operation. however.
CAUTION
If the brake volume is greater Always check the response and

than 75 cm³, at least the first threshold times. It may be
(top) circuit of the foot operated necessary to equip both circuits
brake valve must be equipped of the service brake system with
with a relay valve. relay valves.
5
2 System proposal
Single circuit
841 300 329 0
all pipes of brake line NW 10
Port designations
0 Suction port
1 Energy supply
2 Energy delivery
5 Return connection
Item Quantity Designation Order number Item Quantity Designation Order number
1 1 Pump 11 1 Pressure switch 441 014 049 0
2 1 Pressure filter 12 1 Pressure switch 441 014 055 0
3 1 Cutoff valve 477 397 ... 0 13
4 Pressure test
14 2 connection
5
15
6 1 Brake valve 467 406 1.. 0
16
7
17  Accumulator 458 501 ... 0
8 1 Reservoir
18
9  Wheel brake cylinder
19
10
20
6
841 300 314 0 System proposal
Dual circuit 2
Port designations
0 Suction port 24, 25 Hydraulic accumulator for foot-operated brake valve:
1 Energy supply 26, 27 Hydraulic accumulator 24 Test connection (pressure switch)
11 Energy supply Circuit 1 28 Pressure switch 25 Test connection (pressure switch)
12 Energy supply Circuit 2
2 Energy delivery 4 Control port
21 Energy delivery Circuit 1 5 Return connection
22 Energy delivery Circuit 2 51 Return connection Circuit 1
3 1 Cutoff valve 477 397 015 0 13
4 1 Brake valve 467 406 ... 0 Pressure test
14 3 connection
5
15
6
16
7
17  Accumulator 458 501 ... 0
8 1 Reservoir
18  Accumulator 458 501 ... 0
19
10
20
7
2 System proposal
Dual circuit with auxiliary braking system
841 300 331 0
Port designations
0 Suction port 24, 25 Hydraulic accumulator for foot-operated brake valve
3 1 Cutoff valve 477 397 . . . 0 13 1 Pressure switch 441 014 044 0
4 1 Brake valve 467 406 . . . 0 Pressure test
14 4 connection
5 1 Park 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 Reservoir
18  Accumulator 458 501 . . . 0
10 1 Spring brake actuator 427 001 . . . 0
8
841 300 332 0 System proposal
Dual circuit with relay valves 2
Port designations
0 Suction port 24, 25 Hydraulic accumulator for foot-operated brake valve
3 1 Cutoff valve 477 397 ... 0 13 1 Pressure switch 441 014 044 0
4 1 Brake valve 467 406 ... 0 Pressure test
14 4 connection
5 1 Park 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 Reservoir
18  Accumulator 458 501 ... 0
19 1 Accumulator 458 501 071 0
10 1 Spring brake actuator 427 001 ... 0
20 1 Accumulator 458 501 071 0
9
2 System proposal
Compact valve with brake valve and pump control valve
841 300 276 0
Other consumers
Other load signalling lines
Port designations
1 Energy supply 5 Return port
2 Energy delivery 6.1 Service brake (circuit 1)
2.1 Hydraulic accumulator (circuit 1) 6.2 Service brake (circuit 2)
2.2 Hydraulic accumulator (circuit 2) 6.3 Pressure switch (circuit 1)
2.3 Brake circuit 3 (park brake) 6.4 Pressure switch (circuit 2)
2.4 Pressure switch
1 1 Pump 7 1 Spring brake actuator 427 001 ... 0
2 1 Filter 8 1 Pressure switch 441 014 049 0
3 1 Compact valve 467 415 100 0 9 2 Pressure switch 441 014 048 0
4 3 Accumulator 458 501 ... 0 10 1 Pressure switch 441 014 ... 0
5 1 Check valve 11 1 Shuttle valve
6 1 Park brake valve 467 410 ... 0 12 1 Priority valve
10
Device description
3
Device description
11
3 427 001 Spring brake actuator
Purpose Quick release function
The spring brake actuator has the task to Some variants are available with a quick-
generate the braking force for the wheel release function.
brake in secondary and parking brake
systems. This permits, in the event of the pressure
in the hydraulic part (A) failing, the wheel
brake to be released by applying a blow
Operation
of the hammer in the direction of the
Standby position arrow (F) thus cancelling the friction-
When driving, the output pressure from locked connection established between
the hand brake valve acts directly on port compression spring (B) and piston rod
1 of the spring brake actuator. The (C) and actuating the quick-release
secondary or parking brake is released. facility (D).
Braking position As the pressure in the hydraulic part (A)

When the park brake valve is actuated, builds up again, the connection between
the hydraulic pressure is reduced in compression spring (B) and piston rod
accordance with the angular position of (C) is established once more and the
the park brake lever. spring brake actuator is fully operational
with quick release function again.
As the pressure in the hydraulic part (A)
of the spring brake actuator is reduced, Emergency release function
the force of the decompressing In the case of spring brake actuators
compression spring (B) retracts the without a quick-release function, the
piston rod (C) in the direction of the parking brake can still be released
actuator's axis, thus actuating the wheel should the hydraulic pressure fail. To do
without quick release function brake. The spring brake actuator's so, the hexagon nut (6) on piston rod (K)
maximum braking force is reached when is removed from the yoke end (C1). An
the pressure drops to zero. open-jawed spanner (jaw size 13) is
positioned on the wrench flat (L) of the
piston rod (K). The piston rod (K) is then
turned in such a way that the yoke end
(C1) is shifted towards the brake lever.
12
Spring brake actuator 427 001
3
Technical data
Order number 427 001 002 0 427 001 005 0 427 001 006 0 427 001 007 0 427 001 008 0
Operating pressure max. 150 bar
Stroke 80 ±3 mm
Release pressure 87 ± 4 bar 60 -4 bar 40 ± 4bar 95 +6 bar 60 -4 bar
Thermal range of application -30C to +80C
Medium Mineral oil 10 to 2000 mm2 /s
Output force at 0 mm stroke 2745 N 2270 N 1505 N 3000 N 2270 N
Output force at 80 mm stroke 4320 N 3250 N 2205 N 5000 N 3250 N
Piston rod pivoting range 3° on all sides
Emergency release function No No No Yes Yes
Yoke end No Yes Yes Yes Yes
Bellows Yes Yes Yes Yes Yes
Weight 6.5 kg 6.8 kg 8.0 kg
Repair work those included in the repair

kit are damaged.
CAUTION
WARNING
For safety reasons replace The enclosed section of the
the complete spring brake actuator is spring-loaded.
actuator if other parts than
Replacing the bellows actuators without a quick-release

function, immobilise the piston rod (K) by
Remove clamps (2; 3 or H) from the
applying a spanner (jaw size 13).
bellows. Replace them if necessary
when fitting the new bellows. Pull off the Remove hexagon nut (6) and unscrew
defective bellows (1). Push on new the yoke end (5) from the piston rod. The
bellows and fasten with the new yoke end is screwed into the piston
corresponding clamps (2; 3 or H). rod until the original piston rod length is
reached again (see outline drawing:
distance from centre yoke hole to end
Replacing the yoke end face of port 1). Secure piston rod again
When replacing the yoke end (5) on by means of the hexagon nut.
13
3 427 001 Spring brake actuator
Installation dimensions
427 001 007 0 Quick release function:

Actuation by impact of a blow on the
flange
Thread of pipe connections:

M16 x1.5 - 16 deep
427 001 002 0
427 001 005 0
14
Spring brake actuator 427 001
3
Installation instructions Repair work
CAUTION
The connecting lines must be installed in
such a way as to permit problem-free
bleeding. The actuator should be When working on the braking
mounted at a slight angle, its piston rod system, always make the sure
pointing downwards. that there is absolutely no
pressure in the system.
Even when the engine is
Maintenance switched off there will be some
residual pressure in the system.
Special maintenance that extends
beyond the legally specified inspections When carrying out repair work,
is not required. When using high- make sure your environment is
pressure cleaners on the vehicle, please absolutely clean.
make sure that the water jet is not aimed Immediately close all open ports
directly at the spring brake actuator on the components and pipes
(damage to the bellows). using appropriate plugs.
15
3 441 014 Pressure switch
Purpose The system pressure acts on an effective

area within the switch, breaking an
The pressure switches are used to electrical contact as the pressure on that
visually or audibly warn the driver of the area is increased. The current flow is now
pressure within the system. interrupted, e.g. to deactivate a warning
device.
Operation
Make contact / Circuit Closer Installation instructions
The pressure switch can be fitted in the
brake line or directly on a braking device. No special measures need to be taken.
The system pressure acts on an effective
area within the switch,making an
Maintenance
electrical contact as the pressure on that
area is increased. The resulting current is Special maintenance that extends
used to activatea warning device for beyond the legally specified inspections
example. is not required. When using high-
pressure cleaners on the vehicle, please
Break contact / Circuit breaker make sure that the water jet is not
The pressure switch can be fitted in the directed at the pressure switch (corrosion
NC contact NO contact brake line or directly on a braking device. of the contacts).
Technical data
Switching
H1 H2 Setting range Voltage
Order number Medium G pressure
(mm) (mm) in bar in V
in bar
NC contact
441 014 043 0 Mineral oil M12x1.5 55 9 20 - 50 21 ±2 42
441 014 044 0 Mineral oil M12x1.5 55 9 10 - 20 17 ±1 42
441 014 049 0 Mineral oil M12x1.5 55 9 50 - 150 100 ±10 42
441 014 051 0 Mineral oil M12x1.5 55 9 20 - 50 37 ±2 42
M10x1
441 014 057 0 Mineral oil 55 9 10 - 20 10 -20 42
tapered
441 014 059 0 Mineral oil M12x1.5 55 9 1 - 10 3 ±0,5 42
441 014 064 0 Mineral oil M 12x1.5 55 9 fixed 9 ±0,5 42
NO contact
441 014 052 0 Mineral oil M12x1.5 55 9 20 - 50 37 ±2 42
441 014 055 0 Mineral oil M12x1.5 55 9 1 - 10 1 -10 42
441 014 060 0 Mineral oil M 12x1.5 55 9 fixed 21 ±2 42
441 014 070 0 Mineral oil M12x1.5 55 9 50 - 150 54 ±0,5 42
M 10x1
441 014 071 0 Mineral oil 55 9 1 - 10 ±0,5 adjustable 42
tapered
Breaking capacity of all pressure switches 100 VA ohmic load protective cap for pressure switch:
Order number 897 750 342 4
16
Pressure switch 441 014
3
Repair work
When carrying out repair work,
CAUTION make sure your environment is
absolutely clean.
When working on the braking Immediately close all open
system, always make the sure ports on the components and
that there is absolutely no pipes using appropriate plugs.
pressure in the system. Even
when the engine is switched off For safety reasons replace the
there will be some residual complete pressure switch if
pressure in the system. damaged.
Adjusting and testing the

pressure switch
Adjusting screw
The adjusting screw located between the After making the adjustment, the
two contact plugs can be adjusted to the a adjusting screw should be secured using
customer-specific pressure within a locking wax (or a similar locking material).
certain range. The setting range is
defined in the "Technical Data" table.
17
3 458 501 Hydraulic accumulator
Purpose Operation
Fluids are practically incompressible and
The accumulator consists of a liquid part
are thus incapable of accumulating
pressure energy. In hydropneumatic (A) and a gas part (B) with a diaphragm
accumulators, the compressibility of a (C) as a gas-tight dividing element. The
gas is utilised to accumulate fluid. The liquid part (A) is connected to the
compressible medium used in the hydraulic circuit, causing the diaphragm
accumulators is nitrogen. accumulator to be filled and the gas
volume to be compressed as the
In braking systems, the purpose of the pressure rises. When the pressure falls,
accumulators is to store the energy the compressed gas volume will expand,
supplied by the hydraulic pump. They are thus displacing the accumulated
also used as an energy reserve when the pressure fluid into the circuit.
pump is not working to compensate for
any losses through leakage and for
vibration damping. 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.
Technical data
Order number 458 501 071 0 458 501 101 0 458 501 072 0
Diameter 121 mm 136 mm 174 mm
Installation height 146 mm 160 mm 307 mm
Nominal volume 0.75 l 1.0 l 3.5 l
Priming pressure 50 bar 40 bar
Working medium Mineral oil
Operating pressure max. 180 bar max. 200 bar max. 250 bar
Thread External M 18x1.5 External M 22x1.5 Internal G3/4 ISO 228
Installation position Optional
Priming gas Nitrogen
18
Hydraulic accumulator 458 501
3
Installation instructions The accumulators can be fitted in the tension has fallen by more than 30%
hydraulic circuit, directly on the (see: Functional test and checking the
component or in blocks on suitable accumulator).
consoles.
They should be fitted in the coolest
possible place. Disposal of the accumulator
Any installation position can be chosen.
Before the accumulator is scrapped, its
gas filling pressure must be released. For
Maintenance of the device this purpose, drill a hole through the gas
Special maintenance that extends chamber (B) using a drill approx. 3 mm in
beyond the legally specified inspections diameter. The gas chamber is located on
is not required. the side opposite the threaded port
above the welding seam around the
The accumulators should therefore be centre of the accumulator.
checked once every year. Wear safety goggles when carrying
It should be replaced if the initial gas out this work.
Functional test and checking The accumulator is gradually accumulator can only be determined
the accumulator pressurised via the test pump; until the using the testing method described
initial gas pressure is reached, the above. In this case the accumulators
hydraulic pressure in the accumulator must therefore be checked individually.
will rise abruptly. This is can be read off The accumulator whose initial gas
gauge "M". If the initial gas pressure is pressure is insufficient must be replaced
more than 30% below the prescribed and scrapped following the instructions
value, the accumulator needs to be under "Disposal of the Accumulator".
replaced. If the measuring process
needs to be repeated, wait for intervals Repair work
of 3 minutes between the individual
tests. CAUTION
An accumulator with insufficient gas
initial tension must be scrapped following When working on the braking
the instructions under "Disposal of the system, always make the sure
accumulator". that there is absolutely no
when the engine is switched off
The initial gas pressure level can also be there will be some residual
checked directly in the vehicle. pressure in the system.
Start the vehicle's engine. The pump will
now supply oil to the accumulators. When carrying out repair work,
Until the initial gas pressure is reached, make sure your environment is
A = ball valve for shutting off pump flow the hydraulic pressure in the absolutely clean.
B = ball valve for reducing pressure accumulator will rise abruptly. This can Immediately close all open ports
be read off the gauge in the vehicle. If the on the components and on
S = safety valve, adjusted to max. 180 initial gas pressure is more than 30% pipes using plugs.
bar below the prescribed value, that initial
M = pressure gauge pressure lies outside the permissible For safety reasons replace the
range for at least one of the complete accumulator if it is
H = hydraulic accumulator accumulators fitted in the vehicle. This damaged.
19
3 467 406 Brake valve
for single circuit braking system
Purpose return 5 via the control edge, thus

establishing a connection between
The brake valve has the purpose of accumulator port 1 and the wheel brake
sensitively increasing and decreasing the cylinder port 21. The foot force applied
braking pressure when the treadle (or the now determines the braking pressure to
actuating lever) is operated. be applied. The control slide (C) is held in
the control position by the force applied
Operation (spring assembly) and the hydraulic
pressure below the slide (balance of
Standby position forces). After output of the braking
When the braking system is ready for pressure, the slide (C) is in a partial
operation, the accumulator pressure acts braking position, causing ports 1 and 51
directly on port 1 of the brake valve. A to close and maintaining the pressure in
connection is established between port port 21.
21 and 51 so that the wheel brake (port
21) is switched pressureless via the Full braking position
return (port 51). When the pedal (B) is fully actuated, an
end position of the brakes is reached and
Partial braking a connection established between
When the brake valve is actuated, a accumulator port 1 and brake cylinder
hydraulic braking pressure in proportion port 21. Return 51 is closed at this point.
to the applied foot force is output.
When the braking process is terminated,
The spring assembly (A) beneath the a connection is once again established
support (E) is designed in such a way between brake cylinder port 21 and
that the braking pressure changes return port 51, closing accumulator port
467 406 1.. 0 relative to the angle. In the lower braking 1.
pressure range the vehicle can be
decelerated sensitively in stages. Limiting the braking pressure
The pedal stop screw (D) on the support
When the braking process is initiated, the (E) below the treadle (B) is used to limit
slide (C) is mechanically actuated via the the braking pressure. In this function only
spring assembly (A). As the slide (C) partial accumulator pressure is built up in
moves downward, it will first close the the brake.
467 406 108 0
Control edge
20
Brake valve
467 406
3
Technical data
Slide Ø Pedal angle Pedal force Pedal via Operating Pressure

Order number Remark
[mm] [degrees] approx. [N] port pressure [bar] limitation [bar]
467 406 100 0 14 45 380 21 150
467 406 101 0 14 45 290 21 150 100
467 406 102 0 14 45 240 21 150 80
467 406 103 0 14 45 300 51 150 100
467 406 105 0 20 40 260 21 150 40
467 406 107 0 20 45 360 21 150 65
467 406 108 0 14 820 150 Lever actuation
467 406 111 0 14 45 240 21 150 80
467 406 112 0 20 40 370 24 150 65
467 406 117 0 14 45 290 21 150 100
With triangular
467 406 121 0 14 50 290 51 150 100
support
467 406 124 0 20 40 350 2 150 60+8
467 406 125 0 14 2400 150 plunger actuation
467 406 126 0 20 45 300 51 150 46+8
467 406 127 0 20 45 410 51 150 67+8
467 406 128 0 14 45 300 150 100+10 Pedal plate catch
Operating temperature range for all variants -30C to +80C
M 14x1.5 - 12 deep
Port designations:
1 = Energy supply
21 = Energy delivery
51 = Return connection
467 406 128 0
467 406 108 0
21
shown: 467 406 102 0
Variant 1, 21 and 51 24
100 M 14x1.5 -12
M 12x1.5
deep
101, 102, 108, M 14x1.5 -12
–
128 deep
124 M 16x1.5 -12
M 12x1.5
deep
121 M 16x1.5 -12
M 10x1
deep
Port designations:
1 = Energy supply
24 = Test port
Installation instructions The return line 51 must be connected hand. The new pedal cover is pushed
directly to the tank. The connecting lines over the treadle (B) and clamped
must be installed in such a way as to manually. Fasten the bellows with the
permit problem-free bleeding. strap retainers.
Maintenance of the device

Replacing the complete actuating
mechanism
beyond the legally specified inspections
is not required. Carefully clamp the unit vertically in a
fixture. The actuating mechanism can be
When using high-pressure cleaners on removed by taking out the four screws
the vehicle, please make sure that the (H) below the support (2). Make sure that
water jet is not aimed directly at the foot the spring assembly (A) does not fall out.
brake valve (damage to the bellows). When installing the new actuating
mechanism, make sure that the 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).
22 1
Brake valve
467 406
3
Replacing the bellows during production). If the slide is not
To change the bellows (3) it is advisable damaged in any way, remove the whole
to remove the treadle (B). For this actuating mechanism as described
purpose, loosen the retaining ring (L) and above. Remove the spring assembly (A)
knock out the bolt (M) using a mandril. and lip seal (4) and put in a new
When knocking out the bolt, make sure pregreased lip seal with its lips pointing
that the mandril is applied to the side of downwards. Install both the spring
the bolt without knurls. Remove treadle assembly as shown in the drawing, and
(B) and bellows (3). Now fit the new the complete treadle. Carefully re-insert
bellows and proceed as described above Slide (C) into the housing from below,
in reverse order. The upper section of the turning it slightly. Insert the spring (R)
bellows (3) is fastened to the piston (N), and close the unit again using screw plug
its lower section to the support. (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
Replacing the lip seal slide (C). If this is not the case, change
Carefully clamp the unit vertically in a the setting by removing or adding
fixture. Unscrew the screw plug (P) and distance washers (5) in the upper spring
pull slide (C) out downwards. Check the seat of the spring assembly. Check the
slide for damage. If damage is identified, distance between the lower edge of the
replace the complete foot brake valve hole of port 51 and the control edge of the
(slide and housing are matched as pairs slide (C) again.
Spare parts Designation Position (see figure) Order number

Bellows 3 897 754 865 4
Repair work When carrying out repair work,

make sure your environment is
CAUTION absolutely clean. Immediately
close all open ports on the
When working on the braking components and on pipes
system, always make the sure using plugs.
that there is absolutely no
pressure in the system. Even For safety reasons, replace the
when the engine is switched off complete brake valve if other
there will be some residual parts are damaged.
23
for dual circuit braking systems
Purpose the accumulator ports 1.1/1.2 and ports

2.1/2.2 of the wheel brake cylinders. The
The brake valve has the purpose of
foot force applied now determines the
sensitively increasing and decreasing the
braking pressure output. The control
braking pressure when the treadle (or the
slides (C1 and C2) are held in the control
actuating lever) is operated.
position by the applied foot force (spring
assembly) above the slides and the
Operation hydraulic pressure below the slides
Standby position (balance of forces). Once the initiated
When the braking system is ready for braking pressure is applied, slides (C1
operation, the accumulator pressure acts and C2) are in a partial braking position,
directly on port 1.1/1.2 of the foot brake causing ports 1.1/1.2 and 5.1/5.2 to
valve. A connection is established close, maintaining the pressure in ports
between Ports 2.1/2.2 and Ports 5.1/5.2 2.1/2.2.
so that the wheel brakes (Ports 2..) are
pressureless via the returns (Ports 5..). Full braking position
When pedal (B) is fully actuated, an end
Partial braking position of the brakes is reached and a
When the brake valve is actuated, a connection established between the
hydraulic braking pressure in proportion accumulator ports 1.1/1.2 and brake
to the applied foot force is output. The cylinder ports 2.1/2.2. Returns 5.1/5.2
spring assembly (A) beneath the support are closed at this point.
(E) is designed in such a way that the
braking pressure changes relative to the When the braking process ends, a
angle. In the lower braking pressure connection is once again established
range the vehicle can be decelerated between brake cylinder ports 2.1/2.2 and
sensitively in stages. return ports 5.1/5.2, closing accumulator
ports 1.1/1.2.
When the braking process is initiated, the
upper slide (C1) is mechanically actuated The arrangement of slides in the valve
via the spring assembly (A), and the ensures that even if one braking circuit
lower slide (C2) is actuated hydraulically fails the other remains fully operational.
by slide (C1). As slides (C1 and C2) This is achieved by means of the
move downward they will first close the mechanical actuation of both slides and
returns 5.1/5.2 via the control edges, requires slightly more pedal travel.
thus establishing a connection between
Limiting the braking pressure
The pedal stop screw (D) on the support
(E) below the treadle (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. The
spring assembly (A) will mechanically
actuate the slide (C1). In the event of the
upper circuit failing, the lower circuit will
remain operational. In this case the lower
Slide (C2) is mechanically actuated by
the spring assembly (A) and the slide
(C1).
Control edge
The return lines 5.1/5.2 must be

connected directly to the tank.
bleeding.
24
Brake valve
467 406
3
Technical data
Pedal
Pedal Operating
Order Slide Ø force Pedal via Pressure
angle pressure Remark
number [mm] approx. port limitation [bar]
[degrees] [bar]
[N]
467 406 202 0 20 40 330 21 150 63
467 406 208 0 14 800 150 110 Lever actuation
467 406 216 0 14 40 300 21 150 110
467 406 218 0 14 40 390 21 150 110
467 406 219 0 14 40 190 51 150 60
467 406 220 0 14 40 230 21 150 72
467 406 221 0 14 35 340 5 150 100+/-5 1 return, triangular support
467 406 227 0 14 25 370 51 150
467 406 233 0 14 25 480 51 150
467 406 234 0 14 35 480 51 150
467 406 235 0 14 2880 150 without pedal
467 406 241 0 14 33 310 51 150 105 Pedal plate catch
467 406 242 0 14 45 220 5 150 70+10 Pedal plate catch
467 406 243 0 14 45 390 5 150 120+10 1 return, metall locking device
Pedal plate catch
467 406 244 0 14 40 220 5 150 50...90
Replacement for 4674062110
467 406 246 0 14 2880 150 Plunger, Lancia Valve
467 406 248 0 14 40 390 21 150 110+10
467 406 301 0 20 45 280 51 150 55
467 406 305 0 20 5200 150 without pedal
467 406 307 0 20 50 220 24 150 40 triangular support
467 406 401 0 16 45 300 51 150 70
467 406 403 0 16 45 250 21 150 63
467 406 406 0 16 45 180 21 150 40 1 return; triangular support
467 406 408 0 16 45 250 21 150 63 1 return; triangular support
467 406 411 0 16 45 350 5 150 85 1 return; pedal plate catch
wie 467 406 411 0 without lok-
467 406 412 0 16 45 300 51 150 70+8
king device
467 406 413 0 16 35 300 5 150 60+8 1 return; triangular support
triangular support and hydraulic
467 406 414 0 16 50 180 11 150 50
support
467 406 415 0 16 35 230 5 150 40+8 1 return; triangular support
Operating temperature range for all variants -30C bis +80C
Spare parts Position

Designation (Fig. on Order number for device variant
page 24)
897 752 670 4 208
Bellows 3 897 754 860 4
897 754 865 4
Repair kits Repair kit for device variant

461 318 920 2 309, 411
216, 219, 220, 227, 234, 248, 307, 401, 403,406, 408,
461 318 924 2
412, 414
467 406 000 2 233, 235
467 406 005 2 216
467 406 007 2 220
25
shown: 467 406 202 0
Port designations:
1.1, 1.2 = Hydraulic accumulator
2.1, 2.2 = Service brake
2.4, 2.5 = Test connection
5.1, 5.2 = Return connection
Variant 1.1, 1.2, 2.1, 2.2,

2.4, 2.5
5.1, 5.2
208, 216, 218, Base plate installation opening
M 16x1.5 -12 M 10x1
220, 233, 234,
deep - 8 deep
235, 510
411, 413 M 16x1.5 -12 M 12x1.5
deep - 8 deep
202, 301, 401, M 16x1.5 -12 M 12x1.5
408, 414 deep - 10 deep
shown: 467 406 208 0
26
Brake valve
for dual circuit braking system
467 406
3
shown: 467 406 227 0
Port designations:
1.1, 1.2 = Hydraulic accumulator
2.1, 2.2 = Service brake
2.4, 2.5 = Test connection
5.1, 5.2 = Return connection
shown: 467 406 246 0
27
Installation instructions Maintenance of the device bellows (3) and proceed as described
Special maintenance that extends above in reverse order. The upper
beyond the legally specified inspections section of the bellows (3) is fastened to
is not required. piston (N), its lower portion to the support
When using high-pressure cleaners on (E). Secure the bellows using clamps.
the vehicle, please make sure that the
water jet is not aimed directly at the foot Replacing the lip seal
brake valve (damage to the bellows).
Carefully clamp the unit vertically in a
Replacing the pedal cover fixture. Unscrew screw plug (P) and pull
Pedal cover (1) is simply pulled off by the slides (C1 and C2) out downwards.
hand. The new pedal cover (1) is pushed Check the slides for damage. If damage
over the treadle (B) and tightened is identified, replace the complete foot
manually. Fasten the bellows with the brake valve (slide and housing are
strap retainers. matched as pairs during production). If
the slides are not damaged in any way,
remove the whole actuating mechanism
Replacing the complete
as described above. Remove the spring
actuating mechanism assembly (A) and lip seal (4) and put in a
Carefully clamp the unit vertically in a new pregreased lip seal with its lips
fixture. The actuating mechanism can be pointing downwards. Re-insert the spring
removed by unscrewing the four screws assembly as shown in the exploded view
(H) below the support (E). Make sure that and install the complete treadle. Carefully
the spring assembly (A) does not fall out. re-insert the slide (C1) into the housing
When installing the new actuating from below, turning it slightly. Insert the
mechanism, make sure that the spring spring (R1), followed by the slide (C2),
assembly (A) is fitted in the right order. using a slight turning motion if possible.
Tighten the four screws (H). Insert the spring (R2) and close the unit
with the screw plug (P). Check return port
Replacing the bellows 5.1 to see if there is a gap of approx. 2
To change the bellows (3) it is advisable mm between the lower edge of the hole
to remove the treadle (B). For this and the control edge of slide (C1). If this
purpose, loosen the retaining ring (L) and is not the case, change the setting by
knock out the bolt (M) using a mandril. removing or adding distance washers (5)
When knocking out the bolt, make sure in the upper spring seat. Check the
that the mandril is applied to the side of distance between the lower edge of the
the bolt without knurls. Remove treadle hole at port 5.1 and the control edge of
(B) and bellows (3). Now fit the new slide (C1) again.
Repair work When carrying out repair work,

CAUTION absolutely clean.
Immediately close all open
When working on the braking ports on the components and
system, always make the sure on pipes using plugs.
pressure in the system. Even For safety reasons, replace the
when the engine is switched off complete brake valve if other
there will be some residual parts are damaged.
28
Brake valve
with pilot control
467 406
3
Purpose be applied to the ring surface of the
467 406 414 0 intermediate piston (A), which then
The brake valve has the purpose of operates the top slide (C1) via the spring
sensitively increasing and decreasing the assembly connected in series.
braking pressure when the treadle is
operated. In addition there is the option to
The subsequent mode of action is
connect a further hydraulic actuation to
identical to that of a basic brake valve.
port 3. This could be a single circuit brake
valve, for example, to brake the vehicle in
stages using the respectively other foot. Limiting the braking pressure
The ring nut (D) at the top end of the

Operation
intermediate piston (A) is used to limit the
Actuation on port 3 causes pressure to braking pressure.
1 29
with switch box
Purpose Operation
The brake valve has the purpose of When the brake valve is actuated, the
sensitively increasing and decreasing the microswitches are operated one after the
braking pressure when the treadle is other by means of the intermediate
operated. piston. The retarder is controlled as
required prior to or during the process of
adjusting the hydraulic braking pressure.
It is also equipped with a switch box
containing up to 4 microswitches for The subsequent mode of action is
stepped control of a retarder. identical to that of a basic brake valve.
Technical data
Pedal
Pressure
Slide Ø Pedal angle force Pedal via Operating
Order number Circuits limitation Remark
[mm] [degrees] approx port pressure [bar]
[bar]
. [N]
Retarder
467 406 507 0 2 14 35 400 51 200 128 brake valve,
3 switches
467 406 508 0 2 14 35 450 51 150 128
467 406 509 0 2 14 35 510 51 150
Retarder
467 406 510 0 2 12 45 340 5 250 128+10 brake valve,
2 switches
467 406 511 0 2 12 45 450 5 250 128+10
467 406 512 0 2 12 45 400 5 250 167±5
Spare parts
Order number Designation

897 754 865 4 Bellows
30 1
Park brake valve 467 410
3
Purpose is closed. Once released from its locked
position, the park brake lever will
The purpose of the park brake valve is to automatically return to the driving
sensitively increase and decrease the position.
braking pressure when the park brake
lever is operated.
Installation instructions
Operation The return line 5 must be connected
directly to the tank.
Standby position The connecting lines must be installed in
When the braking system is ready for such a way as to permit problem-free
operation, the accumulator pressure acts bleeding.
directly on port 1 of the park brake valve. The device should be installed in a
A connection is established between port position where it cannot be accidentally
1 and port 21 so that the vehicle's park actuated by the driver's foot (floor of the
brake is released. vehicle).
Secondary braking Maintenance of the device

When the park brake valve is actuated, Special maintenance that extends
the hydraulic release pressure is beyond the legally specified inspections
increased or decreased in accordance is not required.
with the park brake lever's pivoting angle.
The spring assembly (A) below the cam When using high-pressure cleaners on
(B) permits sensitive stepped braking of the vehicle, please make sure that the
the vehicle. water jet is not aimed directly at the park
brake valve (damage to the bellows).
When the secondary braking process is
initiated, slide (C) is mechanically
Repair work
actuated via the spring assembly (A).
(Locked position = pressure released) The upward moving slide (C)first closes
the accumulator port 1 via the control CAUTION
edge and then establishes a connection
between the brake cylinder port 2 and When working on the braking
return 5. The pivoting angle reached by system, always make the sure
the park brake lever will now determine that there is absolutely no
the pressure in the spring brake actuator pressure in the system. Even
(port 2). The control slide (C) is held in when the engine is switched off
the control position by the force of the there will be some residual
spring assembly above the slide and by pressure in the system.
the hydraulic pressure below the slide When carrying out repair work,
(balance of forces). The slide (C) is in a make sure your environment is
partial braking position, causing ports 1 absolutely clean.
and 5 to close and to maintain the Immediately close all open ports
pressure in port 2. on the components and on pipes
using plugs.
Within partial braking range, the hand
lever will automatically return to the For safety reasons, replace the
driving position when the braking complete brake valve if other
process is ended. parts are damaged.
Parking brake action

When the lever is fully actuated, an end Replacing the bellows
position of the brake is reached and a To remove and replace the bellows (D),
connection is established between return the actuating button (E) needs to be
5 and brake cylinder port 2. Accumulator removed from the lever (F). To do this,
port 1 is closed as a result, and the lever push out the two retaining pins (G). The
is locked in position. When parking brake bellows (D) can now be pulled off and the
action ends, the connection between new one installed. Then push actuating
brake cylinder port 2 and accumulator button (E) back onto the lever (F) and
port 1 is re-established, and return port 5 secure it with the retaining pins (G).
31
3 467 410 Park brake valve
Technical data
Operating Working Permissible Thermal range of

Order number in locked position
pressure pressure medium application
467 410 011 0 50 bar
467 410 012 0 150 bar 125 bar Mineral oil -40C to +80C pressure reducing
467 410 015 0 *) 50 bar
*) for replacement only
Spare parts
Designation Order number Device variant
Bellows 897 754 190 4 For all devices still in-use
shown: 467 410 012 0

1,21, 5 = M16 x 1.5 - 10 deep
25 = M 12 x 1.5 -10 deep
Port designations:
1 = Energy supply
24 = Pressure switch connection
32
Compact valve
for dual circuit braking system
467 415
3
467 415 100 0
Purpose hydraulically by slide (C1). As slides
(C1 and C2) move downward they
The compact valve has the purpose will first close the returns 5 via the
of sensitively increasing and control edges and then establish a
decreasing the braking pressure connection between the accumulator
when the treadle is operated and to ports 2.1/2.2 and ports 6.1/6.2 of the
regulate the accumulators. The wheel brake cylinders. The foot force
device is designed for use in load- applied now determines the braking
sensing systems. pressure output. The control slides
(C1 and C2) are held in the control
Operation position by the applied foot force
(spring assembly) above the slides
and the hydraulic pressure below the
Standby position slides (balance of forces). Once the
The accumulator acts directly on the initiated braking pressure is applied,
brake valve circuits 2.1/2.2. A slides (C1 and C2) are in a partial
connection is established between braking position, causing ports 2.1/
ports 6.1/6.2 and port 5 so that the 2.2 and 5 to close, maintaining the
wheel brakes are switched to zero pressure in ports 6.1/6.2.
pressure via the return. Full braking position
Charging process When pedal (B) is fully actuated, an
If the accumulator pressure drops to end position of the brakes is reached
the defined value, the control slide (F) and a connection established
moves up and connects the load- between the accumulator ports 2.1/
sensing port 2 with the pump port 1 2.2 and brake cylinder ports 6.1/6.2.
via the control edge. This causes the Returns 5 are closed at this point.
variable displacement pump to When the braking process ends, a
charge the accumulators with a connection is once again established
defined volume flow. When the cut- between brake cylinder ports 6.1/6.2
off pressure is reached, the control and return port 5, closing
slide (F) moves down and reconnects accumulator ports 2.1/2.2. The
the load-sensing port with the return. arrangement of slides in the valve
The pump then only provides ensures that even if one braking
standby pressure. circuit fails the other remains fully
Simultaneously switching off the pin operational. This is achieved by
(G) provides the switching means of the mechanical actuation of
hysteresis. The shuttle valve (H) both slides and requires slightly more
causes the accumulator with the pedal travel.
lowest pressure to assume the Limiting the braking pressure
switching function of the cutoff valve
The pedal stop screw (D) on the
while still continuing to protect the
support (E) below the treadle (B) is
circuit in the event of a broken pipe.
used to limit the braking pressure.
Partial braking
Failure of a circuit
When the brake valve is actuated, a
In the event of the lower circuit failing,
hydraulic braking pressure in
the upper circuit will remain
proportion to the applied foot force is
operational. The spring assembly (A)
output. The spring assembly (A)
will mechanically actuate the slide
beneath the support (E) is designed
(C1). In the event of the upper circuit
in such a way that the braking
failing, the lower circuit will remain
pressure changes relative to the
operational. In this case the lower
angle. In the lower braking pressure
Slide (C2) is mechanically actuated
range the vehicle can be decelerated
by the spring assembly (A) and the
sensitively in stages. When the
slide (C1).
braking process is initiated, the upper
slide (C1) is mechanically actuated Repair kit 467 415 920 2
via the spring assembly (A), and the (includes springs)
lower slide (C2) is actuated Bellows 897 754 860 4
33
3 477 397 Cutoff valve
for single circuit systems
Purpose Charging process
The purpose of the cutoff valve is to If the accumulator pressure falls to the
control the pressure level in the predefined value, the control slide (B)
accumulators. will, through the force of the spring
assembly (D), overcome its locked
Operation position (E1) and move to a new locked
position (E2). An oil stream flows to the
Standby position rear of the main slide (A) via the orifice
When the braking system is ready for (F) and through the connecting hole (H).
operation (i.e. the accumulators are The pressure building up at the rear of
charged) the pump stream is applied on main slide (A) and the pressure present
port 1 of the cutoff valve. A connection is
below the main slide (A) put the main
established between port 1 and 5 so that
slide (A) in a floating position, permitting
the pump stream can, with a small
a partial stream to continue to reach port
difference in pressure, be returned
directly to the reservoir or other 5 and the remaining stream to flow to port
consumers. The rear of the main slide (A) 2 via the check valve (C) until the
is pressureless. The pressure within the pressure at port 2 is approx. 150 bar. The
braking system will hold the control slide control slide (B) will then move back to
(B ) in its locked position (E1) in which the the locked position (E1) in which a
rear of the main slide (A) is directly connection is established between port 1
connected to return 5 via the hole (G). and port 5, and the full pump flow is
directed into the reservoir again. The
The check valve (C) in the hole to port 2 check valve (C) secures the accumulator
secures the accumulator pressures. pressures again.
Technical data
Order number 477 397 001 0 477 397 011 0 477 397 031 0
Pressure at port 5 max. 200 bar max. 200 bar max. 50 bar
+10 +10
Cut-in pressure 120 bar 120 bar 120 +10 bar
Cut-off pressure 150 -10 bar 150 -10 bar 150 -10 bar
Flow rate from 1 2 = 2..0.3 l /min from 1 2 = 17...19 l /min
from 1  5 = 45 l /min from 1  5 = 45 l /min
max. 16 l /min
Permissible medium Mineral oil: 10 . . . 1,940 mm² /s

Weight 2.4 kg
34
Cutoff valve
for single circuit systems
477 397
3
shown: 477 397 001 0

1, 5 = M 18 x 1.5 -14 deep (M = 50 ± 5 Nm)
2 = M 16 x 1.5 - 14 deep (M = 40 ± 5 Nm)
Port designations:
1 = Energy supply
2 = Service brake
Installation instructions The connecting lines must be installed in Repair work

bleeding. CAUTION
Maintenance of the device When working on the braking

Special maintenance that extends system, always make the sure
beyond the legally specified inspections that there is absolutely no
is not required. pressure in the system.
Even when the engine is
switched off there will be some

absolutely clean.
ports on the components and
on pipes using plugs.
For safety reasons replace the

complete cutoff valve if it is
damaged.
35
for dual circuit systems
Purpose Charging process

The purpose of the cutoff valve is to If the accumulator pressure falls to the
control the pressure level in the predefined value, the control slide (B)
accumulators. will, through the force of the spring
assembly (C), overcome its locked
position (E1) and move to a new locked
Operation
position (E2). An oil stream flows to the
Standby position rear of the main slide (A) via the
When the braking system is ready for connecting hole (F). The pressure
operation (i.e. the accumulators are building up at the rear of the main slide
charged) the pump flow acts directly on and the pressure present below the main
port 1 of the cutoff valve. A connection is slide (A) put the main slide (A) in a
established between port 1 and port 5 so floating position, permitting a partial flow
that the pump flow is, with a small to continue to reach port 5 and the
difference in pressures, returned directly remaining flow ports 21/23 via the check
to the reservoir. The rear of the main valve (D) until the pressure within the
slide (A) is pressureless. braking system is approx. 150 bar. The
control slide (B) will then move to the
The pressure within the braking system locked position (E1) again, in which a
will hold the control slide (B ) in its locked connection is established between ports
position (E1) in which the rear of the main 1 and 5. The full pump flow is directed
slide (A) is directly connected to return 5 into the reservoir again via port 5. The
via the hole (G). The check valve (D) in check valve (D) secures the accumulator
the hole to ports 21 and 23 secures the pressures again.
accumulator pressures. The shuttle valve
(H) causes the accumulator with the
lowest pressure to operate the cutoff
valve while continuing to protect the
circuit in the event of a broken pipe.
Technical data Order number 477 397 015 0 477 397 032 0
Pressure at port 5 200 bar for a short time
Cut-in pressure 120 +8 bar 70 +8 bar
Cut-off pressure 150 -8 bar 100 -8 bar
Rate of flow max. 45 l /min max. 62l /min
Permissible medium Mineral oil: 2000 to 10 mm² /s
Operating range 22 -8 bar
Thermal range of
-30C to +80C
application
Weight 3.8 kg 4.1 kg
Flow rate to the braking
3 +1 dm3/min 10...12 dm3/min
circuits
Pressure switch in port
No Yes
28
36
Cutoff valve
for dual circuit systems
477 397
3
x
477 397 015 0
477 397 032 0
View X
477 397 015 0

1, 5 = M18x1.5 -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 designations:
1 = Energy supply
21, 23 = Service brake
477 397 032 0 27 = Hydraulic accumulator
28 = Pressure switch

CAUTION
bleeding.
When working on the braking
system, always make the sure
is not required.
there will be some residual

absolutely clean.
Immediately close all open ports
on the components and on
pipes using plugs.

complete cutoff valve if it is
damaged.
37
for triple circuit systems
Purpose leakage. The check valves (H)

additionally protect each braking circuit
The purpose of the cutoff valve is to
against pressure losses in the event of a
control the pressure level in the
broken pipe.
accumulators.
Charging process
Operation If the accumulator pressure falls to the
Standby position defined value, the control slide (B) will,
When the braking system is ready for through the force of the spring assembly
operation (i.e. the accumulators are (C), overcome its locked position (E1)
charged) the pump flow acts directly on and move to a new locked position (E2).
port 1 of the cutoff valve. A connection is An oil stream flows to the rear of the main
established between port 1 and port 5 so slide (A) via the connecting hole (F). The
that the pump flow is, with a small pressure building up at the rear of the
difference in pressures, returned directly main slide (A) and the pressure present
to the reservoir. The rear of the main below the main slide (A) put main slide
slide (A) is pressureless. The pressure (A) in a floating position, permitting a
within the braking system will hold the partial flow to continue to reach port 5
control slide (B ) in its locked position and the remaining flow ports 21//22/23
(E1) in which the rear of the main slide via the check valve (D) until the pressure
(A) is directly connected to return 5 via within the braking system is approx. 150
477 397 007 0 the hole (G). The check valve (D) in the bar. The control slide (B) will then move
hole to port 27 secures the accumulator to the locked position (E1) again, in which
pressure of the switching accumulator. a connection is established between
The latter is available as an additional ports 1 and 5. The full pump flow is
braking volume for the braking system, directed into the reservoir again via port
preventing excessively frequent 5. The check valve (D) secures the
actuation of the device in the event of a accumulator pressures again.
477 397 014 0
38
Cutoff valve
for triple circuit systems
477 397
3
Technical data Order number 477 397 007 0 477 397 014 0
Pressure at port 5 temporary
–
max. 200 bar
Pressure limitation 170 + 30 bar none
Cut-in pressure 120 +8
bar
Cut-off pressure 150 - 8 bar
Flow rate max. 16 l /min 45 l /min
+1
Flow rate to the braking circuits 3 l /min 3 + 1 l /min
Permissible medium Mineral oil 10 ... 2,000 mm² /s
Weight 3.8 kg
shown: 477 397 014 0

View X
1, 5 = M18x1.5 -12 deep (M = 50 ± 5 Nm)
21, 22, 23, 27 = M16x1.5 -12 deep (M = 40 ± 5 Nm)
28 = M12x1.5 -12 deep (M = 28 ± 3 Nm)
Port designations:
1 = Energy supply
21, 22, 23 = Service brake
27 = Hydraulic accumulator
28 = Pressure switch
Installation instructions The connecting lines must be installed in pressure in the system. Even
such a way as to permit problem-free when the engine is switched off
bleeding. there will be some residual
Special maintenance that extends When carrying out repair work,
beyond the legally specified inspections make sure your environment is
is not required. absolutely clean.
Repair work ports on the components and
CAUTION
When working on the braking For safety reasons replace the

system, always make the sure complete cutoff valve if it is
that there is absolutely no damaged.
39
3 477 399 Check valve
Purpose can be connected at ports 24, 25 and 26

to check the braking pressure.
The check valve has the purpose of
ensuring that the pressure in the intact
Standby position
braking circuits of a triple circuit braking
system is maintained in the event of one When the pressure at port 1 is reduced,
circuit failing. a return flow of the oil is prevented by
closing of the check valves (A), thus
securing the pressure in the hydraulic
Operation accumulators. When the pressure is
Filling Position increased, the check valves (A) are
After the check valves (A) have opened, opened again to equalise the pressure
the oil flow from port 1 will reach the between the circuits.
downstream accumulators of the brake
valves via ports 21 and 22 and the Pressure limitation
accumulator for the park brake valve via A pressure limiting valve (B) integrated in
port 23. the check valve limits the output pressure
Pressure gauges or pressure switches to a maximum of 180 bar.
Technical data
Pressure limitation 180 +10 bar
Flow rate 0.7 to 16 l /min
Nominal diameter 8 mm
40
Check valve 477 399
3

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

bleeding. CAUTION
Any installation position can be chosen.
Maintenance of the device system, always make the sure
Special maintenance that extends that there is absolutely no
beyond the legally specified inspections pressure in the system.
is not required. Even when the engine is
switched off there will be some

absolutely clean.

complete triple-circle check
valve if it is damaged.
41
3 477 411 Relay valve
Purpose in port 4. When the braking process is

initiated, the slide (A) is actuated via the
The relay valve has the purpose of control port 4 and moves into the braking
transferring large volumes to the wheel position against the force of the spring
brake within a short time. It offers the (B). The slide will first close return port 5
benefit of being able to be actuated with via the control edge and then, via another
a small actuating volume. control edge, connect accumulator port 1
with port 2. The oil now flows from port 1
Operation to port 2 via a hole and the hollow slide
(A), moving it to its final braking position.
Standby position In this process, the output braking
When the braking system is ready for pressure at port 2 is equal to the control
operation, the accumulator pressure is pressure of the foot brake valve at port 4.
present at port 1 of the relay valve. A
connection is established between ports Release position
2 and 5 so that the wheel brake cylinders If the control pressure at port 4 is
of the vehicle are released. reduced, the hollow slide (A) returns to its
initial position. The connection from port
Braking position 1 to 2 is closed again by the control
When the foot brake valve is actuated, a edges. The second control edge will then
hydraulic braking pressure builds up at open the connection between port 2 and
port 2 in proportion to the input pressure return port 5.
Technical data
Control volume 1.3 cm³
Pressure at port 5 < 3 bar
Transmission ratio 1:1
42
Relay valve 477 411
3
Installation instructions The return line must be connected Repair work

directly to the tank.
CAUTION
bleeding.
system, always make the sure
The relay valve should be mounted in
the vicinity of the wheel brake.
there will be some residual
is not required.
absolutely clean.

complete relay valve if it is
damaged.
43
4 Appendix
Appendix
44
General information
4
General information a) All pipes in the braking system must pipes. Leaks are an indication that
have a nominal width of at least 10 the system is not properly sealed.
mm. Check the level of the brake fluid.
Eliminate the leaks.
b) The pipes should be installed in such
a way as to permit problem-free g) When using high-pressure cleaners,
bleeding, i.e. so that no air cushions do not aim the nozzle directly at the
can develop. If you detect noises bellows (possible damage to the
when applying the brake, this is an bellows).
indication of poor bleeding.
h) When working on the braking
c) When fitting the pipes, make sure system, always make the sure that
that no areas of friction can develop. there is absolutely no pressurein the
system.
d) The return lines of the individual
components of the braking system i) Make sure your environment is
must not be combined in one return absolutely clean.
line to the tank.
j) Immediately close all open ports on
e) The return lines of the dual-circuit the components and on pipes using
foot brake valve must not be plugs.
designed as a pipe and combined
into a single return line. This is CAUTION
possible only if ports 5.1 and 5.2 are
connected by means of hoses and Even when the engine is
combined to form one return line. switched off or with the pump
not running the system pressure
f) Look for visible leaks in lines and will be maintained in the system.
45
4 Installation instructions /
Capacity of Accumulators
Installation instructions It is particularly important that the lines from the accumulator to the wheel
components all have their separate brake cylinders are thereby reduced
return lines, otherwise the return because the foot brake valve only
pressure can be present in the wheel actuates the relay valves. The input
brake in the form of residual pressure. volume of the relay valves is approx. 1
This leads to unnecessary wear of the cm³.
brake linings and excessive
temperatures at the wheel brake and can
thus result in hardening of the linings and If cutoff valves with an integrated check
in a failure of the seals on the wheel valve are used, an additional
brake cylinders. accumulator of 0.7 litres needs to be
screwed into the component. That
When combining the returns of the dual additional accumulator is primarily used
circuit foot brake valve, please make to monitor the actual pressure of the
sure that hoses are used for connecting other three accumulators and pass them
the return ports. Using a pipe to connect on to the control piston of the cutoff valve.
the two circuits can result in impaired The accumulators can be drained when
functions due to distortions during the brakes are operated without being re-
installation. charged since all circuits are protected
against one another by the check valves.
For very long vehicles with large cylinder The additional accumulator will also
volumes, the installation of relay valves prevent activation of the cutoff valve in
can be very helpful, reducing response the connection between the check valves
and pressure build-up times to a in the event of minor leaks and
minimum. The relay valve should be associated pressure drops even though
fitted as close to the wheel brake the pressure in the accumulators of the
cylinders as possible. The lengths of the braking circuit is still higher than 120 bar.
Capacity of accumulators The hydraulic accumulators must be For this purpose we require the following
specially designed to comply with the information from you (see page below).
legal provisions for the FPB with regard
to the size of energy accumulators. It would further assist us if you could
send us the data sheet for the wheel
We support our customers, free of brake.
charge, in identifying the appropriate
accumulator layout and capacity.
46
Application Data Sheet
for Hydraulic Full Power Brake Systems
4

Application Data Sheet
for Hydraulic Full Power Brake Systems Date
Name Title
Company
Address Country
Email Phone
Vehicle Specification
Type of vehicle Name and model number
Estimated annual production volume min. max.
Gross vehicle weight kg Empty vehicle weight kg Wheel base m
Maximum speed k.p.h
Countries of use
Braking standards and regulations
Hydraulic Brake Specification

Service Brake Single-circuit Dual-circuit
Service brake pressure bar max. Auxiliary brake pressure bar min.
Parking Brake No
Yes SAHR type No Parking brake pressure bar min. max.
Yes Release pressure bar min. max.
Pushrod force N min. max.
Pump flow l/min min. max. Pump pressure bar max.
Operating temperature °C min. average max.
System fluid used Fluid manufacturer and brand name
Wheel brake type Wheel brake manufacturer
Wheel brake consumption volume per circuit cm 3 max. min.
Parking brake type Parking brake manufacturer

3
Parking brake consumption volume cm max. min.
WABCO, Am Lindener Hafen 21 / 30453 Hannover, Germany

www.wabco-auto.com
47
4 Legal requirements for Europe
Directive 98/12/EC – C Hydraulic Braking Systems with Stored Energy

Annex IV – Section C
from January 27, 1998 1. CAPACITY OF ENERGY STORAGE DEVICES (ENERGY
ACCUMULATORS)
1.1. General
1.1.1. Vehicles whose braking system requires the use of stored energy provided
by hydraulic fluid under pressure must 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 2.2.1.5.1.
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 2.2.1.4. 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.
48
Legal requirements for Europe
4
1.2.2.2.2. The auxiliary equipment and its energy storage devices, if any, shall be
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. Definition of terms
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. Measurement conditions
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.
Other national regulations must be observed if the vehicle is exported.
49
4 Further references
Further references
ISO 3450:2011, Earth-moving machinery – Wheeled or high-speed rubber-

[1]
tracked machines
ISO 7131, Earth-moving machinery – Loaders – Terminology and commercial
[2]
specifications
ISO 7132:2003, Earth-moving machinery – Dumpers – Terminology and
[3]
commercial specifications
ISO 10265, Earth-moving machinery – Crawler machines – Performance
[4]
requirements and test procedures for braking systems
ISO 17063, Earth-moving machinery – Braking systems of pedestrian-
[5]
controlled machines – Performance requirements and test procedures
SABS 1589, The braking performance of trackless underground mining
[6]
machines – Load haul dumpers and dump trucks
CAN/CSA-M424.3-M90 (R2007), Braking Performance – Rubber-Tired, Self-
[7]
Propelled Underground Machines
EN 1889-1, Machines for underground mines - Mobile machines working
[8]
underground - Safety - Part 1: Rubber-tyred vehicles
[9] MSHA Website: http://www.msha.gov
SAE J1329, Minimum Performance Criteria for Braking Systems for
[10]
Specialized Rubber-tired, Self-propelled Underground Mining Machines
[11] SAE J1472:2006, Braking Performance – Rollers
ECE R-13 Rev 1, Add 12, Rev 5 – Annex 18, Special Requirements to be
[12]
applied to the safety aspects of complex electronic vehicle control systems
USA 30 Code of Federal Regulations, Part 57, Safety and health standards –
[13]
Underground metal and non-metal mines
USA 30 Code of Federal Regulations, Part 75, Mandatory safety standards –
[14]
Underground coal mines
50
Testing the WABCO Full
Hydraulic Power Brake System
4
Testing the WABCO Full The legal requirements (abbreviated as "LR" below) listed below match the EC
Hydraulic Power Brake System Directive 98/12/EC (consolidated version of Directive 71/320/EEC) and can be looked
up in the WABCO paperback "Legal Requirements 2000".
(FPB) (after initial installation in
the vehicle)
A. Functional check of the hydraulic accumulators
1. With the engine turned off, depressurise the braking system by repeated full
depression of the foot brake valve (around 30 - 40 times).
The pressure gauge in the driver's cab indicates 0 bar. The warning lamp in the driver's
cab is lit.
2. Start the engine and leave idling.
3. The gauge pressure increases rapidly up to the minimum pressure with which one
of the available hydraulic accumulator is pre-charged with nitrogen (priming
pressure). Then the pressure increases more slowly.
If the pre-charge is lower than 40 bar, at least one hydraulic accumulator is defective.
This accumulator must be identified and replaced. This can only be done by removing
testing the units outside the vehicle. (Please note the disposal instructions on page
19).
Possible WABCO accumulators: 458 501 071 0; 458 501 101 0
LR: Annex IV, Section C, Paragraph 1.1 to 1.1.3. page 86/87
B. Functional check of the warning system
1. Testing at which pressure the warning lamp (warning system) goes out.
The warning lamp must go out at 90 +10 bar *).
*) with WABCO pressure switch: 441 014 049 0
2. Testing at which pressure the warning lamp (warning system) lights up. With the
engine idling, use the foot brake valve to reduce the system pressure to approx.
120 bar cut-in pressure of the corresponding cutoff valve. Then carry out two full
braking actions.
The warning lamp must not light after the second full braking action.
LR: Annex IV, Section C, Paragraph 3, page 88
C. Functional check of the cutoff valve
1. Check if maximum system pressure is reached.
The system pressure must be reached at 150 -10 bar.
2. With the engine idling, use the foot brake valve to reduce the system pressure to
approx. 120 bar (cut-in pressure of the cutoff valve). The carry out 8 full braking
actions. At the 9th full braking application it must be possible to achieve the
(residual) braking effect prescribed for the secondary braking system.
LR:
Annex II, Paragraph 2.1.4. , page 52
Annex IV, Section C, Paragraph 1.2.1.1. , page 87
Annex IV, Section C, Paragraph 1.2.1.2.1., page 87
Annex IV, Section C, Paragraph 1.2.1.2.2., page 87
51
4 Testing the WABCO Full
The pressure gauge indication may drop to a value of 50 bar (accumulator priming
pressure) after nine brake applications.
3. Start the engine.
The maximum system pressure must now increase to 150 -10 bar again.
Possible WABCO cutoff valves:

477 397 001 0
477 397 007 0
477 397 011 0
477 397 014 0
477 397 015 0
477 397 031 0
4. Test if the cutoff valve switches to idle circulation once the system pressure is
reached.
Install a measurement point on port 1 of the cutoff valve (tee). Check the commencing
pressure drop using a connected pressure gauge.
5. At the same time, check if any double switch actions occur in the cutoff valve.
These are also indicated on the pressure gauge (port 1 of the cutoff valve).
One possible reason for any double switching actions may be that the energy source
(accumulator) was installed too far away from the cutoff valve (to optimise the line
layout) or that the switch accumulator is defective (also refer to item "A").
6. Check for interior leaks in the cutoff valve.

With the 'engine idling', the brake not applied and maximum system pressure
having been reached, the system pressure must drop below the cut-in pressure of
the cutoff valve within four to six minutes.
For this test step the working medium (oil) must have been brought to operating
temperature, i.e. the test must not be carried out with the braking system being in a
cold state.
D. Functional test of the parking brake
1. Testing the indicator lamp during pressure reduction (initiation of braking)
At 21 +/-2 bar the park brake indicator lamp must light up.
Possible WABCO pressure switch: 441 014 043 0
2. Testing the pressure reduction and build-up by operating the park brake lever.
It must be possible to sensitively step the pressure.
3. Testing the indicator lamp during pressure reduction (releasing the park brake)
When the park brake is released, the indicator lamp must go out at approx. 23 bar.
4. Testing if the maximum system pressure is reached in the park brake circuit.
The maximum system pressure in accordance with the outline drawing for the installed
park brake valve must be reached.
52
4
Possible WABCO park brake valves:
467,410,011 0; working pressure 50 bar
467 410 015 0; working pressure 50 bar
467 410 017 0, working pressure 50 bar
E. Functional test of the energy source (pump output)
1. Switch off the engine.
120 bar (cut-in pressure of the cutoff valve). Then fully apply the brake four times.
At least 120 bar must be reached again within 30 seconds.
LR: Annex IV, Section C, Paragraph 2.1.3.2., page 88
General information
a) All pipes in the braking system must have a nominal width of at least 10 mm.
b) The pipes must be installed in such a way as to permit problem-free bleeding, i.e.
so that no air cushions can develop.
Pump noises when applying the brake generally indicate poor bleeding.
c) Check for visible leaks in lines and pipes. Leaks must be eliminated immediately
(system pressure protection, protection of the environment).
Frequent switching of the cutoff valve generally indicates leaks in the system.
d) When using high-pressure cleaners, do not aim the nozzle directly at the devices
(possible damage to the bellows).
e) When working on the braking system, always make sure that there is absolutely no
f) Make sure your environment is absolutely clean.
g) Immediately seal all open ports on the components and on pipes using plug.
CAUTION
Even when the engine is switched off or with the pump not running there will
be some residual pressure in the system.
Before starting work on the system make sure that the system pressure was
reduced to 0 bar (is achieved by fully pressing down the foot brake valve
several times [up to 40 times]).
53
4
Possible WABCO park brake valves:
E. Functional test of the energy source (pump output)
1. Switch off the engine.
120 bar (cut-in pressure of the cutoff valve). Then fully apply the brake four times.
At least 120 bar must be reached again within 30 seconds.
LR: Annex IV, Section C, Paragraph 2.1.3.2., page 88
General information
a) All pipes in the braking system must have a nominal width of at least 10 mm.
b) The pipes must be installed in such a way as to permit problem-free bleeding, i.e.
so that no air cushions can develop.
Pump noises when applying the brake generally indicate poor bleeding.
c) Check for visible leaks in lines and pipes. Leaks must be eliminated immediately
(system pressure protection, protection of the environment).
Frequent switching of the cutoff valve generally indicates leaks in the system.
d) When using high-pressure cleaners, do not aim the nozzle directly at the devices
(possible damage to the bellows).
e) When working on the braking system, always make sure that there is absolutely no
f) Make sure your environment is absolutely clean.
g) Immediately seal all open ports on the components and on pipes using plug.
CAUTION
Even when the engine is switched off or with the pump not running there will
be some residual pressure in the system.
Before starting work on the system make sure that the system pressure was
reduced to 0 bar (is achieved by fully pressing down the foot brake valve
several times [up to 40 times]).
53
WABCO (NYSE: WBC) is a leading and transmission automation
global supplier of technologies systems supplied to the world’s
© 2013 WABCO Europe BVBA – All rights reserved – 815 010 044 3 / 09.2013
and control systems for the safety leading commercial truck, bus and
and efficiency of commercial trailer manufacturers. With sales
vehicles. Founded nearly 150 of $2.5 billion in 2012, WABCO is
years ago, WABCO continues to headquartered in Brussels, Belgium.
pioneer breakthrough electronic, For more information, visit
mechanical and mechatronic
technologies for braking, stability
www.wabco-auto.com

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FPB – FULL

HYDRAULIC POWER BRAKE

Full Hydraulic Power Brake

This publication is not subject to an updating service.

© 2013 WABCO Europe BVBA - All rights reserved

Subject to change without notice

2 System proposal ................................................................................................6

3 Device description ...........................................................................................11

General notes ....................................................................................................45

Legal requirements for Europe –

Further references .............................................................................................50

Testing the WABCO Full Hydraulic Power Brake (FPB) ....................................51

If the brake volume is greater Always check the response and

all pipes of brake line NW 10

all pipes of brake line NW 10

all pipes of brake line NW 10

all pipes of brake line NW 10

Other load signalling lines

Purpose Quick release function

Braking position As the pressure in the hydraulic part (A)

Repair work those included in the repair

Replacing the bellows actuators without a quick-release

427 001 007 0 Quick release function:

Thread of pipe connections:

427 001 002 0

427 001 005 0

Purpose The system pressure acts on an effective

Adjusting and testing the

Purpose return 5 via the control edge, thus

467 406 108 0

Slide Ø Pedal angle Pedal force Pedal via Operating Pressure

467 406 128 0

467 406 108 0

shown: 467 406 102 0

Thread of pipe connections:

Maintenance of the device

Spare parts Designation Position (see figure) Order number

Repair work When carrying out repair work,

Purpose the accumulator ports 1.1/1.2 and ports

The return lines 5.1/5.2 must be

Spare parts Position

Repair kits Repair kit for device variant

shown: 467 406 202 0

Thread of pipe connections:

Variant 1.1, 1.2, 2.1, 2.2,

shown: 467 406 208 0

shown: 467 406 227 0

shown: 467 406 246 0

Repair work When carrying out repair work,

The ring nut (D) at the top end of the

Order number Designation

Secondary braking Maintenance of the device

Parking brake action

Operating Working Permissible Thermal range of

*) for replacement only

shown: 467 410 012 0

Thread of pipe connections:

Purpose Charging process

Permissible medium Mineral oil: 10 . . . 1,940 mm² /s