Service Information System Page 1 of 6

Troubleshooting
793F and 797F Off-Highway Trucks Braking System
Media Number -KENR8395-09 Publication Date -01/11/2014 Date Updated -11/07/2017

i07081715

E527 High Brake Pump Command

SMCS - 4014-035
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Illustration 1 g02433236
Tools to help diagnose issue: Cat® ET data log,

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Illustration 2 g02433262
A Cat® ET data log file
(E) Poor charge time
(15) Poor stability

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Illustration 3 g02433264

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A Cat® ET data log file

(F) Good charge time
(16) Good stability

Refer to Systems Operations, KENR8738, "Control Valve (Brake)" for the locations of the
components in the table below.

Table 1
Problem: EID 527 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.
Possible Non-
Corrective
Component Component Component How to Diagnose
Action
Root Causes Root Causes
Contamination: Open circuit/short to ground
Replace
Seal Brake system fault codes logged in ET.
Solenoid
Damaged oil Measure coil resistance when
Valve (Brake
causing (significantly) cool 20° C (68° F). The
Pump
leaking. dirtier than ISO resistance should be close to
Unloader).
18/15 32 +/- 2 ohms.
Stuck Closed: Measure
Valve actual brake pump pressure.
improperly Install 35000 kPa (5000 psi)
Harness
installed gauge on brake pump
connector not
Solenoid causing pressure tap. Brake pump Make sure
locked in place
Valve (Brake screen pressure at 22408 ± 345 kPa that oil is ISO
Pump damage (3250 ± 50 psi) relief 18/15 or
Unloader) pressure constantly. better. If more
than 18/15,
Remove the access plug for
kidney loop
OR1. Install a 35000 kPa
machine and
(5000 psi) gauge. Pressure at
change filter.
OR1 is the same as pump
If kidney loop
discharge pressure, replace
not available,
solenoid valve.
change oil.
Bent or
Remove solenoid and
damaged
visually inspect screen for
solenoid
damage.
valve.
Pumping over relief valve for an extended period > 90 seconds
Valve(Brake Stuck Open Contamination: Stuck Closed: Measure
Pump or Closed Brake system actual brake pump pressure.
Unloader) oil Install 35000 kPa (5000 psi) Replace
(significantly) gauge on brake pump Valve (Brake
dirtier than ISO pressure tap. Brake pump Pump
18/15 pressure at 22408 ± 345 kPa Unloader).
(3250 ± 50 psi) relief
pressure constantly.

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Remove the access plug for

OR1. Install a 35000 kPa
(5000 psi) gauge. Pressure at Make sure
OR1 is less than brake pump that oil is ISO
pressure, replace Valve. 18/15 or
better. If more
Stuck Open: Measure actual
than 18/15,
brake pump pressure. Install
kidney loop
35000 kPa (5000 psi) gauge
machine and
on brake pump pressure tap.
change filter.
Seal damage Brake pump pressure at
If kidney loop
standby constantly.
not available,
Remove valve and visually change oil.
inspect to determine if valve
stuck open
Increase
Stuck Open: Measure actual Relief Valve
brake pump pressure. Install (Main)
35000 kPa (5000 psi) gauge pressure
Stuck Open setting.
on brake pump pressure tap.
Brake pump pressure at low Replace
pressure constantly. Relief Valve
Contamination:
(Main).
Brake system
Relief Valve oil Make sure
(Main) (significantly) Drifting Low: Measure
that oil is ISO
dirtier than ISO actual brake pump pressure.
18/15 or
18/15 Install 35000 kPa (5000 psi)
Pressure better. If more
gauge on brake pump
Setting than 18/15,
pressure tap. Brake pump
Drifting Low kidney loop
pressure below Brake
causing a machine and
Accumulator cut out pressure
stalled charge change filter.
( 20684 kPa (3000 psi)). Low
If kidney loop
Idle Charging may stall or
not available,
charge time be extended.
change oil.
Brake Pump Poor Contamination: If you cannot reach cutout at Replace
Volumetric Brake system low idle, the pump efficiency Brake Pump.
Efficiency oil is possibly too low. To test,
(significantly) run Tank line into bucket and
dirtier than ISO plug Tank port on tank.
18/15 Disconnect charging solenoid
and accumulator purge
solenoid. Activate engine kill
switch (Engine will not start)
and Transmission lockout
switch-on bumper. Turn over
engine until air tank drains
two times. If little oil drains
out of tank line replace pump
due to no large leakage in

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rest of system. If oil does

discharge out of the tank
port, measure and track the
accumulator pressures. If
pressure at service
accumulators drops quickly,
inspect the service brake
valves. If the secondary
accumulator pressures drop
quickly, inspect the
secondary brake valves. If
accumulators do not drop
quickly, inspect the system
relief valve. After testing,
insure that the charging
solenoid and accumulator
purge solenoid are
reconnected. Reconnect all
lines and dry crank engine
again, allow accumulators to
purge back to tank. After
accumulators have been
purged, work may begin on
the truck. After the procedure
is complete, the brakes must
be purged.
Harness With machine off, verify that
connector not the sensors are reading less
locked in place than 517 kPa (75 psi).
Install 35000 kPa (5000 psi) Replace
Brake Failed In gauge on the brake Brake
Accumulator Range /Stuck accumulator pressure taps to
Locking tab Accumulator
Pressure at one verify that the accumulator
broken on Pressure
Sensors pressure pressure matches the gauge
mating Sensors.
pressure. With machine
connector. running at low idle check to
see if the gauge matches the
sensor in Cat® ET.
Solenoid Contamination: Replace
Valve Gp Brake system Solenoid
(Brake Short to oil Valve Gp
Short To Battery Fault Code
Accumulator Battery (significantly) (Brake
Purge) dirtier than ISO Accumulator
18/15 Purge)
Stuck Open If you cannot reach cutout at Make sure
low idle and both that oil is ISO
accumulators cycle rapidly, 18/15 or
then the valve could be stuck better. If more
open. than 18/15,
kidney loop

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machine and
change filter.
If kidney loop
not available,
change oil.
Contamination:
Incorrectly Brake system
Check Valve Verify arrow on hex of check Properly
installed in oil
(Hoist Pilot valve is flowing in the install check
place of tow (significantly)
Check) correct direction. valve.
motor check. dirtier than ISO
18/15
Contamination:
Incorrectly Brake system
Check Valve Verify arrow on hex of check Properly
installed in oil
(Tow Motor valve is flowing in the install check
place of hoist (significantly)
Check) correct direction. valve.
pilot check. dirtier than ISO
18/15
Remove filter element and
Contact
inspect for damage and loose
product
Filter Damaged on System pieces of yellow plastic.
support
Element Installation Overheating Remove and inspect
through the
Accumulator purge solenoid
DSN.
screens for debris.

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