TP-0569

Issued 07-07

Issued
1TP-0569
Technical
07-07 Bulletin
Dual System Foot Brake Valve

Technical Bulletin

Hazard Alert Messages Figure 2

#1 #1
Read and observe all Warning and Caution hazard alert messages in DELIVERY SUPPLY
this publication. They provide information that can help prevent 21 11
serious personal injury, damage to components, or both. PUSH-TO-CONNECT
FITTINGS
(O.E. ONLY)
How to Obtain Additional Maintenance
and Service Information 22
#2 #2
12

DELIVERY SUPPLY
If you have any questions about the material covered in this
publication, or for more information about the Meritor WABCO OEM ASSEMBLY (INCLUDES FITTINGS)
product line, please contact the ArvinMeritor Customer Service
#1
Center at 800-535-5560 or visit our website, meritorwabco.com. #1
SUPPLY
DELIVERY
11
21
Description THREADED
PORTS
The Meritor WABCO dual system foot brake valve provides
12 22
graduated control for applying and releasing the brakes. The valve is
#2 #2
mounted on the floor or on the firewall of commercial vehicles DELIVERY
SUPPLY
equipped with air brakes. Ports on the top portion of the valve,
SERVICE UNIT (DOES NOT INCLUDE FITTINGS)
closest to the mounting face, are identified by a two-digit number
4005452f
ending in 1; port identification on the bottom portion of the valve has
a two-digit number ending in 2. Figure 1. Figure 1

NOTE: Service units are available with threaded ports only. Fittings Function
must be added.
Force is applied by the drivers foot, which results in pressurized air
being delivered from the air tanks to the front and rear axle control
valves in order to apply the brakes. By controlling the force applied
by the driver, the air pressure and subsequent stopping
power can be graduated. The valve incorporates two separate
supply and delivery circuits for primary and secondary service
braking. Ports 11 and 21 are connected to the primary or rear brake
circuit. Ports 12 and 22 are connected to the secondary or front
brake circuit. Figure 2.
Figure 3
Removal
TO REAR
BRAKES 1. Wear safe eye protection.
TO FRONT
BRAKES 2. Place blocks under the tires to prevent the vehicle from
moving.

TO PRIMARY
3. Drain the air brake system. Open all of the drain valves on all of
AIR SUPPLY the reservoirs.
4. Identify the ports, tubes and radial orientation of the valve to
TO SECONDARY ensure that the replacement valve is connected correctly. Color
AIR SUPPLY
coded tubing is recommended for new installations. Mark and
4005453c disconnect all air lines from the valve.
Figure 2 5. Remove the capscrews from the brake valve and treadle or
pedal assembly.
Service Procedures 6. Remove the brake valve and treadle or pedal assembly.
Before servicing the Meritor WABCO Dual System Brake Valve,
carefully read and follow all outlined procedures. New Installation or Valve Replacement
1. Cover valve ports and existing tubes to protect them against
WARNING contamination during installation.
To prevent serious eye injury, always wear safe eye protection
2. Ensure the correct fittings are used with the foot brake valve.
when you perform vehicle maintenance or service.
Several vehicle manufacturer customers mount various
combinations of pressed-in push-to-connect fittings. Service
Open drain valves on all reservoirs to remove all pressure from
units are offered with threaded ports only and fittings must be
the air system before you disconnect any component.
added.
Pressurized air can cause serious personal injury.

Park the vehicle on a level surface. Block the wheels to WARNING

prevent the vehicle from moving. Support the vehicle with When installing fittings, ensure that clamping force on the
safety stands. Do not work under a vehicle supported only by valve does not exceed 500 lb (2224.11 N). Excessive force on
jacks. Jacks can slip and fall over. Serious personal injury and the valve may cause binding and could cause loss of braking
damage to components can result. resulting in loss of vehicle control.

Do not spray the foot brake valve with a power washer. 3. Mount the dual circuit foot valve so that the exhaust port is no
Internally frozen water may cause a loss of braking resulting in more than 90 degrees from the down position. The valve is
loss of vehicle control. mounted using three 5/16 or M8 threaded holes or studs. The
part may be attached directly to the floor of the firewall or it
Do not paint the foot brake valve. Paint may impair valve may be attached to an adapter. Install the capscrews that
function and could cause a loss of braking resulting in loss of retain the brake valve to the treadle or pedal assembly. The
vehicle control. assembly torque is 200 10 lb-in (22.6 1.13 Nm). @
4. Install the brake valve and treadle or pedal assembly.
Inspect the pedals or treadles for binding on a regular basis.
Binding can cause a loss of braking resulting in loss of vehicle 5. Connect all air lines to the valve as previously identified.
control.

CAUTION
Do not use alcohol evaporators with this valve. Excessive
alcohol may damage the valve and void the warranty.

TP-0569
Issued 07-07 (16579/22882)
Page 2 Copyright ArvinMeritor, Inc., 2007 Printed in USA
 CAUTION Leakage Test
Tubes for push-to-connect fittings must be cut cleanly and end 1. Apply and hold a high pressure application.
cuts must be perpendicular within seven degrees. Angles and
2. Apply a soap solution to the exhaust port and body of the brake
sharp edges can damage the seal in the fitting.
valve.

WARNING Leakage of a one-inch (25.4 mm) bubble in three seconds

Follow the manufacturers recommendation for the installation is acceptable.
radius of the tubes. Kinked tubes can block the flow of air and Leakage at the tube fittings should not exceed a 1/4-inch
cause a loss of braking resulting in loss of vehicle control. (6.35 mm) bubble in three seconds.

6. When installing the tubes into the push-to-connect fittings, NOTE: Leakage may be caused by contaminants entering the
insert the tubing until it hits a stop in the fitting. valve and lodging in the seal surface. Several full, rapid pedal
7. Follow the manufacturers recommendation for adjusting applications may clear the valve.
pedals or treadles.
3. If the valve does not function as described or if leakage is
8. After installation, perform both the operation and leakage tests. excessive, replace the valve.
Refer to the test instructions in this bulletin.
9. Remove the blocks from the tires. Troubleshooting the Dual System Foot
Brake Valve
Testing
WARNING
Operation Test The foot valve is a critical part of the air brake system. Never
ignore any symptom such as leakage or a change in pedal
Use a test gauge to check the delivery pressure of both the
force. Loss of braking may result.
number 1 and number 2 circuits. Depress the treadle to several
positions between fully released and fully applied. Check that the
Open the drain valves on all reservoirs to remove all pressure
delivered pressure on the gauge varies equally and proportionately
from the air system before you disconnect any component.
with the movement of the brake pedal. The gauge should fall
Pressurized air can cause serious personal injury.
promptly to ZERO after a full application is released.
The secondary delivery pressure is designed to be slightly lower Pedal Force and Travel
than the primary pressure. The differential is indicated on the valve
Inspect the pedals or treadles for binding on a regular basis.
name tag. A designation of BV 550-030 describes a valve with a
Binding can cause a loss of braking.
55 lb (244.65 N) primary crack force and a 3 psi (0.2 bar)
secondary crack pressure. A designation of BV 550-060 describes Check pedals or treadles for excessive pre-travel. Follow the
a valve with a 55 lb (244.65 N) primary crack force and a 6 psi manufacturers recommendation for adjusting pedals or treadles.
(0.4 bar) secondary crack pressure. Check pedal force. If a change in pedal force is detected,
If the valve does not function as described, replace the valve. examine the valve and the pedals carefully.
The pedal arrangement and valve must be free of corrosion,
debris or contamination.
Force to start pressure application of the valve without the
pedal advantage will be 55 10 lb (244.65 44.8 N)
Replace the valve if necessary.

TP-0569
(16579/22882) Issued 07-07
Printed in USA Copyright ArvinMeritor, Inc., 2007 Page 3
Pressure Values
The secondary delivery pressure is designed to be slightly lower
than the primary pressure. The differential is indicated on the
valve name tag. A designation of BV 550-030 describes a valve
with a 55 lb (244.65 N) primary crack force and a 3.0 psi
(0.2 bar) secondary crack pressure. The most common
secondary crack pressure will be 3.0 psi (0.2 bar).

Air Leakage
Inspect the valve and fittings for air leakage on a regular basis.
Internal leaks will generally exit the valve through the exhaust
port on the bottom of the valve. This may be due to
contamination entering the valve and lodging in the seal
surfaces. Make several full, rapid pedal applications. Debris
may be blown out of the valve. If the leak persists, replace the
valve.
Some push-to-connect fittings can be repaired by replacing
the internal O-ring. Contact the truck manufacturer for fitting
repair instructions and components.
Valve leaks at the exhaust port with all brakes released:
Examine the two-way check valves to ensure there is no air
entering the system from another source.
Examine the inversion valve to ensure there is no back flow
into the service control line.
Check the seal in the spring brake for back flow of spring
hold-off pressure through the service port to open the
exhaust on the valve.
Valve leaks at exhaust with foot brake applied:
Replace the valve.
Valve leaks at exhaust with all park brakes set in the park
position and foot brake released:
Replace the valve.

Meritor WABCO Vehicle Control Systems Information contained in this publication was in effect at the time the publication was approved for printing and is subject to
2135 West Maple Road change without notice or liability. Meritor WABCO reserves the right to revise the information presented or to discontinue the
Troy, MI 48084-7121 production of parts described at any time.
800-535-5560
Copyright 2007 TP-0569
meritorwabco.com
ArvinMeritor, Inc. Issued 07-07
All Rights Reserved Printed in USA (16579/22882)