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HPB Hydraulic Power Braking System
4th Edition
This publication is not subject to any update service.New
versions are available in INFORM atwww.wabco-auto.com
© Copyright WABCO 2007
Vehicle Control SystemsAn American Standard Company
The right of amendment is reservedVersion 004/01.07(en)
8150100443 815 010 044 3
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31
1. General Comments
............................................................................................5
2. Diagrams of HPB Systems
................................................................................7
841 300 329 0 single -
circuit................................................................
8
841 300 314 0 dual - circuit
..................................................................
9
841 300 331 0 dual - circuit with auxiliary braking system
................. 10
841 300 332 0 dual - circut with relay
valves...................................... 11
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
......................................................................
31
47. 399 Double Check
Valve...................................................................
33
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 (Excerpt)
........................................................ 50
Table of Contents
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6
General Comments1.At present the majority of special-purpose
vehicles, particularly con-struction vehicles up to a deadweight of
approx. 7 tonnes, areequipped with hydraulic muscularpower braking
systems. Vehicleswith a higher dead weight usualyhave
compressed-air braking sys-tems.
Since wet inboard disk brakes arebeing increasingly used in
Europeanconstruction vehicles, WABCO hasdeveloped a Hydraulic Power
Brak-ing System (HPB) which takes intoaccount the special
requirements forconstruction vehicles.
The components of the hydraulicbraking system are suitable for
fluidson the basis of mineral oils and somebio-fluids which means
that the fluidspresent in the construction vehicle'shydraulics can
be used as the energytransmitter for the braking system.
The cross-sections of the compo-nents have been designed to
ac-count for the higher viscosity of suchfluids rather than
conventional brakefluid.
The components are particularly ro-bust to ensure that they are
capableof withstanding the tough conditionsof everyday
operation.
The legal requirements for the HPBwith regard to the size of its
energyaccumulators, the performance of itsenergy source and the
properties ofthe alarm devices are defined in ECE- Regulation No.
13, Annex 7c.
(Please refer to our manual "LegalRequirements", 2004 Edition,
orpage 50 to this brochure).
The HPB system is not really suitablefor operating a trailer
braking system.This requires a system for supplyingcompressed air
with a hydraulicallyoperated Trailer Control Valve (470015 ...0) to
be installed. The handbrake facility for the trailer can thenbe
operated, for instance, via a hydropressure switch, a solenoid
valveand a relay valve (pneumatic).
In order to take into account the trendtowards dual circuit
service brakingsystems, we recommend that vehi-cles > 25 k.p.h.
are fitted with a dualcircuit HPB system. Although according to the
GermanMotor Vehicle Construction and UseRegulation construction
vehiclesmerely require a single circuit sys-tem.
HPB Hydraulic Power Braking System
IMPORTANT !
If the brake volume is greater than75 cm³, at least the first
(top circuit)of the pedal brake valve must beequipped with a relay
valve.
The response and threshold timesmust be checked in all cases. If
nec-essary, both circuits of the servicebrake system must be
equipped withrelay valves.
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HPB - Diagram 841 300 329 0single - circuit2.
No. Qty. Description Part Number
1 1 Pump
2 1 Pressure Filter
3 1 Shut-Off Valve 477 397 . . . 0
4
5
6 1 Brake Valve 467 406 1 . . 0
7
8 1 Tank
9 • Wheel brake cylinder
10
No. Qty. Description Part Number
11 1 Pressure Switch 441 014 049 0
12 1 Pressure Switch 441 014 055 0
13
14 2 Test connection
15
16
17 • Accumulator 458 501 . . . 0
18
19
20
all pipes of brake line NW 10
Port connections:0 Suction1 Energy supply2 Energy delivery5
Return connection
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No. Qty. Description Part Number
1 1 Pump
2 1 Pressure Filter
3 1 Shut-Off Valve 477 397 015 0
4 1 Brake Valve 467 406 . . . 0
5
6
7
8 1 Tank
9 • Wheel brake cylinder
10
No. Qty. Description Part Number
11 1 Pressure Switch 441 014 049 0
12 2 Pressure Switch 441 014 055 0
13
14 3 Test connection
15
16
17 • Accumulator 458 501 . . . 0
18 • Accumulator 458 501 . . . 0
19
20
841 300 314 0 HPB - Diagramdual - circuit 2.
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 connection21 Energy delivery Circuit 1
5 Return connection22 Energy delivery Circuit 2 51 Return
connection Circuit 123 Energy delivery Circuit 3 52 Return
connection Circuit 2
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10
HPB - Diagram 841 300 331 0dual - circuit with auxiliary braking
system2.
No. Qty. Description Part Number
1 1 Pump
2 1 Pressure Filter
3 1 Shut-Off Valve 477 397 . . . 0
4 1 Brake Valve 467 406 . . . 0
5 1 Hand Brake Valve 467 410 . . . 0
6
7
8 1 Tank
9 • Wheel brake cylinder
10 1 Spring Brake Actuator 427 001 . . . 0
No. Qty. Description Part Number
11 1 Pressure Switch 441 014 049 0
12 2 Pressure Switch 441 014 055 0
13 1 Pressure Switch 441 014 044 0
14 4 Test connection
15 1 Accumulator 458 501 071 0
16 • Accumulator 458 501 . . . 0
17 • Accumulator 458 501 . . . 0
18 • Accumulator 458 501 . . . 0
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20
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 22 Energy delivery 4
Pilot connection
21 Energy delivery Circuit 1 5 Return connection22 Energy
delivery Circuit 2 51 Return connection Circuit 123 Energy delivery
Circuit 3 52 Return connection Circuit 2
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No. Qty. Description Part Number
1 1 Pump
2 1 Pressure Filter
3 1 Shut-Off Valve 477 397 . . . 0
4 1 Brake Valve 467 406 . . . 0
5 1 Hand Brake Valve 467 410 . . . 0
6
7 2 Relay Valve 477 411 . . . 0
8 1 Tank
9 • Wheel brake cylinder
10 1 Spring Brake Actuator 427 001 . . . 0
No. Qty. Description Part Number
11 1 Pressure Switch 441 014 049 0
12 2 Pressure Switch 441 014 055 0
13 1 Pressure Switch 441 014 044 0
14 4 Test connection
15 1 Accumulator 458 501 071 0
16 • Accumulator 458 501 . . . 0
17 • Accumulator 458 501 . . . 0
18 • Accumulator 458 501 . . . 0
19 1 Accumulator 458 501 071 0
20 1 Accumulator 458 501 071 0
841 300 332 0 HPB - Diagramdual-circut with relay valves 2.
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 connection21 Energy delivery Circuit 1
5 Return connection22 Energy delivery Circuit 2 51 Return
connection Circuit 123 Energy delivery Circuit 3 52 Return
connection Circuit 2
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3.
Description of Components
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14
Spring Brake Actuator427 0013.Purpose:The spring brake actuator
serves to gen-erate the braking force for the wheelbrake in
secondary and parking brakingsystems.
Operation:Ready PositionIn the driving condition, the
pressurefrom the hand brake valve is acting di-rectly on Port 1 of
the Spring Brake Actu-ator. The secondary or parking brake
isreleased.
Braking positionWhen the hand brake valve is actuated,the
hydraulic pressure is reduced as afunction of the angular position
of thehand brake lever.
As the pressure in the hydraulic portion(A) of the Spring Brake
Actuator is re-duced, the force of the releasing Com-pression
Spring (B) makes Piston Rod(C) retract in the direction of the
Actua-tor's axis, thus actuating the wheel brake.The Spring Brake
Actuator's maximumbrake force is reached when the pres-sure falls
to zero.
Quick Release Facility:Some variants are available with a
quick-release facility.
This permits, in the event of the pressurein the hydraulic
portion (A) failing, thewheel brake to be released by applying
ablow in the direction of the arrow (F), us-ing a hammer, thus
severing the frictionalconnection established between Com-pression
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 be-tween Compression Spring (B) and Pis-ton Rod (C) is
established once more andthe Spring Brake Actuator is fully
opera-tive again.
Emergency Release FacilityIf Spring Brake Actuators without a
quick-release facility are used, the parkingbrake can still be
released should the hy-draulic pressure fail. To do so, the
Hexa-gon Nut (6) on Piston Rod (K) is taken offYoke (C1). An
open-jawed spanner (jawsize 13) is applied to Section (L) on
Pis-ton Rod (K). Piston Rod (K) is then turnedin such a way that
Yoke (C1) is displacedtowards the brake lever.
with quick-release facility
without quick-release facility
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Replacing the BellowsRemove clamps (2; 3 or H) from thebellows,
replace as necessary whenfitting the new bellows. Pull off the
faultybellows (1), push on new bellows andfasten with clamps (2; 3
or H).
Replacing the YokeWhen replacing the Yoke (5) onactuators
without a quick-release facility,immobilize the piston rod (K) by
applyinga spanner (jaw size 13). RemoveHexagon Nut (6) and unscrew
Yoke (5)
from the piston rod. The new Yoke (5) isscrewed into the piston
rod up to thepoint where the original piston rod lengthis once
again achieved (see outlinedrawing: distance from centre yoke
holeto end face of Port 1). Secure piston rodby means of hexagon
nut.
Technical Data:
Spring Brake Actuator 427 001 3.
Part Number 427 001 002 0 427 001 005 0 427 001 006 0 427 001
007 0 427 001 008 0
Operating pressure 150 bar max.
Stroke 80 ± 3 mm
Release pressure 87 ± 4 bar 60 -4 bar 40 ± 4bar 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
Repair Kits:
Attention ! The enclosed portion of the actuator is
spring-loaded !
For safety reasons the whole of the Spring Brake Actuator must
bereplaced if parts other than those listed above are damaged.
Repair kit Variant of Actuator
427 001 002 2 427 001 007 0427 001 008 0
427 001 003 2 427 001 002 0427 001 005 0
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Spring Brake Actuator427 0013.Installation dimensions:
quick release facility:actuation by applying a blow to the
flange
showing: 427 001 007 0
Variant 002
Thread of pipe connections:M16 x1.5 - 16 deep
showing: 427 001 005 0
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Installation Requirements:The connecting lines must be installed
insuch a way as to permit proper bleeding.The actuator should be
mounted at aslight angle, its piston rod pointingdownwards.
Maintenance:No special maintenance beyond the legalrequirements
is necessary.
When using high-pressure cleaners onthe vehicle, please make
sure that thewater jet is not aimed directly at theSpring Brake
Actuator (to prevent dam-aging the bellows)
Repair Work:When working on the brakingsystem, always make sure
thatthere is absolutely no pressurein the system. Even when the
engine isswitched off there will be someresidual pressure in the
system!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
Spring Brake Actuator 427 001 3.
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Pressure Switch441 0143.Purpose:The Pressure Switches are used
tovisually or audibly warn the driver of thepressure within the
system.
Operation:Make Contact / Circuit CloserThe Pressure Switch can
be fitted in thebraking system or directly on one of itscomponents.
The system pressure actson an absorption area within the
switch,making an electrical contact as thepressure on that area is
increased. Theresulting current is used to activateawarning
facility, for instance.
Break Contact / Circuit BreakerThe Pressure Switch can be fitted
in thebraking system or directly on one of itscomponents. The
system pressure actson an absorption area within the switch,
breaking an electrical contact as thepressure on that area is
increased. Thecurrent is now broken, e.g. to deactivatea warning
facility.
Installation Requirements:No special measures need to be
taken.
Maintenance:No special maintenance beyond the legalrequirements
is necessary. When using high-pressure cleaners onthe vehicle,
please make sure that thewater jet is not directed at the
PressureSwitch. (corrosion of contacts).
Break Contact Make Contact
Technical Data:
Part Number Medium G H 1(mm)H 2
(mm)
Adjusting range in bar
Actuating pressure
in bar
Voltagein V
Break 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
441 014 057 0 mineral oil M10x1 tapered 55 9 10 - 20 10 - 20
42
441 014 059 0 mineral oil M12x1.5 55 9 1 - 10 3 ± 0,5 42
Make Contact
441 014 048 0 mineral oil M12x1 tapered 43 9 3 - 6 3 - 6 42
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
441 014 058 0 mineral oil M10x1 tapered 55 9 20 - 50 20 - 50
42
441 014 070 0 mineral oil M12x1.5 55 9 50 - 150 54 ± 0,5
42Breaking capacity of all pressure switches 100 Voltampere
resistive load Boot for Pressure Switch: Part Number 897 750 342
4
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Repair Work:
When working on the brakingsystem, always make sure thatthere is
absolutely no pressurein the system. Even when the engine
isswitched off there will be someresidual pressure in the
system!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
Installation dimensions:
Adjusting and testing the Pressure Switch:
The adjusting screw located between thetwo contact plugs can be
set to thedesired value within a certain range. Foradjusting range,
please refer to the table"Technical Data" on the previous page.
After making the adjustment, theadjusting screw should be
secured usingwax or a similar material.
Pressure Switch 441 014 3.
For safety reasons the Pressure Switch needs to bereplaced as a
whole if damaged.
Adjusting screw
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Hydraulic Accumulator458 5013.Purpose:Fluids are practically
incompressible andare thus incapable of accumulatingpressure
energy. In hydropneumaticaccumulators, the compressibility of agas
is utilized to accumulate fluid. Thecompressible medium used in
theaccumulators is nitrogen.
In braking systems, the purpose of theaccumulators is to store
the energysupplied by the hydrailc pump. They arealso used as an
energy reserve when thepump is not working, as a compensatorfor any
losses through leakage, and asoscillation dampers.
Operation:The accumulator consists of a fluidportion (A) and a
gas portion (B) with a
diaphragm (C) as a gas-tight dividingelement. The fluid portion
(A) isconnected to the hydraulic circuit,causing the diaphragm
accumulator tobe filled and the gas volume to becompressed as the
pressure rises. Whenthe pressure falls, the compressed gasvolume
will expand, thus displacing theaccumulated pressure fluid into
thecircuit.
The diaphragm bottom contains a valvedisk (D) which, if the
diaphragmaccumulator is completely empty, closesthe hydraulic
outlet, thus preventingdamage to the diaphragm.
Technical Data:
Part Number 458 501 071 0 458 501 101 0
Diameter 121 mm 136 mm
Mounting height 146 mm 160 mm
Nominal volume 0.75 dm³ 1.0 dm³
Priming pressure 50 bar
Operating medium mineral oil
Operating pressure 180 bar max. 200 bar max.
Thread M18x1.5 M22x1.5
Operating temperature range –30°C to +80°C
Mounting position optional
Priming gas nitrogen
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The accumulators can be fitted in thehydraulic circuit, directly
on a componentor in blocks on suitable consoles.
They should be fitted in as cool a locationas
possible.Installation can be in any position.
Maintenance:No special maintenance beyond the legalrequirements
is necessary.
The accumulator should be checkedannually. It should be replaced
if theinitial gas pressure has fallen by morethan 30% (please refer
to "Performance
testing and checking of theAccumulator").
Disposal of the Accumulator:Before the accumulator is scrapped,
itsgas filling pressure must be reduced. Forthis purpose, drill a
hole through GasChamber (B) using a drill approx. 3 mm indiameter.
The gas chamber is located onthe side opposite the threaded
portabove the welding seam around thecentre of the accumulator.Wear
safety goggles when doing thisjob!
Installation Requirements:
Performance testing and checking of the Accumulator:
Hydraulic Accumulator 458 501 3.
The accumulator is gradually pressurizedvia the test pump; until
the initial gaspressure is reached, the hydraulicpressure in the
accumulator will riseabruputly. This is apparent from gauge"M". If
the initial gas pressure is morethan 30% below the prescribed
value, theaccumulator needs to be replaced. If themeasuring process
needs to berepeated, wait for intervals of 3 minutesbetween the
individual tests. Any accumulator whose initial gaspressure is
insufficient must be scrappedfollowing the instructions under
"Disposalof the Accumulator".
The amount of initial gas pressure canalso be checked from the
vehicle.Start the vehicle's engine. The pump willnow supply oil to
the accumulators. Untilthe initial gas pressure is reached,
thehydraulic pressure in the accumulator willrise abruputly. This
is apparent from thegauge in the cab. If the initial gaspressure is
more than 30% below theprescribed value, that initial pressure
liesoutside the permissible range for at leastone of the
accumulators fitted in thevehicle. This accumulator can be
tracedonly by using the method describedabove, i.e. all
accumulators have to be
individually tested. The accumulatorwhose initial gas pressure
is insufficientmust be replaced and scrapped followingthe
instructions under "Disposal of theAccumulator".
Repair Work:When working on the brakingsystem, always make sure
thatthere is absolutely no pressurein the system. Even when the
engine isswitched off there will be someresidual pressure in the
system!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
For safety reasons the Accumulators need to be replaced as a
whole if damaged.
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
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Brake Valvefor single circuit braking system
467 4063.Purpose:The purpose of the Brake Valve is tosensitively
increase and decrease thebraking pressure when the brake pedal(or
the actuating lever) is actuated.
Operation:Ready PositionWhen the braking system is ready
foroperation, its accumulator pressure actsdirectly on Port 1 of
the Brake Valve. A connection is established betweenPorts 21 and 51
so that the wheel brake(Port 21) is pressureless via the
return(Port 51).
Partial BrakingWhen the Brake Valve is actuated, anamount of
hydraulic pressure is output asa ratio of the foot force
applied.
The Spring Assembly (A) beneath BasePlate (E) is designed in
such a way thatthe braking pressure changes dependingon the angle.
In the lower brakingpressure range, the vehicle can beslowed
sensitively.
When the braking process iscommenced, Slide (C) is
mechanicallyactuated via Spring Assembly (A). AsSlide (C) moves
downward, it will first
close Return 51 via the control edge, thusestablishing a
connection betweenAccumulator Port 1 and Port 21 for thewheel brake
cylinders. The foot forceapplied now determines the outputbraking
pressure. Control Slide (C) isheld in the control position by the
forceapplied (spring assembly) and thehydraulic 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 51 to close andholding the pressure in Port 21.
Full Braking PositionWhen Pedal (B) is fully actuated, an
endposition of the brakes is reached and aconnection established
between Accu-mulator Port 1 and Brake Cylinder Port21. Return 51 is
closed at this point.
When the braking process is ended, aconnection is once again
established be-tween Brake Cylinder Port 21 and ReturnPort 51,
closing Accumulator Port 1.
Limiting the Braking PressurePedal Restriction Screw (D) on
BasePlate (E) below Pedal (B) is used to limitthe braking pressure.
This will cause theaccumulator pressure building up in thebraking
system to be limited.
467 406 108 0
467 406 1 . . 0
Leading edge
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showing: 467 406 108 0
showing: 467 406 108 0
Thread of pipe connections:M 14x1.5 - 12 deep
Port connections:1 = Energy supply
21 = Energy delivery51 = Return connection
Variant 128 0
Technical Data:
Brake Valvefor single circuit braking system
467 406 3.
Part Number Pedal Angle Actuating path Brake pressure Actuating
force Comments
467 406 100 0 45° 130 ± 10 mm 150 bar 360 N 1)
467 406 101 0 45° 90 ± 10 mm 100 +10 bar 280 N 1)
467 406 102 0 45° 90 ± 10 mm 80 +10 bar 240 N 1)
467 406 103 0 45° 85 ± 10 mm 100 +10 bar 240 N 1)
467 406 108 0 Lever – 150 bar 875 N 1)
467 406 112 0 40° 85 ± 5 mm 65 +5 bar 350 N 1)
467 406 121 0 50° 28° 100 +10 bar 280 N 1)
467 406 124 0 40° 22° 60 +8 bar 360 N 1)
467 406 128 0 45° 24° 100 +10 bar 300 N with pedal locking
device 1)
Operating temperature range for all variants –30°C to +80°C /
Operating pressure: 150 bar
1) Pressure at the return port 51 < 5 bar
Installation dimensions:
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24
Brake Valvefor single circuit braking system
467 4063.
Return Line 51 must be connecteddirectly to the tank. The
connecting linesmust be installed in such a way as topermit proper
bleeding.
Maintenance of the Brake ValveNo special maintenance beyond the
legalrequirements is necessary.
When using high-pressure cleaners onthe vehicle, please make
sure that thewater jet is not aimed directly at theBrake Valve. (to
prevent damaging thebellows)
Replacing the Pedal CoverPedal Cover (1) is simply pulled off
byhand. The new pedal cover is pushed
over Pedal (B) and tightened manually.Fasten the bellows with
the strapretainers.
Replacing the complete ActuatingMechanism
Carefully clamp the unit vertically in afixture. The actuating
mechanism can beremoved by taking out the four Screws(H) below Base
Plate (E). Make sure thatSpring Assembly (A) does not fall out.When
installing the new actuatingmechanism, make sure that
SpringAssembly (A) is fitted in the right order. Tighten the four
Screws (H).
Installation dimensions:
showing: 467 406 102 0
Thread of pipe connections:
Port connections:1 = Energy supply
21 = Energy delivery24 = Test port 51 = Return connection
Installation Requirements:
Variant 1, 21 and 51 24100 M 14x1.5 -12 deep M 12x1.5101, 102,
108, 128 M 14x1.5 -12 deep –
124 M 16x1.5 -12 deep M 12x1.5121 M 16x1.5 -12 deep M 10x1
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25
Replacing the BellowsTo change Bellows (3) it is advisable
toremove Pedal (B). For this purpose,loosen Retaining Ring (L) and
knock outBolt (M) using a mandril. When knockingout the bolt, make
sure that the mandril isapplied to the side of the bolt without
aknurl. Remove Pedal (B) and Bellows (3).Now fit the new Bellows
(3) and proceedin reverse order as described above. Theupper
portion of Bellows (3) is fastened toPiston (N), its lower portion
to Base Plate(E).
Replacing the Grooved RingCarefully clamp the unit vertically in
afixture. Unscrew Screw Plug (P) and pullSlide (C) out downwards.
Check the slidefor damage. If they are found to bedamaged, the
whole Brake Valve needsto be replaced. (Pairs of slides andhousings
are matched in manufacturing.)If the slide is not damaged in any
way,remove the whole actuating mechanism
as described above. Remove SpringAssembly (A) and Grooved Ring
(4) andput in a new greased grooved ring with itslips pointing
downwards. Install both thespring assembly as shown in thedrawing,
and the pedal. Carefully re-insert Slide (C) into the housing
frombelow, turning it slightly. Put in Spring (R)and close the unit
with Screw Plug (P).Check Return Port 51 to see if there is agap of
approx. 2 mm between the loweredge of the hole and the control edge
ofSlide (C). If this is not the case, changethe setting by removing
or addingdistance washers (5) in the upper springplate of the
spring assembly. Check thedistance between the lower edge of
thehole and the control edge of Slide (C)again.
Spare parts: Description No. Part Number Variant of Brake
Valvecomplete Actuating Mechanism
2 467 406 782 2 101, 102, 103
2 467 406 791 2 112, 124
Bellows 3 897 754 865 4 112, 121, 124
Repair kit Variant of Brake Valve
467 406 004 2 467 406 102 0
Repair Work:
Brake Valvefor single circuit braking system
467 406 3.
For safety reasons the whole of the Brake Valve must be replaced
if parts other than those listed above are damaged.
When working on the brakingsystem, always make sure thatthere is
absolutely no pressurein the system. Even when the engine
isswitched off there will be someresidual pressure in the
system!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
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26
Brake Valvefor dual circuit braking system
467 4063.Purpose:The purpose of the Brake Valve is tosensitively
increase and decrease thebraking pressure when the brake pedal(or
the actuating lever) is actuated.
Operation:Ready PositionWhen the braking system is ready for
op-eration, its accumulator pressure acts di-rectly on Port 1.1/1.2
of the Brake Valve.A connection is established betweenPorts 2.1/2.2
and Ports 5.1/5.2 so thatthe wheel brakes (Ports 2..) are
pres-sureless via the returns (Ports 5..).
Partial BrakingWhen the Brake Valve is actuated, anamount of
hydraulic pressure is output asa ratio of the foot force applied.
TheSpring Assembly (A) beneath Base Plate(E) is designed in such a
way that thebraking pressure changes depending onthe angle. In the
lower braking pressurerange, the vehicle can be
slowedsensitively.
When the braking process iscommenced, the upper Slide (C1)
ismechanically actuated via SpringAssembly (A), and the lower Slide
(C2) isactuated hydraulically by Slide (C1). AsSlides (C1 and C2)
move downward,they will first close Returns 5.1/5.2 via thecontrol
edges, thus establishing a
connection between Accumulator Ports1.1/1.2 and Ports 2.1/2.2
for the wheelbrake cylinders. The foot force appliednow determines
the output brakingpressure. The Control Slides (C1 andC2)) are held
in the control position bythe force applied (spring assembly)above
the slides and the hydraulicpressure below the slides (balance
offorces). After output of the brakingpressure, Slides (C1 and C2)
are in apartial braking position, causing Ports1.1/1.2 and 5.1/5.2
to close and holdingthe pressure in Ports 2.1/2.2.
Full Braking PositionWhen Pedal (B) is fully actuated, an
endposition of the brakes is reached and aconnection established
betweenAccumulator Ports 1.1/1.2 and BrakeCylinder Ports 2.1/2.2.
Returns 5.1/5.2are closed at this point.
When the braking process is ended, aconnection is once again
establishedbetween Brake Cylinder Ports 2.1/2.2and Return Ports
5.1/5.2, closingAccumulator Ports 1.1/1.2.
The arrangement of slides in the valveensures that even if one
braking circuitfails the other remains fully operational.This is
achieved by means of themechanical actuation of both slides
andrequires slightly more pedal travel.
Limiting the Braking PressurePedal Restriction Screw (D) on
BasePlate (E) below Pedal (B) is used to limitthe braking
pressure.
Failure of a CircuitIn the event of the lower circuit failing,
theupper circuit will remain operational.Spring Assembly (A) will
mechanicallyactuate Slide (C1). In the event of theupper circuit
failing, the lower circuit willremain operational since the lower
Slide(C2) is mechanically actuated by SpringAssembly (A) and Slice
(C1).
Leading edge
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27
Technical Data:
Spare parts:
Repair Kits:
Brake Valvefor dual circuit braking system
467 406 3.
1) Pressure at the return port 5: 5 bar max. 2) Port 5.1 closed
with plug
Part Number Pedal Angle Actuating pathOperating Pressure Brake
pressure
Actuating force Comments
467 406 202 0 40° 103 ± 10 mm 150 bar 63 + 7 bar 320 N 1)
467 406 208 0 Lever 28 mm 150 bar 120 bar 800 N 1)
467 406 216 0 40° 103 mm 150 bar 110 + 10 bar 300 N 1)
467 406 218 0 40° 93 ± 10 mm 150 bar 100 + 10 bar 380 N 1)
467 406 219 0 40° 79 ± 2 mm 150 bar 60 + 10 bar 200 N 1)
467 406 220 0 40° 73 ± 5 mm 150 bar 72 + 10 bar 220 N 1)
467 406 227 0 25° 88 mm 150 bar 150 bar 320 N 1)
467 406 233 0 25° 128 mm 150 bar 150 bar 400 N 1)
467 406 234 0 35° 128 mm 150 bar 150 bar 400 N 1)
467 406 235 0 Piston 12 mm 150 bar 150 bar 2700 N 1)
467 406 246 0 Piston 13 mm 150 bar 150 bar 3000 N Flange valve,
1)
467 406 247 0 45° 18° 150 bar 50 bar 250 N with pedal locking
device, 1)
467 406 301 0 45° 74 ± 10 mm 150 bar 55 + 7 bar 290 N 1)
467 406 309 0 45° 19° 150 bar 40 bar 280 N with pedal locking
device, 1)
467 406 401 0 45° 49 ± 10 mm 150 bar 70 + 8 bar 300 N 1)
467 406 408 0 45° 73 ± 10 mm 150 bar 63 + 7 bar 240 N 1), 2)
467 406 411 0 45° 22° 150 bar 90 bar 350 N with pedal locking
device, 1), 2)
467 406 413 0 35° 22° 150 bar 60 + 8 bar 340 N 1), 2)
467 406 414 0 50° 15° 150 bar 50 + 7 bar 200 N with hydr.
actuation (Port 3 M 12x1.5), 1)
467 406 508 0 35° 6° to 26° 200 bar 128 + 10 bar 460 N with
electrical actuation of the retarder, 1)
467 406 510 0 45° 8° to 21° 250 bar 128 + 14 bar 460 N for VOLVO
with electrical actuation of
the retarder, 1)467 406 512 0 45° 9° to 24° 250 bar 167 ± 5 bar
420 N
Operating temperature range for all Variants –30°C to +80°C
Description No. Part Number Variant of Brake Valve
complete Actuating Mechanism
2 467 406 782 2 2182 467 406 791 2 2022 467 406 795 2 235
Bellows
3 897 752 270 4 2183 897 752 670 4 208
3 897 754 865 4 202, 216, 220, 227, 233, 235, 246,401, 408, 411,
414, 508, 510
Repair kit Variant of Brake Valve467 406 000 2 467 406 233 0,
467 406 235 0467 406 001 2 467 406 208 0467 406 005 2 467 406 216
0467 406 007 2 467 406 220 0, 467 406 223 0467 406 921 2 467 406
211 0, 467 406 238 0
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28
Brake Valvefor dual circuit braking system
467 4063.Installation dimensions:
showing: 467 406 202 0
Port connections:1.1, 1.2 = Hydraulic accumulator2.1, 2.2 =
Service brake2.4, 2.5 = Test connection5.1, 5.2 = Return
connection
Thread of pipe connections:
Variant 1.1, 1.2, 2.1, 2.2, 5.1, 5.2 2.4, 2.5
208, 216, 218, 219, 220, 227, 233, 234, 235, 247, 508, 510,
512
M 16x1.5 -12 deep
M 10x1- 8 deep
411, 413, M 16x1.5 -12 deep
M 12x1.5- 8 deep
202, 301, 309, 401, 408, 414
M 16x1.5 -12 deep
M 12x1.5- 10 deep
246 Flange valve
showing: 467 406 208 0
Base plate panel opening
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29
Installation dimensions:
showing: 467 406 227 0
Port connections:1.1, 1.2 = Hydraulic accumulator2.1, 2.2 =
Service brake2.4, 2.5 = Test connection5.1, 5.2 = Return
connection
showing: 467 406 246 0
Brake Valvefor dual circuit braking system
467 406 3.
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30
Brake Valvefor dual circuit braking system
467 4063.Return Lines 5.1/5.2 must be connecteddirectly to the
tank. The connecting lines must be installed insuch a way as to
permit proper bleeding.
Maintenance of the Brake ValveNo special maintenance beyond the
legalrequirements is necessary. When using high-pressure cleaners
onthe vehicle, please make sure that thewater jet is not aimed
directly at theBrake Valve (to prevent damaging thebellows)
Replacing the Pedal CoverPedal Cover (1) is simply pulled off
byhand. The new pedal cover is pushedover Pedal (B) and tightened
manually.Fasten the bellows with the strapretainers.
Replacing the complete ActuatingMechanismCarefully clamp the
unit vertically in afixture. The actuating mechanism can beremoved
by taking out the four Screws(H) below Base Plate (E). Make sure
thatSpring Assembly (A) does not fall out.When installing the new
actuatingmechanism, make sure that SpringAssembly (A) is fitted in
the right order.Tighten the four Screws (H).
Replacing the BellowsTo change Bellows (3) it is advisable
toremove Pedal (B). For this purpose,loosen Retaining Ring (L) and
knock outBolt (M) using a mandril. When knockingout the bolt, make
sure that the mandril isapplied to the side of the bolt without
a
knurl. Remove Pedal (B) and Bellows (3).Now fit the new Bellows
(3) and proceedin reverse order as described above. Theupper
portion of Bellows (3) is fastened toPiston (N), its lower portion
to Base Plate(E). Secure the bellows using clamps.
Replacing the Grooved RingCarefully clamp the unit vertically in
afixture. Unscrew Screw Plug (P) and pullSlides (C1 and C2) out
downwards.Check the slides for damage. If they arefound to be
damaged, the whole BrakeValve needs to be replaced. (Pairs ofslides
and housings are matched inmanufacturing.) If the slides are
notdamaged in any way, remove the wholeactuating mechanism as
describedabove. Remove Spring Assembly (A) andGrooved Ring (4) and
put in a newgreased grooved ring with its lips pointingdownwards.
Install both the springassembly as shown in the drawing, andthe
pedal. Carefully re-insert Slide (C1)into the housing from below,
turning itslightly. Put in Spring (R1), followed bySlide (C2),
using a slight turning motion ifpossible. Insert Spring (R2) and
close theunit with Screw Plug (P). Check ReturnPort 5.1 to see if
there is a gap of approx.2 mm between the lower edge of the holeand
the control edge of Slide (C1). If thisis not the case, change the
setting byremoving or adding Distance Washers (5)in the upper
spring plate. Check thedistance between the lower edge of thehole
at Port 5.1 and the control edge ofSlide (C1) again.
Installation Requirements:
Repair Work:
For safety reasons the whole of the Brake Valve must be replaced
if parts other than those listed above are damaged.
When working on the brakingsystem, always make sure thatthere is
absolutely no pressurein the system. Even when the engine
isswitched off there will be someresidual pressure in the
system!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
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31
Purpose:The purpose of the Hand Brake Valve isto sensitively
increase and decrease thebraking pressure when the hand brakelever
is actuated.
Operation:Ready PositionWhen the braking system is ready
foroperation, its accumulator pressure actsdirectly on Port 1 of
the Hand BrakeValve. A connection is establishedbetween Ports 1 and
21 so that thevehicle's hand brake is released.
Secondary Braking SystemWhen the Hand Brake Valve is
actuated,the hydraulic release pressure isincreased or decreased as
a function ofthe hand brake lever's pivoting angle.Spring Assembly
(A) below Cam Plate(B) permits a sensitive braking processfor the
vehicle.
When the secondary braking process iscommenced, Slide (C) is
mechanicallyactuated via Spring Assembly (A). Slide(C) moves
upwards, it first closesAccumulator Port 1 via the control edgeand
then establishes a connection
between Brake Cylinder Port 2 andReturn 5. The pivoting angle of
the handbrake lever will now determine thepressure in the spring
brake actuator(Port 2). Slide (C) is held in the controlposition by
the force (spring assembly)above the slide and by the
hydraulicpressure below the slide (balance offorces). Slide C is in
a partial brakingposition, causing Ports 1 and 5 to closeand to
hold the pressure in Port 2.
In the range of partial brake application,the hand lever will
automatically return tothe driving position when the brakingprocess
is ended.
Parking BrakeWhen the lever is fully actuated, an endposition of
the brake is reached and aconnection is established betweenReturn 5
and Brake Cylinder Port 2.Accumulator Port 1 is closed and thelever
is locked in position. When theparking brake is released, a
connectionbetween Brake Cylinder Port 2 andAccumulator Port 1 is
once moreestablished, and Return Port 5 is closed.Once released
from its locked position,the hand brake lever will
automaticallyreturn to the driving position.
Hand Brake Valve 467 410 3.
(Locked position = pressure reduc
Installation Requirements:Return Line 5 must be connected
directlyto the tank. The connecting lines must be installed insuch
a way as to permit proper bleeding.The Hand Brake Valve should
beinstalled in a position where it cannot beaccidentally actuated
by the driver's foot.
Maintenance of the Brake ValveNo special maintenance beyond the
legalrequirements is necessary.
When using high-pressure cleaners onthe vehicle, please make
sure that thewater jet is not aimed directly at the HandBrake Valve
(to prevent damaging thebellows)
Repair Work:When working on the brakingsystem, always make sure
thatthere is absolutely no pressurein the system. Even when the
engine isswitched off there will be someresidual pressure in the
system!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
Replacing the BellowsTo change Bellows (D), removeActuating
Button (E) from Lever (F). Todo this, push out the two Retaining
Pins(G). The Bellows (D) can now be pulledoff and the new ones
installed. PushActuating Button (E) back onto Lever (F),securing it
with Retaining Pins (G).
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32
Hand Brake Valve467 4103.Technical Data:
*) ONLY FOR REPLACEMENT !
Spare parts:
Part Number Operating pressureWorking pressure Permissible
medium
Operating temperature range in locked position
467 410 011 0
150 bar
50 bar
mineral oil –40°C to +80°C pressure reducing467 410 012 0 125
bar
467 410 015 0 *) 50 bar
Description Part Number Variant of Hand Brake Valve
Bellows 897 754 190 4 For all devices still in use
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 delivery24 = Pressure switch connection5 = Return
connection
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33
Purpose:
The purpose of the Double Check Valveis to permit alternate
actuation of thebraking circuits. It permits a hydraulicbraking
circuit to be actuated by twoactuating valves.
Operation:
When the control pressure is built up, thecontrol pressure is
passed unrestrictedly
from Port 11 or 12, depending on the typeof actuation of the
valve, to Port 2. A ballseat valve arrangement ensures that asthe
foot brake valve is actuated, Port 12remains pressureless when the
pressureis increased at Port 11, and vice versa.The ball seat also
prevents the controlpressure being reduced through the partof the
line which is not being utilized.
NO LONGER AVAILABLE ! ONLY FOR INFORMATION !
Installation dimensions:
Thread of pipe connections:M 14 x 1.5 DIN 74 235
Port connections:11, 12 = Energy supply
2 = Energy delivery
Technical data
Part Number 476 399 001 0 478 399 002 0
Operating pressure 200 bar max., 2 bar min.
Permissible medium mineral oil10 mm²/s to 1936 mm²/s brake
fluid
Operating temperaturerange –40°C to +80°C
Rate of flow max. 12 dm³ / min
Weight 0.42 kg
Maintenance of the Double CheckValveNo special maintenance
beyond the legalrequirements is necessary.
Repair Work:When working on the brakingsystem, always make sure
thatthere is absolutely no pressurein the system.
Even when the engine isswitched off there will be someresidual
pressure in the system!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
Double check valve 476 399478 399 3.
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34
Shut-Off Valvefor Single Circuit Systems
477 3973.Purpose:The purpose of the Shut-Off Valve is tocontrol
the pressure level in theaccumulators.
Operation:Ready PositionWhen the braking system is ready
foroperation (i.e. the accumulators arecharged) the pump stream is
present atPort 1 of the Shut-Off Valve. Aconnection is established
between Ports1 and 5 so that the pump stream can,with a small
difference in pressures, bereturned directly to the reservoir or
otherconsumers. The rear of Main Slide (A) ispressureless. The
pressure within thebraking system will hold Control Slide (B)in its
locked position (E1) in which therear of Main Slide (A) is
directlyconnected to Return 5 via Hole (G). Check Valve (C) in the
hole to Port 2secures the accumulator pressures.
Charging Process
As the accumulator pressure falls to thepreset 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 throughConnecting Hole (H), an oil stream
flowsto the rear of Main Slide (A). Thepressure building up at the
rear of MainSlide (A) and the pressure present belowMain Slide (A)
put Main Slide (A) in afloating position, permitting a
partialstream to continue to reach Port 5 andthe remaining stream
to flow to Port 2 viaCheck Valve (C) until the pressure at Port2 is
approx. 150 bar. Control Slide (B) willthen once again move to
Locked Position(E1) in which a connection is establishedbetween
Ports 1 and 5 and the whole ofthe pump stream once again flows to
thereservoir. Check Valve (C) once againsecures the accumulator
pressures.
Technical Data: Part Number 477 397 001 0 477 397 011 0 477 397
031 0Operating pressure 200 bar max.
Pressure at port 5 200 bar max. 200 bar max. 50 bar max.
Cut-in pressure 120 +10 bar 120 +10 bar 120 +10 bar
Cut-off pressure 150 -10 bar 150 -10 bar 150 -10 bar
Flow rate max. 16 l /min from 1 ⇒ 2 = 2...3 l /minfrom 1 ⇒ 5 =
45 l /minfrom 1⇒ 2 = 17...19 l /min
from 1 ⇒ 5 = 45 l /minPermissible medium mineral oil: 10 . . .
1940 mm² /s
Operating temperaturerange
–30°C to +80°C
Weight 2.4 kg
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35
Installation dimensions:
showing: 477 397 001 0
Thread of pipe connections: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 connections:1 = Energy supply2 = Service brake5 = Return
connection
Shut-Off Valvefor Single Circuit Systems
477 397 3.
Installation Requirements: The connecting lines must be
installed insuch a way as to permit proper bleeding.
Maintenance of the Shut-Off ValveNo special maintenance beyond
the legalrequirements is necessary.
Repair Work:When working on the brakingsystem, always make sure
thatthere is absolutely no pressurein the system. Even when the
engine isswitched off there will be someresidual pressure in the
system!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
For safety reasons the whole of the Shut-off Valve must be
replaced if damaged.
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36
Shut-Off Valvefor Dual Circuit Systems
477 3973.Purpose:The purpose of the Shut-Off Valve is tocontrol
the pressure level in theaccumulators.
Operation:Ready PositionWhen the braking system is ready
foroperation (i.e. the accumulators arecharged) the pump stream is
present atPort 1 of the Shut-Off Valve. Aconnection is established
between Ports1 and 5 so that the pump stream is, witha small
difference in pressures, returneddirectly to the reservoir. The
rear of MainSlide (A) is pressureless.
The pressure within the braking systemwill hold Control Slide (B
) in its lockedposition (E1) in which the rear of MainSlide (A) is
directly connected to Return5 via Hole (G). Check Valve (D) in
thehole to Ports 21 and 23 secures theaccumulator pressures.
Shuttle Valve (H)causes the accumulator with the lowestpressure to
operate the Shut-Off Valvewhilst securing the circuit in the event
ofa broken pipe.
Charging ProcessAs the accumulator pressure falls to thepreset
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 tothe rear
of Main Slide (A). The pressurebuilding up at the rear of Main
Slide (A)and the pressure present below MainSlide (A) put Main
Slide (A) in a floatingposition, permitting a partial stream
tocontinue to reach Port 5 and theremaining stream to flow to Ports
21/23via Check Valve (D) until the pressurewithin the braking
system is approx. 150bar. Control Slide (B) will then once
againmove to Locked Position (E1) in which aconnection is
established between Ports1 and 5. The whole of the pump streamonce
again flows to the reservoir via Port5. Check Valve (D) once again
securesthe accumulator pressures.
Technical Data: Part Number 477 397 015 0Operating pressure 200
bar max.
Pressure at port 5 temporary 200 bar
Cut-in pressure 120 +8 bar
Cut-off pressure 150 -8 bar
Rate of flow max. 45 l /min
Permissible medium mineral oil: 2000 to 10 mm² /sVAI 6 to 12
Operating range 20 +10 bar
Operating temperature range –30°C to +80°C
Weight 3.8 kg
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37
Installation dimensions:
Shut-Off Valvefor Dual Circuit Systems
477 397 3.
Installation Requirements: The connecting lines must be
installed insuch a way as to permit proper bleeding.
Maintenance of the Shut-Off ValveNo special maintenance beyond
the legalrequirements is necessary.
Repair Work:When working on the brakingsystem, always make sure
thatthere is absolutely no pressurein the system. Even when the
engine isswitched off there will be someresidual pressure in the
system!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
For safety reasons the whole of the Shut-off Valve must be
replaced if damaged.
View X
x
showing: 477 397 015 0
Thread of pipe connections: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 connections:1 = Energy supply
21, 23 = Service brake 27 = Hydraulic accumulator 28 = Pressure
switch
5 = Return connection
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38
Shut-Off Valvefor Triple Circuit Systems
477 3973.Purpose:The purpose of the Shut-Off Valve is tocontrol
the pressure level in theaccumulators.
Operation:Ready PositionWhen the braking system is ready
foroperation (i.e. the accumulators arecharged) the pump stream is
present atPort 1 of the Shut-Off Valve. Aconnection is established
between Ports1 and 5 so that the pump stream is, witha small
difference in pressures, returneddirectly to the reservoir. The
rear of MainSlide (A) is pressureless. The pressurewithin the
braking system will holdControl Slide (B ) in its locked
position(E1) in which the rear of Main Slide (A) isdirectly
connected to Return 5 via Hole(G). Check Valve (D) in the hole to
Port27 secures the accumulator pressure ofthe operating
accumulator. This isavailable as an additional braking volumefor
the braking system, preventingexcessively frequent actuation of
theShut-Off Valve in the event of a leakage.Shuttle Valves (H)
additionally secureeach braking circuit against pressurelosses in
the event of a broken pipe.
Charging ProcessAs the accumulator pressure falls to thepreset
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 tothe rear
of Main Slide (A). The pressurebuilding up at the rear of Main
Slide (A)and the pressure present below MainSlide (A) put Main
Slide (A) in a floatingposition, permitting a partial stream
tocontinue to reach Port 5 and theremaining stream to flow to Ports
21//22/23 via Check Valve (D) until the pressurewithin the braking
system is approx. 150bar. Control Slide (B) will then once
againmove to Locked Position (E1) in which aconnection is
established between Ports1 and 5. The whole of the pump streamonce
again flows to the reservoir via Port5. Check Valve (D) again
secures theaccumulator pressures.Variant 007
Variant 014
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39
Shut-Off Valvefor Triple Circuit Systems
477 397 3.Part Number 477 397 007 0 477 397 014 0
Pressure at port 5 – temporary200 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
Technical Data:
Installation dimensions:
View X
x
showing: 477 397 014 0
Thread of pipe connections: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 connections:1 = Energy supply
21, 22, 23 = Service brake 27 = Hydraulic accumulator 28 =
Pressure switch
5 = Return connection
Installation Requirements:
For safety reasons the whole of the Shut-off Valve must be
replaced if damaged.
The connecting lines must be installed insuch a way as to permit
proper bleeding.Maintenance of the Shut-Off ValveNo special
maintenance beyond the legalrequirements is necessary.
Repair Work:
When working on the brakingsystem, always make sure thatthere is
absolutely no pressurein the system. Even when the
engine is switched off there willbe some residual pressure in
thesystem!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
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40
Check Valve477 3993.Purpose:The purpose of the Check Valve is
tosecure the pressure in the intact brakingcircuits of a triple
circuit braking system inthe event of one circuit failing.
Operation:Filling PositionAfter Check Valves (A) have opened,
theoil stream from Port 1 will reach thedownstream accumulators of
the brakevalves via Ports 21 and 22 and flows viaPort 23 to the
accumulator for the handbrake valve. Pressure gauges or
manometricswitches can be connected at Ports 24,25 and 26 to check
the braking pressure.
Ready PositionWhen the pressure at Port 1 is reduced,return flow
of the oil is prevented byclosing of Check Valves (A), thussecuring
the pressure in the hydraulicaccumulators. As the pressure
isincreased, Check Valves (A) are openedonce again, permitting the
pressures inthe cirucits to be balanced.
Pressure Limiting FacilityA Pressure Limiting Valve (B)
integratedin the Check Valve limits the outputpressure to a maximum
of 180 bar.
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
Nominal diameter 8 mm
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41
Installation dimensions:
Thread of pipe connections:1, 5, 2122, 23 = M14x1.5 DIN 74
23524, 25
26 = M14x1.5 -12 deep
Port connections:1 = Energy supply
21 – 26 = Energy delivery5 = Return connection
Check Valve 477 399 3.
Installation Requirements: The connecting lines must be
installed insuch a way as to permit proper bleeding.The Check Valve
can be mounted in anyposition.
Maintenance of the Check ValveNo special maintenance beyond the
legalrequirements is necessary.
Repair Work:When working on the brakingsystem, always make sure
thatthere is absolutely no pressurein the system. Even when the
engine isswitched off there will be someresidual pressure in the
system!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
For safety reasons the whole of the Check Valve must be replaced
if damaged.
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42
Relay Valve477 4113.Purpose:The purpose of the Relay Valve is
torapidly transfer large volumes to thewheel brake. It offers the
benefit of beingable to operate with a small actuatingvolume.
Operation:Ready PositionWhen the braking system is ready
foroperation, the accumulator pressure ispresent at Port 1 of the
Relay Valve. Aconnection is established between Ports2 and 5 so
that the wheel brake cylindersof the vehicle are released.
Braking positionWhen the foot brake valve is actuated,
ahydraulic braking pressure builds up atPort 2 as a function of the
input pressureat Port 4. When the braking process is
commenced, Slide (A) is actuated viaControl Port 4 and moves
into the brakingposition against the force of Spring (B).The slide
will first close Return Port 5 viathe control edge and then, via
anothercontrol edge, connect Accumulator Port1 with Port 2. Via a
hole, the oil streamnow flows from Port 1 to Port 2 throughHollow
Slide (A), moving it to its finalbraking position. In this process,
theoutput braking pressure at Port 2 is equalto the control
pressure of the foot brakevalve at Port 4.
Release positionAs the control pressure at Port 4 isreduced,
Hollow Slide (A) returns to itsinitial position. The connection
betweenPorts 1 and 2 is closed once again by thecontrol edges. The
second control edgewill then open the connection betweenPort 1 and
Return Port 5.
Technical Data:Part Number 477 411 000 0
Operating pressure 250 bar max.
Control volume 1.3 cm³
Pressure at port 5 < 3 bar
Permissible medium mineral oil: 2000 to 10 mm² /s
Operating temperature range –40°C to +80°C
Transmission ratio 1 : 1
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43
Installation dimensions:
Relay Valve 477 411 3.
Installation Requirements: The return line must be
connecteddirectly to the tank. The connecting lines must be
installed insuch a way as to permit proper bleeding.The Relay Valve
should be mounted inthe vicinity of the wheel brake.
Maintenance of the Relay ValveNo special maintenance beyond the
legalrequirements is necessary.
Repair Work:When working on the brakingsystem, always make sure
thatthere is absolutely no pressurein the system. Even when the
engine isswitched off there will be someresidual pressure in the
system!
When doing repair work, makesure your environment is veryclean.
Immediately close all open portson the components and on pipesusing
plugs!
For safety reasons the whole of the Relay Valve must be replaced
if damaged.
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a) All pipes in the braking system musthave a nominal width of
at least10 mm.
b) The pipes should be installed in sucha way as to permit
proper bleeding,i.e. so that no air cushions candevelop. If you
detect noises whencommencing the braking process,this is an
indication of poor bleeding.
c) When fitting the pipes, make sure thatthere are no areas of
friction.
d) The return lines of the individualcomponents of the braking
systemmust not be combined in one returnline to the tank.
e) Do not use a pipe for the return linesof the dual circuit
brake valve tocombine them in one return line. (Thisis possible
only if Ports 5.1 and 5.2are connected by means of hosesand
combined to form one returnline.)
f) Look for visible leaks in lines andpipes. Leaks are an
indication thatthe 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 thebellows. (This may cause damage tothe bellows.)
h) When working on the braking system,always make the sure that
the system is completely pressureless!
i) Make sure that everything isspotlessly clean!
j) Immediately close all open ports onthe components and on
pipes usingplug!
General Comments
Information for Installation 4.
IMPORTANT !
Even when the engine is switched off or thepump is not running,
the system pressure
will be maintained!
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Information for Installation4.It is particularly important that
thecomponents all have their separatereturn lines since otherwise
the returnpressure can be present in the wheelbrake in the form of
residual pressure.This leads to unnecessary wear of thebrake
linings and excessivetemperatures at the wheel brake and canthus
result in hardening of the linings,and in a failure of the seals on
the wheelbrake cylinders.
When combining the returns of the dualcircuit foot brake valve,
please makesure that hoses are used for connectingthe return ports.
Using a pipe to connectthe two circuits can cause functionaldefects
through distortions in installation.
For very long vehicles with large cylindervolumes, the
installation of relay valvescan be very helpful, reducing
responseand pressure build-up times to aminimum. The relay valve
should befitted as close to the wheel brakecylinders as possible.
Thus the lengths ofthe lines from the accumulator to the
wheel brake cylinders are reduced sincethe foot brake valve only
actuates therelay valves. The input volume of therelay valves is
approx. 1 cm³.
If shut-off valves with an integrated checkvalve are used, an
additionalaccumulator of 0.7 litres needs to bescrewed into the
component. Thatadditional accumulator is primarily usedto monitor
the actual pressure of theother three accumulators and to
reportthem to the shut-off valve. Theaccumulators can be emptied
when thebrakes are operated, without being re-charged since all
circuits are securedfrom each other by the check valves.
Theadditional accumulator will also preventactivation of the
shut-off valve as aconsequence of small leakages and thusa fall in
pressure in the connectionestablished between the check valveseven
though the pressure in theaccumulators of the braking circuit is
stillhigher than 120 bar.
Information for Installation
Capacity of Accumulators The capacity of the
hydraulicaccumulators must be designedaccording to the legal
provisions for theHPB with regard to the size of
energyaccumulators.
We support our customers, free ofcharge, in designing the
accumulators.
For this purpose we require the followinginformation from
you:
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It would further assist us if you couldsend us the data sheet
for the wheelbrake.
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 systemfront axle rear axle
V min cm³ cm³ V max cm³ cm³
Input volume of wheel brake cylinders per axle for actuation of
secondary braking systemfront axle rear axle
V min cm³ cm³V max cm³ cm³
Input volume of spring brake actuator cm³
braking pressuresPressure for secondary braking system
barPressure for service braking system bar
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Legal Requirements5.C HYDRAULIC BRAKING SYSTEMS WITH STORED
ENERGY
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 ofstored energy provided by hydraulic fluid under
pressure shall be equippedwith energy storage devices (energy
accumulators) of a capacity meetingthe 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 aprescribed capacity if the braking system is such that in
the absence of anyenergy reserve it is possible with the service
braking system control toachieve a braking performance at least
equal to that prescribed for thesecondary 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 possibleand, for paragraph 1.2.1., the
rate of full-stroke actuations must be such asto 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 withstored energy shall meet the following requirements:
1.2.1.1. After eight full-stroke actuations of the service
braking system control, itshall still be possible to achieve, on
the ninth application, the performanceprescribed 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 themanufacturer 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 energystorage device(s) for auxiliary equipment shall
be isolated.
1.2.2. Power-driven vehicles equipped with a hydraulic braking
system withstored 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 followingrequirements 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 theninth application, at least the
performance prescribed for the secondarybraking system or, where
secondary performance requiring the use ofstored energy is achieved
by a separate control, it shall still be possibleafter eight
full-stroke actuations to achieve, at the ninth application,
theresidual 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 tothe engine idling speed, any transmission
failure may be induced. Beforeinducing such a failure, the energy
storage device(s) shall be at a pressurethat may be specified by
the manufacturer but not exceeding the cut-inpressure.
ECE Regulation 13 - Annex 7C -
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1.2.2.2.2. The auxiliary equipment and its energy storage
devices, if any, shall beisolated.
2. CAPACITY OF HYDRAULlC FLUID ENERGY SOURCES
2.1. The energy sources shall meet the requirements set out in
the followingparagraphs:
2.1.1. Definitions
2.1.1.1. ”p1“ represents the maximum system operational pressure
(cut-outpressure) 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 servicebrake control, starting at „p1“ without
having fed the energy storagedevice(s).
2.1.1.3. ”t“ represents the time required for the pressure to
rise from p2 to p1 in theenergy storage device(s) without
application of the service braking systemcontrol.
2.1.2. Conditions of Measurement
2.1.2.1. During the test to determine the time t, the feed rate
of the energy sourceshall be that obtained when the engine is
running at the speedcorresponding 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) forauxiliary 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 timet shall not exceed 20 seconds.
2.1.3.2. In the case of vehicles of categories M3, N2 and N3 the
time t shall notexceed 30 seconds.
3. CHARACTERISTICS OF WARNING DEVICES
With the engine stationary and commencing at a pressure that may
bespecified by the manufacturer but does not exceed the cut-in
pressure, thewarning device shall not operate following two
full-stroke actuations of theservice braking system control.
Legal Requirements 5.