WABCO 461 307 User manual

1/5
© 2004 American Standard Companies Inc. All rights reserved. 461 307 961 3/01.2005
Test instruction
Prior to testing read carefully the safety instruc-
tions.
Safety Instructions
Testing the device on the test bench is to be made
only by qualified personnel with a specific system
knowledge.
Always start testing only after you have read and un-
derstood all information required for testing.
Test the device only on a calibrated test bench.
In case of doubt, use test values specified by the ve-
hicle manufacturer.
While testing the device implicitly observe this test
instruction.
Comply with internal as well as national accident
prevention regulations.
Unlock screws, hoses and equipment parts only
when the respective lines of the test bench are vent-
ed.
Test instruction for device 461 307 ... 0
Symbols and signal terms
Possible danger: Any non-compliance can result in severe
personal injuries or death.
Possible danger: Any non-compliance can result in minor or me-
dium severe personal injuries.
– Handling
• Enumeration
Instructions, explanations, information, tips
Gauge indication
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WARNING CAUTION
200 207 216 350 516
202 208 250 370 520
204 211 254 500 521
WARNING
CAUTION
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461 307
1/2
Brake Valve
with pedal

2/5 © 2004 American Standard Companies Inc. All rights reserved. 461 307 961 3/01.2005
Fig. 1 + 2 Brake valve 461 307 ... 0, functional symbol
Necessary equipment/tools
• Test Bench 435 197 000 0 or an adequate
testing equipment
• Adequate equipment:
• for clamping the brake valve,
• for actuating the pedal with ° graduation.
Additional documents:
(see www.wabco-auto.com => INFORM)
• Test Values 2/2:
to be found by entry of the product number in
INFORM
• Test Bench - Operating Instructions:
435 197 000 0
• General Repair and Test Hints:
820 001 074 3 (de)
820 001 075 3 (en)
820 001 076 3 (es)
820 001 077 3 (fr)
820 001 078 3 (it)
Check sequence
Perform test procedure as per specified se-
quence
Find test values P1 to P12 and G1 to G6 in
document "test values 2/2".
Reservoir pressure is 8.0 bar max. / 7.0 bar
min.
Before starting any test ensure that cut-off cocks are
in their correct normal position (see table 1).
Table 1: Normal position of cut-off cocks on the test bench
1. External evaluation
– Inspect device for external visible damage.
– Check all ports of the device for free passage
by visual inspection.
2. Preparations
2.1 Adjustment arrangement of brake valves
– Assemble the brake valve except for the inser-
tion of fully assembled graduating piston and
the flange of the whole actuation.
– Measure dimensions a and b (see fig. 3), di-
mension C = b - a .
Fig. 3 Dimension C
– Adjust dimension d = C + 0,8 mm in the gradu-
ating piston by turning the set screw (see fig.
4).
Fig. 4 Dimension d (Device with one rubber spring)
– Counter set screw by turning the hexagon nut
(see fig. 4).
The adjustment levels off also at devices with
longer graduation travel (two rubber springs),
see fig. 5.
Fig. 5 Dimension d (Device with two rubber springs)
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Cock A B C D F L V 23467 11 12 21 22
on x x x
off xxxxxx xxxxx x x
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CAUTION
a
b
C
C = b - a
d
set screw
hexagon nut
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hexagon nut
d = C + 0,8
d
set screw
Brake Valve
with pedal
461 307
1/2

3/5
© 2004 American Standard Companies Inc. All rights reserved. 461 307 961 3/01.2005
– Assemble the device.
– Fix device in clamping
equipment.
– Connect device to test
bench ports (see fig. 6).
Fig. 6 Test bench ports
Make sure that plug-in connections on test bench
and device are safely plugged.
– Close one of the port 21 and 22 with screw
plug M 22x1.5.
3. Check tightness
Never install an untightened brake valve on the ve-
hicle.
3.1 Exhaust
From a non-actuated device no air must ex-
ceed from the exhaust.
– Vent ports 11 and 12 with P1.
– Fully operate device several times.
– Wait until excess pressure has decreased.
- Check exhaust of the device for tightness.
No leakages admissible.
3.2 Complete device
– Fix measuring scale to device.
0-position of the pedal means 0-position
of the graduation at the same time.
– Adjust pedal to G1 (stop within device).
Gauges 3 and 4 must indicate P2.
– Cover complete device with soap and check
tightness.
No leakages admissible.
With soap bubbling the device is not tight.
– Re-adjust pedal to 0°.
Gauges 3 and 4 must indicate 0 bar.
4. Obtain maximum pressure
– Adjust pedal to G1 (stop within device).
Pressure must increase immediately.
Gauges 3 and 4 must indicate P2.
– Re-adjust pedal to 0°.
Gauges 3 and 4 must indicate 0 bar.
5. Adjust pedal
– Adjust stop screw for the pedal without clear-
ance.
The stem must not execute any stroke
movement at the same time.
– Counter stop screw with M = 20 Nm.
Fig. 7 Position of stop screw in the device
6. Graduability
In all pressure scopes incremental steps of
max. 0.3 bar must be possible.
7. Check pressure increase
– Operate pedal several times.
Gauges 3 and 4 must indicate immediate
pressure increase resp. decrease.
In accordance with the type of device, one cir-
cuit must have predominance.
7.1 Check sudden pressure increase
– Adjust pedal to G2.
Gauge 3 must indicate P3.
Gauge 4 must indicate P4.
7.2 Distance until venting of P5/P6
– Adjust pedal to G3.
Gauge 3 must indicate P5.
Gauge 4 must indicate P6.
1234
11 21
22
12
CAUTION
WARNING
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Stop Screw Stem
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461 307
1/2
Brake Valve
with pedal

4/5 © 2004 American Standard Companies Inc. All rights reserved. 461 307 961 3/01.2005
7.3 Adjust predominance
Carry out test step only on variants 250 and
254.
The exact adjustement can be done by inser-
tion or removing of compensation washers.
Use washers with the following composition:
Material: Steel
Surface protection: gal Zn 6 c yellow
– Adjust exact pressure with the cap (see fig. 8).
Clockwise rotation: pressure increase
Counter-clockwise rotation: pressure de-
crease
Fig. 8 Position of cap in the device
– Counter cap by turning the hexagon nut.
– Adjust pedal to G3.
Gauge 3 must indicate P5.
Gauge 4 must indicate P6.
– Re-adjust pedal to 0°.
Gauges 3 and 4 must indicate 0 bar.
– Adjust pedal to G4.
Gauge 3 must indicate P7.
Gauge 4 must indicate P8.
7.4 Check predominance
– Adjust pedal to G3.
Gauge 3 must indicate P5.
Gauge 4 must indicate P6.
7.5 Distance until venting of P9/P10
– Adjust pedal to G5.
Pressure must increase immediately.
Gauge 3 must indicate P9.
Gauge 4 must indicate P10.
7.6 Distance until venting of P11/P12
– Adjust pedal to G6.
Pressure must increase immediately.
Gauge 3 must indicate P11.
Gauge 4 must indicate P12.
7.7 Distance until venting of P2
– Adjust pedal to G1 (stop within device).
Pressure must increase immediately.
Gauges 3 and 4 must indicate P2.
– Re-adjust pedal to 0°.
Gauges 3 and 4 must indicate 0 bar.
8. Circuit failure
8.1 Failure of circuit 1
– Vent port 11 to 0 bar.
Gauge 1 must indicate 0 bar.
– Adjust pedal to G1.
Gauge 3 must indicate 0 bar.
Gauge 4 must indicate P2.
– Re-adjust pedal to 0°.
Gauges 3 and 4 must indicate 0 bar.
– Vent port 11 with P1.
8.2 Failure of circuit 2
– Vent port 12 to 0 bar.
– Adjust pedal to G1.
Gauge 3 must indicate P2.
Gauge 4 must indicate 0 bar.
– Re-adjust pedal to 0°.
Gauges 3 and 4 must indicate 0 bar.
Washer (approx. 0.4
bar pressure
changement)
Diameter: 25 cm
Thickness: 4 cm
Washer (approx. 0.05
bar pressure
changement)
Diameter: 25 cm
Thickness: 0.5 cm
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Cap
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Brake Valve
with pedal
461 307
1/2

5/5
© 2004 American Standard Companies Inc. All rights reserved. 461 307 961 3/01.2005
9. Completion of test
– Vent port 11 to 0 bar.
Gauges 1 and 2 must indicate 0 bar.
Disconnect pipe connections only after having ex-
hausted the device to 0 bar before.
– Remove device from fixture.
– Cleaning device.
CAUTION
461 307
1/2
Brake Valve
with pedal