Brake System (KENR8395-13)

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2017/06/29 Brake System (KENR8395-13)
SMCS - 4250 i07081432
PIP
Personal injury or death can result from sudden machine
movement.
- 1
Sudden movement of the machine or release of air pressure or
202 085
oil pressure can cause injury to persons on or near the machine.
To help prevent possible injury before testing and adjusting any
2 3
air system or hydraulic system, perform the procedure in the
13: /12/2 253

Testing and Adjusting, "General Information" section.
0
KE :17- 6 1
©2 N R 0 3
Do not check for leaks with your hands. Pin hole (very small)
839 :00
leaks can result in a high velocity oil stream that will be invisible
close to the hose. This oil can penetrate the skin and cause
0
personal injury. Use cardboard or paper to locate pin hole leaks.
Cat 2 C2 5
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Con pilla terpi
NOTICE a
fide r: llar
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with
ntia Inc
suitable containers before opening any compartment or
disassembling any component containing fluids.
lG .
Refer to Special Publication, PERJ1017, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain
ree
fluids on Cat® products.
n
Dispose of all fluids according to local regulations and
mandates.
Make sure that the transmission is in the NEUTRAL position. Stop the engine. Perform a visual inspection before you troubleshoot a problem.
Refer to Testing and Adjusting, Visual Inspection  . During the visual checks, use a magnet to separate ferrous particles (iron and steel) from
nonferrous particles (aluminum, rubber, and paper).
Note: If any particles are found during any visual checks, all components of the hydraulic system and of the brake cooling system must be cleaned.
Do not use any damaged parts. Damaged parts must be replaced with new parts.
Refer to the following publications for more information:
Operation and Maintenance Manual
Systems Operation/Testing and Adjusting, "Hydraulic System"
Troubleshooting The Braking System

Terminology
https://sis2.cat.com/#/print-preview/service/%257B%2522title%2522%253A%2522Brake%2520System%2520(KENR8395-13)%2522%252C%2522formattedPublicationDate%2522%253A%25222017%252F06%25… 1/29
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Illustration 1 g03485153
Typical Cat® Electronic Technician (Cat® ET) data log
(A) Time between charges is the time from cut out pressure (3) to cut in pressure (1), usually 25 to 45 seconds
(1) Cut-In Pressure of 14479 kPa (2100 psi) is the minimum accumulator pressure while the system is cycling
(2) Stand by Pressure of 1034 kPa (150 psi) is the lowest pressure that the pump will produce during the cycle
(B) Charge time is the time the pump is charging the accumulator, typically less than 10 seconds
(3) Cut-Out Pressure of 20684 kPa (3000 psi) is the maximum accumulator pressure while the system is cycling
The information in Illustration (1) is a data trace from a Cat® Electronic Technician (Cat® ET) data log. The data trace includes service brake
accumulator pressure, secondary brake accumulator pressure, and brake pump pressure. The combined information is a typical brake charge
cycle. The terminology in the caption helps diagnose brake system issues.
Using Cat ET
Parameter setting screen in Cat ET
1. Install Cat ET to the machine. Select the following channels to record data on:
Brake pump pressure
Secondary brake accumulator pressure
Service brake accumulator pressure
2. Take a Cat ET data log file of the system. Sample the system at 240 samples per minute.
3. Start the machine. Run the machine at LOW idle and record data for 5 minutes.
4. Open the data log file and select the channels. Select the "OK" button.
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Typical view
A Cat ET data log file
5. Click the settings button (6) in the lower left-hand corner.
A view of the setting using the data log viewer
6. Type zeros in the "Y min" column (7). Type 3200.00 in the "Y max" column (8). Select "OK" button (9).
Symptom/Fault Code: Frequent Brake Charging for the Parking and Secondary
Brake Accumulators
Problem: Time From Cutout to Cut-in Shorter Than Normal (Less Than 60 Seconds). Measured With Machine in Park and without the
Application of the Retarder or Service Brakes With Machine at Operating Temperature.
Possible Component Non-Component Root
How to Diagnose Corrective Action
Root Causes Causes
Apply and release the parking brake. Brake pressure Service with new diverter valve for
Diverter Valve for the
should be within tolerance. If the pressure is unstable, the parking and secondary brake.
Parking and Secondary Contamination
ensure that the system cleanliness is ISO 18/15 or Make sure that oil is ISO 18/15 or
Brake
better. better.
Apply and release the parking brake. Brake pressure Service with new parking brake
Parking Brake Solenoid should be within tolerance. If the pressure is unstable, solenoid valve.
Contamination
Valve ensure that the system cleanliness is ISO 18/15 or Make sure that oil is ISO 18/15 or
better. better.
Service with new solenoid valve for
Solenoid Valve for
Check to see if both primary and secondary purging the brake accumulators.
Purging the Brake Contamination
accumulator pressures are dropping rapidly. Make sure that oil is ISO 18/15 or
Accumulators
better.
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If pressure is high, replace defective

parking brake solenoid valve or
diverter valve for the parking and
Apply parking brake and measure the pressure at the
Brake Pack (Seal secondary brake.
Overpressurization brake packs. All four pressures should be within
Damage) Replace if one or more brake packs
tolerance.
are significantly lower than the
others.
Inspect for seal damage.
Check to see if the AETA self test is working properly.
Ensure that the left and right rear parking brake Service with new TCS/AETA valve.
TCS/AETA Valve Contamination pressure increases and decreases smoothly. If one Make sure that oil is ISO 18/15 or
side does not cycle, then inspect and repair the AETA better.
valve.
Service with new check valve
Check Valve (Parking Clean around the check valve. (parking brake accumulator).
Contamination
Brake Accumulator) Remove and inspect for damage. Make sure that oil is ISO 18/15 or
better.
Tow Motor Check Valve The pressure at the hoist pilot pressure tap will be
Contamination Replace Check Valve.
Stuck Open equal to secondary Accumulator pressure.
Service Brake
Low pre-charge or oil on Measure the pre-charge. If pre-charge does not hold a
Accumulator or Parking
gas side of piston Watch to see which accumulator is cycling rapidly. charge, replace the accumulator.
Brake Accumulators
Table 1
Symptom/Fault Code: Service Brake/Retarder Pressure Too High

Problem: Service Brake and Retarder Actuation Pressure Out of Specifications
Possible
Non-Component
Component Root How to Diagnose Corrective Action
Root Causes
Causes
Perform brake system pressure check. The pressure at the slack adjuster Service with new kit for
Diverter Valve Contamination should be 240 ± 35 kPa (35 ± 5 psi) less than the brake pedal pilot the diverter valve
(Front/Rear Service Out of Adjustment pressure. (service brakes).
Brake) (XLP only) If the spring bias on the diverter valves is too low, the brake pressure will Make sure that oil is
be high. ISO 18/15 or better.
Service with new pedal
Perform brake system pressure check. The brake pedal pilot pressure valve.
Brake Pedal Valve Contamination
must be within specification. Make sure that oil is
ISO 18/15 or better.
Perform brake system pressure check. If the pedal pilot pressure and Service with new ARC
Solenoid Valves
relay spring bias is correct, but the brake pressure with manual retarder solenoid valve.
(Automatic Retarder Contamination
and/or ARC pressure is not, then there may be an issue with front or rear Make sure that oil is
Control)
ARC solenoid. ISO 18/15 or better.
Slack Adjustor Stuck / Only flowing oil through make up piston in slack adjustor. Brake pressure
Contamination Replace Slack adjustor.
sticking may be high or unstable for 2-8 seconds.
Table 2
Symptom/Fault Code: Service Brake and Retarder Pressure Too Low

Problem: Service Brake and Retarder Actuation Pressure Out of Specifications
Possible
Non-Component
Root Causes
Causes
Replace if one or more
Apply retarder and service brakes independently and measure the brake packs are
Brake Pack (Seal Over
pressure at the brake packs. All four pressures should be within significantly lower than the
Damage) pressurization
tolerance. others.
Service with kit for the
Perform brake system pressure check. The pressure at the slack
Diverter Valve Contamination diverter valve (service
adjuster should be 240 ± 35 kPa (35 ± 5 psi) less than the brake pedal
(Front/Rear Service Out of Adjustment brakes).
pilot pressure. If the spring bias on the relay valves is too high, the
Brakes) (XLP only) Make sure that oil is ISO
brake pressure will be low.
18/15 or better.
Service with new pedal
Perform brake system pressure check. The brake pedal pilot pressure valve.
Brake Pedal Valve Contamination
must be within specifications. Make sure that oil is ISO
18/15 or better.
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Perform brake system pressure check. If the pedal pilot pressure and Service with New ARC
Front/Rear ARC relay spring bias is correct, but the brake pressure with manual retarder solenoid valve.
Contamination
Solenoid Valves or ARC pressure is not, then there may be an issue with front or rear Make sure that oil is ISO
ARC solenoid. 18/15 or better.
Table 3
Symptom/Fault Code: Parking Brake Pressure Too High

Problem: Parking Brake Actuation Pressure Out of Specifications
Possible Component Root Non-Component
Causes Root Causes
Relief valve Stuck open Contamination Brake Pump at Relief pressure Replace or reset Relief Valve.
Service with new diverter valve for
Diverter Valve for the Parking the parking and secondary brake.
Contamination
and Secondary Brake Make sure that oil is ISO 18/15 or
Perform brake system pressure check. The brake better.
pedal pilot pressure must be within specification. Service with new parking brake
Parking Brake Solenoid solenoid valve.
Contamination
Valve Make sure that oil is ISO 18/15 or
better.
Table 4
Symptom/Fault Code: Parking Brake Pressure Too Low

Problem: Parking Brake Actuation Pressure Out of Specifications
Possible Component Non-Component
Root Causes Root Causes
Service with new diverter
Diverter Valve for the valve for the parking and
Parking and Contamination secondary brake.
Secondary Brake Make sure that oil is ISO
Perform brake system pressure check. The brake pedal pilot 18/15 or better.
pressure must be within specification.
Service with new parking
Solenoid Valve for the brake solenoid valve.
Contamination
Parking Brake Make sure that oil is ISO
18/15 or better.
Replace if one or more
Over Apply parking brake and measure the pressure at the brake packs. brake packs are significantly
Brake Pack
pressurization All four pressures should be within tolerance. lower than the others.
Check to see if the "AETA" self test is working properly. Ensure that Service with new "AETA"
the left and right rear parking brake pressure increases and valve.
"AETA/TCS" Valve Contamination
decreases smoothly. If one side does not cycle, then inspect and Make sure that oil is ISO
repair the "AETA" valve. 18/15 or better.
Table 5
Symptom/Fault Code: Hoist Pilot Pressure Too High

Problem: Hoist Pilot Pressure Out of Specifications
Possible Component Root Non-Component
Causes Root Causes
Tow Motor Check Valve The pressure at the hoist pilot pressure tap will
Contamination Replace Check Valve.
Stuck Open be equal to secondary Accumulator pressure.
Hoist Pressure Reducing Adjust and/or replace hoist pressure
N/A Check hoist pilot pressure.
Valve (Incorrect Setting) reducing valve if not within tolerance.
Table 6
Symptom/Fault Code: Hoist Pilot Pressure Too Low

Problem: Hoist Pilot Pressure Out of Specifications
Check for excessive leakage. Plug the TCS pilot port
Excessive Leakage in TCS Inspect the "AETA/TCS" Valve for
Contamination on the brake manifold. Check to see if the pilot
Pilot damage.
pressure returns to an acceptable value.
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Check for excessive leakage. Plug the hoist pilot port

Excessive Leakage in Hoist Inspect the Hoist Valves for
Contamination on the brake manifold. Check to see if the pilot
Valve damage.
pressure returns to an acceptable value.
Excessive Leakage on Replace any damaged seal, or
BCD Solenoid and TCS N/A Check for seal damage. replace the BCD solenoid valve or
Pilot Valve the TCS pilot valve.
Adjust and/or replace hoist pressure
Hoist Pressure Reducing May be low due to incorrect setting or may have
Contamination reducing valve if not within
Valve drifted low due to wear.
tolerance.
FL1 Hoist Pilot Screen
Contamination Remove screen and inspect. Replace Screen if plugged.
Plugged
Table 7
Symptom/Fault Codes
If the machine experiences brake system-related problems, the on-board VIMS system will display one (or more) of the following error codes:
Event Identifier (EID) Codes for 793F, 795F AC, and 797F Off-Highway Trucks
EID Level Description

86-89 3 Brakes Dragging
525 3 High Brake Pump Pressure Event
526 3 Brake Pump Pressure Not Responding to Command
527 (2),(3) High Brake Pump Command
528 2, 3 Service Brake Accumulator Pressure Not Responding
652 2, 3 Low Service Brake Accumulator Pressure
653 2, 3 Low Secondary Brake Accumulator Pressure
660 2, 3 Secondary Brake Accumulator Pressure Not Responding
716 3 Conflicting Brake Pressure Information
1443 2 Brake Accumulator Pressure Charging Rapidly
Table 8
Symptom/Fault Code: High Brake Pump Pressure Event EID 525 (3)
Refer to Systems Operation, KENR8738 , "Control Valve (Brake)" for the locations of the components in the table below.
Problem: EID 525 High Brake Pump Pressure Event is active if the brake pump pressure is greater than 20685 kPa (3000 psi)for more
than 90 seconds.
Component How to Diagnose Corrective Action
Contamination: Open circuit/short to ground fault codes
Brake system oil logged in Cat ET. Measure coil resistance Replace Solenoid Valve
significantly dirtier when cool 20° C (68° F). The resistance (Brake Pump Unloader)
than ISO 18/15 should be close to 32 ± 2 ohms. (12).
Stuck Closed: Measure actual brake pump
pressure. Install 35000 kPa (5000 psi)
gauge on brake pump pressure tap. Brake
Valve improperly installed Harness connector pump pressure at 22408 ± 345 kPa
causing screen damage not locked in place (3250 ± 50 psi) relief pressure constantly.
Locking tab broken Remove the access plug for OR1. Install a
on mating 35000 kPa (5000 psi) gauge. Pressure at
Partially stuck closed connector. OR1 is the same as (stuck closed)
Make sure that oil is ISO
18/15 or better. If more than
two ISO codes high, kidney
Solenoid Valve loop machine and change
(Brake Pump Bent or damaged solenoid Remove solenoid and visually inspect filter. If kidney loop not
Unloader) (12) valve. screen for damage. available, change oil.
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pressure. Install 35000 kPa (5000 psi)
gauge on brake pump pressure tap. Brake
pump pressure at 22408 ± 348 kPa
(3250 ± 50 psi) relief pressure constantly. Replace Unloader Valve.
Make sure that oil is ISO
Remove the access plug for OR1. Install a 18/15 or better. If more than
Contamination: 35000 kPa (5000 psi) gauge. Pressure at two ISO codes high, kidney
Brake system oil OR1 is less than (stuck closed) brake pump loop machine and change
significantly dirtier pressure. filter. If kidney loop not
Stuck Closed
Unloader Valve than ISO 18/15 available, change oil.
Increase Relief Valve (Main)
(13) pressure setting.
Replace Relief Valve (Main)
(13).
Drifting Low: Measure actual brake pump
pressure. Install 35000 kPa (5000 psi) Make sure that oil is ISO
gauge on brake pump pressure tap. Brake 18/15 or better. If more than
Contamination: pump pressure below Brake Accumulator two ISO codes high, kidney
Pressure Setting Drifting Brake system oil cut out pressure ( 20684 kPa (3000 psi)). loop machine and change
Relief Valve Low causing a stalled significantly dirtier Low Idle Charging may stall or charge time filter. If kidney loop not
(Main) (13) charge than ISO 18/15 be extended. available, change oil.
Harness connector With machine off, verify that the sensors are
not locked in place reading less than 517 kPa (75 psi).
Failed In Range / Stuck at Install 35000 kPa (5000 psi) gauge on the
one pressure (sensor tells brake accumulator pressure taps to verify
Brake ECM to continue to charge that the accumulator pressure matches the
Accumulator when in fact the sensor Locking tab broken gauge pressure. With machine running at
Pressure should be telling the ECM on mating low idle check to see if the gauge matches Replace Brake Accumulator
Sensors to cut out) connector. the sensor in Cat ET. Pressure Sensors.
Install 35000 kPa (5000 psi) gauge on the
brake accumulator pressure taps to verify
that the accumulator pressure matches the
Brake Pump gauge pressure. With machine running at
Pressure Failed In Range / Stuck at Locking tab broken low idle check to see if the gauge matches Replace Brake Pump
Sensors one pressure on mating connector. the sensor in Cat ET. Pressure Sensors.
Orifice plug loose Remove OR1 Access plug and inspect.
Measure actual brake pump pressure. Install
35000 kPa (5000 psi) gauge on brake pump Remove OR1 Plug and
pressure tap. Brake pump pressure at basket screen from port.
22408 ± 345 kPa (3250 ± 50 psi) relief Replace O-ring on plug and
OR1 Orifice seal damaged. pressure constantly. reinstall.
Remove filter element and inspect for
damage and loose pieces of yellow plastic.
System Remove and inspect Accumulator purge Contact product support
Filter Element Damaged on Installation Overheating solenoid screens for debris. through the DSN.
Table 9
Symptom/Fault Code: Brake Pump Not Responding EID 526 (3)
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Tools to help diagnose issue: Cat ET data log, VIMS snapshot, etc.
Problem: EID 526 Brake Pump Pressure Not Responding to Command is active if the engine is running, and the brake system is
commanding a charge, and pump pressure is less than 2100 kPa (305 psi) for more than 3 seconds.
Possible
Non-Component
Component Component Root How to Diagnose Corrective Action
Root Causes
Causes
Hook up Cat ET and compare the time from
Unloader Status changes to how fast the
Contamination: Brake brake pump pressure rises. If the pressure
Seal Damaged system oil significantly rises too slowly, the valve could have an Replace Solenoid Valve (Brake
causing leaking. dirtier than ISO 18/15 internal failure. Pump Unloader) (12).
Valve improperly
installed causing
screen damage
Stuck Open: Measure actual brake pump
pressure. Install 35000 kPa (5000 psi) gauge
on brake pump pressure tap. Brake pump
Slow to close pressure at standby constantly.
Remove the access plug for OR1. Install a
35000 kPa (5000 psi) gauge. Pressure at OR1
Partially stuck is less than (stuck open) brake pump Make sure that oil is ISO 18/15
open pressure. or better. If more than two ISO
Solenoid Valve codes high, kidney loop machine
(Brake Pump Bent or damaged Remove solenoid and visually inspect screen and change filter. If kidney loop
Unloader) (12) solenoid valve. for damage. not available, change oil.
brake pump pressure rises. If the pressure
rises too slowly, the valve could have an
internal failure. Replace Unloader Valve.
is the same as (stuck open) brake pump
Stuck Open pressure.
on brake pump pressure tap. Brake pump Make sure that oil is ISO 18/15
pressure at standby constantly. or better. If more than two ISO
Contamination: Brake codes high, kidney loop machine
system oil significantly Remove valve and visually inspect to and change filter. If kidney loop
Unloader Valve Slow to Close dirtier than ISO 18/15 determine if valve stuck open not available, change oil.
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Replace Relief Valve (Main)

Stuck Open (13).
Make sure that oil is ISO 18/15
Stuck Open: Measure actual brake pump or better. If more than two ISO
Contamination: Brake pressure. Install 35000 kPa (5000 psi) gauge codes high, kidney loop machine
Relief Valve system oil significantly on brake pump pressure tap. Brake pump and change filter. If kidney loop
(Main) (13) dirtier than ISO 18/15 pressure at low pressure constantly. not available, change oil.
Orifice Plugged Remove OR1 Access plug and inspect.
Remove the access plug for OR1. Install a Remove OR1 Plug and basket
35000 kPa (5000 psi) gauge. See if pressure screen from port. Flush orifice
OR1 Orifice is slow to build in the OR1 Port and reinstall
With machine off, verify that the sensors are
reading less than 517 kPa (75 psi).
brake accumulator pressure taps to verify that
the accumulator pressure matches the gauge
Brake Pump Failed In Range / pressure. With machine running at low idle
Pressure Stuck at one check to see if the gauge matches the sensor Replace Brake Pump Pressure
Sensors pressure in Cat ET. Sensors.
Screen Plugged Remove OR1 Access plug and inspect.
OR1 Orifice 35000 kPa (5000 psi) gauge. See if pressure screen from port. Flush orifice
Basket Screen is slow to build in the OR1 Port and reinstall
Remove filter element and inspect for damage
and loose pieces of yellow plastic. Remove
Damaged on and inspect Accumulator purge solenoid Contact product support through
Filter Element Installation System Overheating screens for debris. the DSN.
Table 10
Symptom/Fault Code: High Brake Pump Command EID 527 (2),(3)
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(E) Poor charge time
(15) Poor stability
(F) Good charge time
(16) Good stability
Problem: EID 527 (2) High Brake Pump Command is active if the engine is running, and the brake system is charging for more than 90
seconds without cutting out.
Problem: EID 527 (3) High Brake Pump Command is active if the engine is running, and the brake system is charging for more than 300
seconds without cutting out.
Possible
Non-Component
Component Component How to Diagnose Corrective Action
Root Causes
Root Causes
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Contamination: Brake Open circuit/short to ground fault codes logged in

system oil Cat ET. Measure coil resistance when cool 20° C
Seal Damaged significantly dirtier (68° F). The resistance should be close to 32 ± 2 Replace Solenoid Valve (Brake
causing leaking. than ISO 18/15 ohms. Pump Unloader) (12).
pressure. Install 35000 kPa (5000 psi) gauge on
Valve improperly brake pump pressure tap. Brake pump pressure
installed causing Harness connector at 22408 ± 345 kPa (3250 ± 50 psi) relief
screen damage not locked in place pressure constantly.
brake pump pressure tap. Brake pump pressure
at standby constantly.
35000 kPa (5000 psi) gauge. Pressure at OR1 is Make sure that oil is ISO 18/15
Partially stuck Locking tab broken the same as (stuck closed) or less than (stuck or better. If more than two ISO
open or closed on mating connector. open) brake pump pressure. codes high, kidney loop
Solenoid Valve machine and change filter. If
(Brake Pump Bent or damaged Remove solenoid and visually inspect screen for kidney loop not available,
Unloader) (12) solenoid valve. damage. change oil.
brake pump pressure tap. Brake pump pressure
at 22408 ± 345 kPa (3250 ± 50 psi) relief
pressure constantly. Replace Unloader Valve.
35000 kPa (5000 psi) gauge. Pressure at OR1 is
Stuck Open or the same as (stuck open) or less than (stuck
Closed closed) brake pump pressure.
pressure. Install 5000psi gauge on brake pump Make sure that oil is ISO 18/15
pressure tap. Brake pump pressure at standby or better. If more than two ISO
Contamination: Brake constantly. codes high, kidney loop
system oil machine and change filter. If
significantly dirtier Remove valve and visually inspect to determine if kidney loop not available,
Unloader Valve Seal damage than ISO 18/15 valve stuck open change oil.
Increase Relief Valve (Main)
Stuck Open: Measure actual brake pump (13) pressure setting.
brake pump pressure tap. Brake pump pressure Replace Relief Valve (Main)
Stuck Open at low pressure constantly. (13).
Drifting Low: Measure actual brake pump Make sure that oil is ISO 18/15
pressure. Install 35000 kPa (5000 psi) gauge on or better. If more than two ISO
Pressure Setting Contamination: Brake brake pump pressure tap. Brake pump pressure codes high, kidney loop
Drifting Low system oil below Brake Accumulator cut out pressure ( machine and change filter. If
Relief Valve causing a stalled significantly dirtier 20685 kPa (3000 psi)). Low Idle Charging may kidney loop not available,
(Main) (13) charge than ISO 18/15 stall or charge time be extended. change oil.
Contamination: Brake
system oil
significantly dirtier
than ISO 18/15
Pumping over relief
Poor Volumetric valve for an extended If you cannot reach cutout at low idle, this may be
Brake Pump Efficiency period > 90 seconds a sign that the pump efficiency is too low. Replace Brake Pump.
Install 35000 kPa (5000 psi) gauge on the brake
Brake accumulator pressure taps to verify that the
Accumulator Failed In Range / accumulator pressure matches the gauge
Pressure Stuck at one Locking tab broken pressure. With machine running at low idle check Replace Brake Accumulator
Sensors pressure on mating connector. to see if the gauge matches the sensor in Cat ET. Pressure Sensors.
Replace Solenoid Valve Gp
(Brake Accumulator Purge)
Short to Battery Short To Battery Fault Code (14)
or better. If more than two ISO
Solenoid Valve Contamination: Brake codes high, kidney loop
Gp (Brake system oil If you cannot reach cutout at low idle and both machine and change filter. If
Accumulator significantly dirtier accumulators cycle rapidly, then the valve could kidney loop not available,
Purge) (14) Stuck Open than ISO 18/15 be stuck open. change oil.
Incorrectly Contamination: Brake
Check Valve installed in place system oil
(Hoist Pilot of tow motor significantly dirtier Verify arrow on hex of check valve is flowing in
Check) check. than ISO 18/15 the correct direction. Properly install check valve.
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Incorrectly Contamination: Brake

installed in place system oil
Check Valve (Tow of hoist pilot significantly dirtier Verify arrow on hex of check valve is flowing in
Motor Check) check. than ISO 18/15 the correct direction. Properly install check valve.
and loose pieces of yellow plastic. Remove and
Damaged on inspect Accumulator purge solenoid screens for Contact product support
Filter Element Installation System Overheating debris. through the DSN.
Table 11
Symptom/Fault Code: Service Brake Accumulator Not Responding EID 528 (2, 3)
Problem: EID 528 Service Brake Accumulator Pressure Not Responding is active if the engine is running, and the brake system is
commanding a charge, and service accumulator is less than 11032 kPa (1600 psi) for more than 60.5 seconds. Level 3 is the same with
the addition of machine is moving.
Possible
Non-Component
Root Causes
Root Causes
Contamination: Brake Unloader Status changes to how fast the brake
Seal Damaged system oil significantly pump pressure rises. If the pressure rises too Replace Solenoid Valve (Brake
causing leaking. dirtier than ISO 18/15 slowly, the valve could have an internal failure. Pump Unloader) (12).
Valve improperly
installed causing
screen damage
pressure at standby constantly.
Remove the access plug for OR1. Install a Make sure that oil is ISO 18/15
Partially stuck 35000 kPa (5000 psi) gauge. Pressure at OR1 or better. If more than two ISO
open is less than (stuck open) brake pump pressure. codes high, kidney loop
(Brake Pump Bent or damaged Remove solenoid and visually inspect screen kidney loop not available,
Unloader) (12) solenoid valve. for damage. change oil.
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Unloader Status changes to how fast the brake
pump pressure rises. If the pressure rises too
slowly, the valve could have an internal failure. Replace Unloader Valve.
on brake pump pressure tap. Brake pump or better. If more than two ISO
pressure at standby constantly. codes high, kidney loop
Contamination: Brake machine and change filter. If
system oil significantly Remove valve and visually inspect to determine kidney loop not available,
Unloader Valve Seal Damaged dirtier than ISO 18/15 if valve stuck open or for seal damage change oil.
on brake pump pressure tap. Brake pump Replace Relief Valve (Main)
Stuck Open pressure at low pressure constantly. (13).
pressure. Install 35000 kPa (5000 psi) gauge Make sure that oil is ISO 18/15
Pressure Setting pressure below Brake Accumulator cut out codes high, kidney loop
Drifting Low Contamination: Brake pressure ( 20685 kPa (3000 psi)). Low Idle machine and change filter. If
Relief Valve causing a stalled system oil significantly Charging may stall or charge time be kidney loop not available,
(Main) (13) charge dirtier than ISO 18/15 extended. change oil.
35000 kPa (5000 psi) gauge. See if pressure is screen from port. Flush orifice
OR1 Orifice slow to build in the OR1 Port and reinstall
Brake the accumulator pressure matches the gauge
Accumulator Failed In Range / pressure. With machine running at low idle
Pressure Stuck at one check to see if the gauge matches the sensor in Replace Brake Accumulator
Sensors pressure Cat ET. Pressure Sensors.
Screen plugged Remove OR1 Access plug and inspect.
OR1 Orifice 35000 kPa (5000 psi) gauge. See if pressure is screen from port. Flush orifice
Basket Screen slow to build in the OR1 Port and reinstall
system oil significantly
dirtier than ISO 18/15
Pumping over relief
Poor Volumetric valve for an extended If you cannot reach cutout at low idle, this may
Brake Pump Efficiency period > 90 seconds be a sign that the pump efficiency is too low. Replace Brake Pump.
Solenoid Valve codes high, kidney loop
Gp (Brake Contamination: Brake If you cannot reach cutout at low idle and both machine and change filter. If
Accumulator system oil significantly accumulators cycle rapidly, then the valve could kidney loop not available,
Purge) (14) Stuck Open dirtier than ISO 18/15 be stuck open. change oil.
Table 12
Symptom/Fault Code: Low Service Brake Accumulator Pressure EID 652 (2, 3)
21/12/2022 10:06 SIS 2.0
Problem: EID 652 Low Service Brake Accumulator Pressure is active if the engine has been running for 10 seconds, the truck has been
in gear for 2.5 seconds, and Accumulator pressure is less than 12300 kPa (1784 psi) for more than 2.5 seconds. Level 3 is the same
with the addition of machine is moving.
Possible
Non-Component
Root Causes
Root Causes
Valve improperly
installed causing
screen damage
Slow to Close pressure at standby constantly.
35000 kPa (5000 psi) gauge. Pressure at
Partially stuck OR1 is less than (stuck open) brake pump Make sure that oil is ISO 18/15 or
open pressure. better. If more than two ISO codes
Solenoid Valve high, kidney loop machine and
(Brake Pump Bent or damaged Remove solenoid and visually inspect screen change filter. If kidney loop not
Unloader) (12) solenoid valve. for damage. available, change oil.
OR1 is the same as (stuck open) brake
Stuck Open pump pressure.
pressure at standby constantly. Make sure that oil is ISO 18/15 or
better. If more than two ISO codes
Contamination: Brake Remove valve and visually inspect to high, kidney loop machine and
system oil significantly determine if valve stuck open or for seal change filter. If kidney loop not
Unloader Valve Slow to Close dirtier than ISO 18/15 damage available, change oil.
21/12/2022 10:06 SIS 2.0

35000 kPa (5000 psi) gauge. See if pressure screen from port. Flush orifice and
OR1 Orifice is slow to build in the OR1 Port reinstall
Brake Failed In Range / gauge pressure. With machine running at low
Accumulator Stuck at one idle check to see if the gauge matches the Replace Brake Accumulator
Pressure Sensors pressure sensor in Cat ET. Pressure Sensors.
OR1 Orifice 35000 kPa (5000 psi) gauge. See if pressure screen from port. Flush orifice and
Basket Screen is slow to build in the OR1 Port reinstall
Damaged on Remove and inspect Accumulator purge Contact product support through
Filter Element Installation System Overheating solenoid screens for debris. the DSN.
Pumping over relief If you cannot reach cutout at low idle, this
Poor Volumetric valve for an extended may be a sign that the pump efficiency is too
Brake Pump Efficiency period > 90 seconds low. Replace Brake Pump.
Short to Battery Short To Battery Fault Code (Brake Accumulator Purge) (14)
Make sure that oil is ISO 18/15 or
Solenoid Valve Gp better. If more than two ISO codes
(Brake Contamination: Brake If you cannot reach cutout at low idle and high, kidney loop machine and
Accumulator system oil significantly both accumulators cycle rapidly, then the change filter. If kidney loop not
Purge) (14) Stuck Open dirtier than ISO 18/15 valve could be stuck open. available, change oil.
Leaking Accumulator Follow Accumulator Gas Charging Recharge Accumulator to
Low Pre-charge Gas Valve Procedure specifications
Hook up hose to charge valve and let the oil
drain into a bucket. Start the truck and let the
Oil Trapped in the accumulator piston push the oil into the Replace or rebuild the
Gas side of the bucket. There should not be more than a cup accumulator if too much oil is
Accumulator accumulator Failed piston seals of oil. leaking past the piston seals.
Table 13
Symptom/Fault Code: Low Secondary Brake Accumulator Pressure EID 653 (2, 3)
Problem: EID 653 Low Secondary Brake Accumulator Pressure is active if the engine has been running for 10 seconds, the truck has
been in gear for 2.5 seconds, and Accumulator pressure is less than 12300 kPa (1784 psi) for more than 2.5 seconds. Level 3 is
machine is moving and Secondary Brake Accumulator Pressure is less than 6900 kPa (1001 psi) for 2.5 seconds.
Possible
Non-Component
Root Causes
Root Causes
21/12/2022 10:06 SIS 2.0

Valve improperly
installed causing
screen damage
Slow to Close pressure at standby constantly.
Partially stuck OR1 is less than (stuck open) brake pump Make sure that oil is ISO 18/15 or
open pressure. better. If more than two ISO codes
Solenoid Valve high, kidney loop machine and
(Brake Pump Bent or damaged Remove solenoid and visually inspect screen change filter. If kidney loop not
Unloader) (12) solenoid valve. for damage. available, change oil.
OR1 is the same as (stuck open) brake
Stuck Open pump pressure.
pressure at standby constantly. Make sure that oil is ISO 18/15 or
better. If more than two ISO codes
Contamination: Brake Remove valve and visually inspect to high, kidney loop machine and
system oil significantly determine if valve stuck open or for seal change filter. If kidney loop not
Unloader Valve Slow to Close dirtier than ISO 18/15 damage available, change oil.
35000 kPa (5000 psi) gauge. See if pressure screen from port. Flush orifice and
OR1 Orifice is slow to build in the OR1 Port reinstall
Brake Failed In Range / gauge pressure. With machine running at low
Accumulator Stuck at one idle check to see if the gauge matches the Replace Brake Accumulator
Pressure Sensors pressure sensor in Cat ET. Pressure Sensors.
OR1 Orifice 35000 kPa (5000 psi) gauge. See if pressure screen from port. Flush orifice and
Basket Screen is slow to build in the OR1 Port reinstall
Damaged on Remove and inspect Accumulator purge Contact product support through
Filter Element Installation System Overheating solenoid screens for debris. the DSN.
Pumping over relief If you cannot reach cutout at low idle, this
Poor Volumetric valve for an extended may be a sign that the pump efficiency is too
Brake Pump Efficiency period > 90 seconds low. Replace Brake Pump.
Short to Battery Short To Battery Fault Code (Brake Accumulator Purge) (14)
Make sure that oil is ISO 18/15 or
Solenoid Valve Gp better. If more than two ISO codes
(Brake Contamination: Brake If you cannot reach cutout at low idle and high, kidney loop machine and
Accumulator system oil significantly both accumulators cycle rapidly, then the change filter. If kidney loop not
Purge) (14) Stuck Open dirtier than ISO 18/15 valve could be stuck open. available, change oil.
21/12/2022 10:06 SIS 2.0
Leaking Accumulator Follow Accumulator Gas Charging Recharge Accumulator to

Low Precharge Gas Valve Procedure specifications
Hook up hose to charge valve and let the oil
drain into a bucket. Start the truck and let the
Oil Trapped in the accumulator piston push the oil into the Replace or rebuild the
Gas side of the bucket. There should not be more than a cup accumulator if too much oil is
Accumulator accumulator Failed piston seals of oil. leaking past the piston seals.
Table 14
Symptom/Fault Code: Secondary Brake Accumulator Pressure Not Responding EID

660 (2, 3)
Problem: EID 660 Secondary Brake Accumulator Pressure Not Responding is active if the engine is running, and the brake system is
commanding a charge, and secondary accumulator pressure is less than 11032 kPa (1600 psi) for more than 60.5 seconds. Level 3 is
the same with the addition of machine is moving.
Possible
Non-Component
Root Causes
Root Causes
Contamination: Brake Unloader Status changes to how fast the brake
Seal Damaged system oil significantly pump pressure rises. If the pressure rises too Replace Solenoid Valve (Brake
causing leaking. dirtier than ISO 18/15 slowly, the valve could have an internal failure. Pump Unloader) (12).
Valve improperly
installed causing
screen damage
pressure at standby constantly.
Remove the access plug for OR1. Install a Make sure that oil is ISO 18/15
Partially stuck 35000 kPa (5000 psi) gauge. Pressure at OR1 or better. If more than two ISO
open is less than (stuck open) brake pump pressure. codes high, kidney loop
(Brake Pump Bent or damaged Remove solenoid and visually inspect screen kidney loop not available,
Unloader) (12) solenoid valve. for damage. change oil.
21/12/2022 10:06 SIS 2.0

Unloader Status changes to how fast the brake
pump pressure rises. If the pressure rises too
slowly, the valve could have an internal failure. Replace Unloader Valve.
pressure at standby constantly. codes high, kidney loop
Contamination: Brake machine and change filter. If
system oil significantly Remove valve and visually inspect to determine kidney loop not available,
Unloader Valve Seal Damaged dirtier than ISO 18/15 if valve stuck open or for seal damage change oil.
on brake pump pressure tap. Brake pump Replace Relief Valve (Main)
Stuck Open pressure at low pressure constantly. (13).
pressure. Install 35000 kPa (5000 psi) gauge Make sure that oil is ISO 18/15
Pressure Setting pressure below Brake Accumulator cut out codes high, kidney loop
Drifting Low Contamination: Brake pressure ( 20685 kPa (3000 psi)). Low Idle machine and change filter. If
Relief Valve causing a stalled system oil significantly Charging may stall or charge time be kidney loop not available,
(Main) (13) charge dirtier than ISO 18/15 extended. change oil.
35000 kPa (5000 psi) gauge. See if pressure is screen from port. Flush orifice
OR1 Orifice slow to build in the OR1 Port and reinstall
reading less than 75psi.
Brake the accumulator pressure matches the gauge
Accumulator Failed In Range / pressure. With machine running at low idle
Pressure Stuck at one check to see if the gauge matches the sensor in Replace Brake Accumulator
Sensors pressure Cat ET. Pressure Sensors.
OR1 Orifice 35000 kPa (5000 psi) gauge. See if pressure is screen from port. Flush orifice
Basket Screen slow to build in the OR1 Port and reinstall
Pumping over relief
Poor Volumetric valve for an extended If you cannot reach cutout at low idle, this may
Brake Pump Efficiency period > 90 seconds be a sign that the pump efficiency is too low. Replace Brake Pump.
Solenoid Valve codes high, kidney loop
Gp (Brake Contamination: Brake If you cannot reach cutout at low idle and both machine and change filter. If
Accumulator system oil significantly accumulators cycle rapidly, then the valve could kidney loop not available,
Purge) (14) Stuck Open dirtier than ISO 18/15 be stuck open. change oil.
Table 15
Symptom/Fault Code: Frequent Brake Charging for the Service Brake Accumulator
EID 1443 (2)
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A Cat ET data log file showing poor time between charges
(C) 3 seconds between charges
A Cat ET data log file showing good time between charges
(D) 38 seconds between charges
(10) Secondary pressure does not fall off
Look at the data trace shown in Illustration 14 to determine which system the leakage is coming from. Illustration 14 shows that the leak is
somewhere in the service brake side of the system. The secondary pressure does not fall off and primary is the one triggering cut in. Look for leaks
in the primary accumulator side of the system.
21/12/2022 10:06 SIS 2.0
Problem: EID 1443 Time From Cutout to Cut-in is Shorter Than Normal (Less Than 25 Seconds). Measured With Machine in Park
Without the Application of Retarder or Service Brakes With Machine at Operating Temperature.
Apply retarder and service brakes independently, measure
Service with kit for diverter valve
PIP
Diverter Valve (Front that pressure at the brake packs, all four pressures should
(service brakes).
Service Brake) (Seal Contamination be within tolerance. Pressure should fall to less than
Damage or Stuck Open) 103 kPa (15 psi). If pressure does not fall, then the valve
-
or better.
1
may be stuck open.
202 085
Solenoid Valve (Front Service with new ARC solenoid
that pressure at the brake packs, all four pressures should
Automatic Retarder valve.
2 3
Contamination be within tolerance. Pressure should fall to less than
13: /12/2 253

Control) (Seal Damage or Make sure that oil is ISO 18/15
103 kPa (15 psi). If the pressure does not, then the valve
Stuck open) or better.
may be stuck open.
0
1
Solenoid Valve (Rear Service with new ARC solenoid
6
that pressure at the brake packs, all four pressures should
:
Automatic Retarder valve
KE 17-
Contamination be within tolerance. Pressure should fall to less than
Control) (Seal Damage or Make sure that oil is ISO 18/15
103 kPa (15 psi). If the pressure does not, then the valve
Stuck open) or better
N
may be stuck open.
©2 R 0 3
Service with new solenoid valve
839 :00
Solenoid Valve for Purging
for purging the brake
the Brake Accumulators Check to see if both primary and secondary accumulator
Contamination accumulators.
(Seal Damage or Stuck pressures are dropping rapidly.
0
Cat 22 C 5
open)
or better.
Hoist Pressure Reducing Service with new hoist pressure
Measure the hoist pilot pressure and verify that the
e
Valve (Seal Damage, Seat reducing valve.
a
Contamination pressure is to specification and is stable. If the valve is
r
Con pilla terpi
Wear, Unstable pressure Make sure that oil is ISO 18/15
unstable, verify system cleanliness.
output) or better.
Solenoid Valve for the Service with new BCD solenoid.
fide r: llar
Clean around the solenoid valve.
Brake Cooling Diverter (If Contamination Make sure that oil is ISO 18/15
Remove solenoid valve and inspect for damage.
equipped) or better.
TCS Pilot Diverter (Seal

ntia Inc
Clean around the diverter valve.
Service with new TCS pilot
diverter.
.
N/A
Damage) Remove diverter valve and inspect for damage. Make sure that oil is ISO 18/15
lG or better.
ree
Check Valve for the Service Service with new check valve.
Clean around the check valve.
Brake Accumulator (Seal Contamination Make sure that oil is ISO 18/15
Remove check valve and inspect for damage.
n
Damage or Stuck open) or better.
Apply retarder and service brakes independently. Measure
Replace pedal valve.
Brake Pedal Valve (Stuck the pressure that goes into the control valve (brake).
Contamination Make sure that oil is ISO 18/15
open) Pressure should fall to 0 kPa (0 psi). If the pressure does
or better.
not, then the valve may be stuck open.
If pressure is high, replace
defective pilot valve, if one or
Apply retarder and service brakes independently and
Brake Pack (Seal more brake packs are
Over-pressurization measure the pressure at the brake packs. All four
Damage) significantly lower than the
pressures should be within tolerance.
others.
Service Brake Accumulator Low pre-charge or If pre-charge does not hold a
Measure the precharge.
or Parking Brake oil on gas side of charge, replace the
Watch to see which accumulator is cycling rapidly.
Accumulators piston accumulator.
Table 16
Check: Check the Oil level in the hydraulic tank.
21/12/2022 10:06 SIS 2.0
(1) Sight gauge for the hoist and brake cooling
(2) Sight gauge for the brake actuation oil
Check the oil level in the hydraulic tank. Look for air or water in sight gauge (1) and sight gauge (2). Add oil to the hydraulic tank, if necessary. See
the Operation and Maintenance Manual for the correct type of oil.
Note: The oil levels in the hydraulic tank need to be checked with the body lowered.
Problem: There is an indication of water in the oil.

Probable Cause
(3) Rear brake oil cooler
(4) Front brake oil cooler
(5) Optional front brake oil cooler (if equipped)
Failure of the rear brake oil cooler (3)
Failure of either front brake oil cooler (4) or front brake oil cooler (5)
Problem: There is an indication of air in the oil.

Probable Cause
There is leakage in the oil lines. See "Check: Check for oil leakage.".
Problem: The oil level is too low.
Final drive plug
Probable Cause
There is leakage in the oil lines. See "Check: Check for oil leakage.". Add oil before you perform any tests.
Brake cooling oil may leak into the final drive. Check the oil level in each final drive.
21/12/2022 10:06 SIS 2.0
Check: Check for oil leakage.

Inspect all oil lines, all hoses, and all connections for damage or for leaks. Look for oil on the ground under the machine.
Note: If oil can leak out of a fitting or out of a connection, air can enter the system. Air in the system can be as harmful as having too little oil.
Check: Check the oil filter for brake actuation oil.
(1) Oil filter for the brake actuation oil
(2) Bypass switch for the brake actuation
Remove oil filter (1) for the brake actuation oil. Inspect oil filters (1) for foreign material. Cut the oil filter open, if necessary.
Note: Oil filter (1) for the brake actuation oil has an oil bypass valve. The bypass valve allows the oil to bypass the oil filter elements whenever the
pressure difference between the inlet oil and the outlet oil becomes too high. Any oil that does not flow through the filter element goes directly into
the hydraulic circuit. Dirty oil can cause sticking valves and restrictions in valve orifices. Bypass switch (2) will notify the operator of a restriction.
Problem: Rubber particles are found.

Probable Cause
Seal failure
Hose failure
Problem: Shiny steel particles are found.

Probable Cause
Mechanical failure of brake actuation pump section
Check: Check the oil filter for the hoist and brake cooling oil.
Oil filter for the brake cooling oil
(1) Oil filter for the hoist and brake cooling oil
(2) Bypass switch
21/12/2022 10:06 SIS 2.0
Remove oil filter (1) for the hoist and brake cooling oil. Inspect oil filter (1) for foreign material. Cut the filter open, if necessary.
Note: Oil filter (1) for the hoist and brake cooling oil has an oil bypass valve. The bypass valve allows the oil to bypass the oil filter element or the
screen whenever the pressure difference between the inlet oil and the outlet oil becomes too high. Any oil that does not flow through the filter
element or through the screen goes directly into the hydraulic circuit. Dirty oil can cause sticking valves and restrictions in valve orifices. Bypass
switch (2) will notify the operator of a restriction.

Probable Cause
Seal failure
Hose failure

Probable Cause
Mechanical failure of gear pump for the hoist and for the brake cooling system
Refer to "Check: Check the screens for the brake oil coolers.".
Check: Check the screens for the brake oil coolers.
(1) Screen for the rear brake oil cooler (if equipped)
(2) Screen for the front brake oil coolers (if equipped)
(3) Screen for the front and rear oil coolers (if equipped)
Remove screen (1), screen (2), or screen (3) brake cooling oil. Inspect the screens for foreign material or for restrictions.

Probable Cause
Seal failure
21/12/2022 10:06 SIS 2.0
Hose failure

Probable Cause
(3) Gear pump for the brake cooling system
Mechanical failure of gear pump (3) for the brake cooling system
Check: Check inside the hydraulic tank.
Side view of the hydraulic tank
(1) Brake cooling motor
(2) Check valves
(3) Screens
(4) Brake cooling pumps
(5) Drain port for the hoist and brake section of the hydraulic tank
(6) Drain port for the steering section of the hydraulic tank
Drain the oil from the hydraulic tank at drain port (5) for the section of the hydraulic tank that is for the hoist and brake. Inspect the bottom of the
hydraulic tank for debris. Remove the hoses from the back of the hydraulic tank to remove return screens (3) and clean the screens.

Probable Cause
21/12/2022 10:06 SIS 2.0
Seal failure
Hose failure

Probable Cause
(9) Gear pump for the brake cooling system
Mechanical failure of the brake actuation pump section
Mechanical failure of the gear pump for the hoist and for the brake cooling system
Mechanical failure of gear pump (9) for brake cooling system
Problem: Pieces of black fiber are found. These pieces are part of the brake disc.
Probable Cause
Failure of the wheel brakes.
Problem: Shiny steel particles and/or chrome particles are found.

Probable Cause
There is a mechanical failure of a hydraulic cylinder and/or of a cylinder rod. Inspect the cylinder rods for scoring.
Troubleshooting for Brake Oil Overheating

If an overheating condition in the hydraulic system occurs, the operator will probably become aware of the overheating condition through the
Advisor.
21/12/2022 10:06 SIS 2.0
(1) Brake oil temperature gauge
(2) Display for the Advisor
The Advisor receives signals from temperature sensors. At each of the four brakes, there is a temperature sensor that senses the temperature of
the oil. Brake oil temperature gauge (1) will display this sensor input.
(A) Temperature reading of 110°C (230°F)
(B) Temperature reading of 124°C (255°F)
Check brake oil temperature gauge (1) regularly. During this test sequence, do not allow the temperature of the brake oil to get too hot. Heat can
cause damage to the brakes.
When the oil temperature is too hot for the current conditions, Advisor (2) will alert the operator. An event will be displayed on the display for
Advisor (2). If the brake oil is too hot, reduce the load on the machine or slow the machine speed. Also, downshift the transmission to a lower
speed. For extra cooling, park the truck in a convenient location. Put the transmission in NEUTRAL, and run the engine at approximately 1500 rpm.
Symptom/Fault Code: Service Brakes Dragging/Overheating EID 86-89 (25,3)

Problem: Brake Cooling Temperature Too High (Above 120° C (248° F))
Possible
Non-Component
Root Causes
Causes
Unloader tank spikes Refer to Table 11 in the
Unloader System Back pressure from Refer to Table 11 in the "Symptom/Fault Code: High Brake Pump "Symptom/Fault Code: High
Failure high pump command Command EID 527 (2),(3)" Section. Brake Pump Command EID 527
fault (2),(3)" Section.
Check brake system pressure to ensure that pressure upstream Service with new kit for the
Diverter Valve
of the slack adjustor drops to 0 kPa (0 psi) in less than 1 second diverter valve (service brakes).
(Front Service Contamination
with normal operating conditions. If the pressure takes more than Make sure that oil is ISO 18/15
Brake)
1 second to decay, then the valves may not be shifting properly. or better.
21/12/2022 10:06 SIS 2.0
Check brake system pressure to ensure that pressure upstream Service with new kit for the
Diverter Valve (Rear of the slack adjustor drops to 0 kPa (0 psi) less than 1 second diverter valve (service brakes).
Contamination
Service Brake) with normal operating conditions. If the pressure takes more than Make sure that oil is ISO 18/15
Check brake system pressure to ensure that pressure upstream Service with new ARC solenoid
Solenoid valve Contamination
of the slack adjustor drops to 0 kPa (0 psi) in less than 1 second valve.
(Front Automatic Minimum current set
Retarder Control) too high
Check brake system pressure to ensure that pressure upstream Service with new ARC solenoid
Solenoid valve Contamination
of the slack adjustor drops to 0 kPa (0 psi) in less than 1 second valve.
(Rear Automatic Minimum current set
Retarder Control) too high
Perform residual pressure check. If the residual pressure is Service Slack adjustor.
Slack Adjustor N/A higher than specification, then there may be a problem with the Make sure that oil is ISO 18/15
slack adjustor. or better.
Ensure that pedal is clean and
Check brake system pressure to ensure that pressure upstream
Contamination free of debris.
of the slack adjustor drops to 0 kPa (0 psi) in less than 1 second
Brake Pedal Valve Debris under heal Service with New Pedal Valve.
with normal operating conditions. If the pressure takes more than
stop of pedal. Make sure that oil is ISO 18/15
1 second to decay, then the valves may not be shifting properly.
or better.
Table 17
Symptom/Fault Code: Parking Brakes Dragging/Overheating EID 239 (2) / 240 (2)
Problem: Brake Cooling Temperature Too High (Above 120° C (248° F))
Possible Component Non-Component Root
Root Causes Causes
Unloader tank spikes Refer to Table 11 in the
Unloader System and/or back pressure from Refer to Table 11 in the "Symptom/Fault Code: High Brake "Symptom/Fault Code: High
Failure high pump command Pump Command EID 527 (2),(3)" Section Brake Pump Command EID
fault 527 (2),(3)" Section
Check to see if the "AETA" self test is working properly.
Service with New "AETA" valve.
Ensure that the left and right rear parking brake pressure
TCS On/Off Valve Contamination Make sure that oil is ISO 18/15
increases and decreases smoothly. If one side does not
or better.
cycle, then inspect and repair the AETA valve.
Check to see if the "AETA" self test is working properly.
Service with new "AETA" valve.
TCS Proportional Contamination Ensure that the left and right rear parking brake pressure
Valve Set too low increases and decreases smoothly. If one side does not
or better.
cycle, then inspect and repair the AETA valve.
Check brake system pressure to ensure that pressure at Service with new diverter valve
Diverter Valve for the the brake pack drops to 0 kPa (0 psi) in less than 1 second for the parking and secondary
Parking and Secondary Contamination with normal operating conditions. If the pressure takes brake.
Brake more than 1 second to decay, then the valves may not be Make sure that oil is ISO 18/15
shifting properly. or better.
Check brake system pressure to ensure that pressure at Service with new solenoid
Solenoid Valve for the the brake pack drops to 0 kPa (0 psi) in less than 1 second valve for the parking and
Parking and Secondary Contamination with normal operating conditions. If the pressure takes secondary brake.
Brake more than 1 second to decay, then the valves may not be Make sure that oil is ISO 18/15
shifting properly. or better.
Perform manual brake wear
Glycol in the oil Check to see if the tolerance/stack up is OK.
check.
Brake Pack Tolerance Check to see if the coolers are leaking, or if the coolant is
Check for glycol in the oil
Stack up incorrect low.
sample.
With machine off, verify that the sensors are not reading
Left and Right
any pressure.
Pressure Sensors for Replace pressure sensors for
N/A With Parking Brake released, the TCS valve pressure on
the Traction Control the TCS valve
the sensors and the TCS valve pressure on the gauges
System Valve
should match.
Table 18
Problem: The oil temperature is hot.

The oil temperature is too hot according to brake oil temperature gauge (1). Advisor (2) is alerting the operator of high brake oil temperature.
Probable Cause
The truck is being operated improperly.
Reference: See the Operation and Maintenance Manual for the correct operating techniques of the brake and retarder system.
21/12/2022 10:06 SIS 2.0
Operate the machine again. Make sure that engine rpm does not drop below 1700 rpm. This level ensures that enough oil flows through the brake
oil coolers to keep the oil at normal operating temperature.
Problem: The oil temperature is hot on a properly operated machine.

The oil temperature is too hot according to brake oil temperature gauge (1) and Advisor (2) after the truck is operated correctly. Advisor (2) can
display an event about the brake oil temperature.
Probable Cause
There is a restriction in the oil cooling system. Refer to the Braking System Testing and Adjusting, "Brake Cooling Pressure - Check". Also,
use a flow meter to determine if there is proper brake cooling oil flow.
One of the following pumps has failed: The gear pump for the hoist and for the brake cooling, the piston motor that drives the brake cooling
pump, or the brake cooling pump. Refer to this publication to check the appropriate filters or screens.
The pressure setting of the rear brake oil cooler relief valve is too low. Refer to the Braking System Testing and Adjusting, "Relief Valve
(Brake Oil Cooler) - Test and Adjust".
The pressure setting of the front brake oil cooler relief valve is too low. Refer to the Braking System Testing and Adjusting, "Relief Valve
(Brake Oil Cooler) - Test and Adjust".
Brake drag that can be caused by high command of the brake pump.
Conflicting Brake Pressure Information 716 (3)

Problem: Conflicting Brake Pressure Information
Possible Non-
Component Root Component How to Diagnose Corrective Action
Causes Root Causes
Key OFF. Purge brake Accumulators. Key ON and compare all three brake
Replace suspect
Secondary brake sensors. The pressures should read close to 0 kPa () psi). Start machine and
Spikes in sensor or repair
accumulator recharge the brake accumulators. Monitor the three sensors while charging the
Hydraulic hydraulic circuit.
pressure sensor accumulators. The brake pump and accumulators should increase at the same
system Confirm pressure
has failed rate. If one sensor of the three does not match the other two sensors, that sensor
readings with a gauge.
or hydraulic circuit needs investigated.
Replace suspect
Service brake sensors. The pressures should read close to 0 kPa () psi). Start machine and
Spikes in sensor or repair
accumulator recharge the brake accumulators. Monitor the three sensors while charging the
Hydraulic hydraulic circuit.
pressure sensor accumulators. The brake pump and accumulators should increase at the same
system Confirm pressure
has failed rate. If one sensor of the three does not match the other two sensors, that sensor
Replace suspect
sensors. The pressures should read close to 0 kPa () psi). Start machine and
Brake pump Spikes in sensor or repair
recharge the brake accumulators. Monitor the three sensors while charging the
pressure sensor Hydraulic hydraulic circuit.
accumulators. The brake pump and accumulators should increase at the same
failed system Confirm pressure
rate. If one sensor of the three does not match the other two sensors, that sensor
Table 19
This code activates when there is a difference between the Service Brake Accumulator Pressure and the Secondary Brake Accumulator Pressure.
This code occurs when the difference in pressure exceeds 2345 kPa (340 psi) threshold, with the Brake Pump Pressure above Cut-Out, over 5
charging cycles, with the Engine running.
If this Event occurs while the Machine is in operation, perform the following tasks:
Park the Machine
Shut down the Machine safely
Turn the key to the ON position (Key ON), (Engine OFF)
The Brake ECM should create a Data Drifted High diagnostic for either the Service Brake Accumulator Pressure Sensor or the Secondary
Brake Accumulator Pressure Sensor.
The user should then follow the troubleshooting procedure for which ever diagnostic pops up.
PIP-10853253
2022/12/21
12:59:44-03:00
i03635327
21/12/2022 10:06 SIS 2.0
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Brake System (KENR8395-13)

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21/12/2022 10:06 SIS 2.

2017/06/29 Brake System (KENR8395-13)

SMCS - 4250 i07081432

To help prevent possible injury before testing and adjusting any

13: /12/2 253

Refer to the following publications for more information:

Operation and Maintenance Manual

Systems Operation/Testing and Adjusting, "Hydraulic System"

Troubleshooting The Braking System

Brake pump pressure

Secondary brake accumulator pressure

Service brake accumulator pressure

If pressure is high, replace defective

Symptom/Fault Code: Service Brake/Retarder Pressure Too High

Symptom/Fault Code: Service Brake and Retarder Pressure Too Low

Symptom/Fault Code: Parking Brake Pressure Too High

Symptom/Fault Code: Parking Brake Pressure Too Low

Symptom/Fault Code: Hoist Pilot Pressure Too High

Symptom/Fault Code: Hoist Pilot Pressure Too Low

Check for excessive leakage. Plug the hoist pilot port

EID Level Description

Stuck Closed: Measure actual brake pump

Symptom/Fault Code: Brake Pump Not Responding EID 526 (3)

Replace Relief Valve (Main)

Symptom/Fault Code: High Brake Pump Command EID 527 (2),(3)

Contamination: Brake Open circuit/short to ground fault codes logged in

Incorrectly Contamination: Brake

Hook up Cat ET and compare the time from

Orifice Plugged Remove OR1 Access plug and inspect.

Hook up Cat ET and compare the time from

Leaking Accumulator Follow Accumulator Gas Charging Recharge Accumulator to

Symptom/Fault Code: Secondary Brake Accumulator Pressure Not Responding EID

Hook up Cat ET and compare the time from

13: /12/2 253

TCS Pilot Diverter (Seal

Check: Check the Oil level in the hydraulic tank.

Problem: There is an indication of water in the oil.

Failure of the rear brake oil cooler (3)

Problem: There is an indication of air in the oil.

Problem: The oil level is too low.

Check: Check for oil leakage.

Check: Check the oil filter for brake actuation oil.

Problem: Rubber particles are found.

Problem: Shiny steel particles are found.

Mechanical failure of brake actuation pump section

Problem: Rubber particles are found.

Problem: Shiny steel particles are found.

Check: Check the screens for the brake oil coolers.

Problem: Rubber particles are found.

Problem: Shiny steel particles are found.

Check: Check inside the hydraulic tank.

Problem: Rubber particles are found.

Problem: Shiny steel particles are found.

Mechanical failure of the brake actuation pump section

Mechanical failure of gear pump (9) for brake cooling system

Failure of the wheel brakes.

Problem: Shiny steel particles and/or chrome particles are found.

Troubleshooting for Brake Oil Overheating

Symptom/Fault Code: Service Brakes Dragging/Overheating EID 86-89 (25,3)

Problem: The oil temperature is hot.