IK0400147

IK0400147 ­ Hydraulic Power Brake cap/grounds diagnostics and repair procedure
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IK0400147
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0
Major System:
BRAKES
Created:
11/28/2016
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1/17/2017
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James
Santos
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Title : Hydraulic Power Brake cap/grounds diagnostics and repair procedure
Applies To : All Hydraulic HPB units
CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
1/17/2017 - Initial Article Release


DESCRIPTION
This document will guide the user through procedures to perform on Wabco HPB to aid in diagnostics and proper
repairs before HCU replacements.
SYMPTOM(s)
Park brake will not release, Multiple ABS fault.
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):
DTC/Light
Description
SPN 2581 FMI 4
Wabco 60-4
Pump motor operates when not expected
SPN 2581 FMI 6
Wabco 60-6
Pump motor operates when not expected
SPN 2581 FMI 10
SPN 2580 FMI 4
SPN 2580 FMI 6
SPN 2580 FMI 10
Wabco 60-10
Wabco 57-4
Wabco 57-6
Wabco 57-10
Extended accumulator charging time
Pump motor operates when not expected
Pump motor operates when not expected
Extended accumulator charging time
Customer Observations or Concerns:
Multiple dash light, Park brake will not release
SPECIAL TOOL(s) / SOFTWARE
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IK0400147 ­ Hydraulic Power Brake cap/grounds diagnostics and repair procedure
Tool Description
Tool Number
Comments
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Instructions
N/A
N/A
SERVICE PARTS INFORMATION
Kit Description
Part Number
Quantity
Notes
Required
N/A
N/A
DIAGNOSTIC STEP(s)
To prevent unexpected movement of the vehicle and possible serious personal injury or death,
park the vehicle on a flat, level surface, set the parking brake, turn the engine off and chock the
wheels to prevent vehicle from moving in both directions.
Step Action
DIAGNOSTIC:
Decision
Yes.
Proceed to step 2
Are any of the faults listed in DTC's section of article present?
#1
Step Action
No. Continue to repair steps.
Decision
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DIAGNOSTIC:
1. Yes
Remove Brake Fluid Reservoir Cap.
Was there a hissing noise when the cap is removed?
Replace the cap and proceed to repair
procedure section of this article.
2. No
#2
Proceed to step 3.
Step Action
DIAGNOSTIC:
Decision
1. Yes
With the cap removed deplete the accumulators using Toolbox Software
Replace the HCU unit and follow repair
diagnostics or by disconnecting the battery or pulling the fuses then press brake steps
pedal minimum of 30 times.
Reconnect the battery or fuses if disconnected and measure the time it takes for
the pumps to run and shut off.
Did the pumps Run longer than 60 seconds?
#3
2. NO
Proceed to step 4
Step Action
Decision
DIAGNOSTIC:
1. YES
Did the pump shut off before 60 seconds and/or did the failure disappear?
Replace Cap and proceed to repair
steps section of this article
#4
4. NO
Contact Meritor Ontrac1-800-535-5560
for further assistance
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REPAIR STEP(s)
1. Locate bulkhead ground studs. Reference Figure 1 highlighted in blue
Figure 1 #: Bulk Head Ground Studs
2. Remove and clean ground connections and terminals.
3. Locate under cab electrical connections clean and inspect. If locks are broken on connectors replace or repair connectors.
Reference Figure 2 highlighted in blue
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IK0400147 ­ Hydraulic Power Brake cap/grounds diagnostics and repair procedure
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FRONT 
Figure # 2: Electrical connections under cab
4. Locate inside ground stud remove clean and inspect Figure 3 highlighted in blue
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Figure # 3: Inside Cab Ground Stud
5. Remove and clean battery connections
6. Remove and clean power feed wires pay close attention to bus fuse replace if needed. Reference Figure 4 highlighted in blue
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Figure # 4: Main Power Feed and Bus Fuse
7. Inspect clean and repair 31 and 2 pin connectors at HCU Reference Figure 5 highlighted in blue
Figure # 5: HCU connections
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8. Inspect SAHR canister connections. If terminals are damaged or corroded replace connecter and terminals Reference Figure
6 highlighted in blue
Figure # 6: SAHR Connections
9. If park brake faults are present follow adjustment and operational checks in TSI–08–04–01
10. After repairs are complete wiggle test connections while ignition key is on test drive vehicle and make certain no other faults
present in ECU
WARRANTY INFORMATION
Warranty Claim Coding:
NA
Standard Repair Time(s):
Refer to the SRT Manual for Repair Times
OTHER RESOURCES
http://www.meritorwabco.com/literature/Hydraulic-Power-Brake
Master Service Information Site
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Copyright © 2017 Navistar, Inc.
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