Frenos HPB

WABCO HYDRAULIC
POWER BRAKE (HPB)

SYSTEM
MAINTENANCE MANUAL
Service Notes
About This Manual 앫 Maintenance Manual 38, Hydraulic ABS for Medium-Duty
Trucks, Buses and Motor Home Chassis (C Version Hydraulic
This manual contains maintenance procedures for WABCO’s ABS)
Hydraulic Power Brake (HPB) system for trucks, tractors and buses.
앫 Maintenance Manual 39, Hydraulic ABS for Medium-Duty
Trucks, Buses and Motor Home Chassis (D Version Hydraulic
Before You Begin ABS)
1. Read and understand all instructions and procedures before
앫 Maintenance Manual MM-0677, Hydraulic Anti-Lock Braking
you begin to service components.
Systems (HABS) for Medium-Duty Trucks, Buses and Motor
2. Read and observe all Warning and Caution hazard alert Home Chassis (E Version Hydraulic ABS)
messages in this publication. They provide information that can
Contact WABCO North America Customer Care at 855-228-3203
help prevent serious personal injury, damage to components,
(United States and Canada); 001-800-889-1834 (Mexico); or email
or both.
wnacustomercare@wabco-auto.com.
3. Follow your company’s maintenance and service, installation,
and diagnostics guidelines. If Tools and Supplies are Specified in
4. Use special tools when required to help avoid serious personal This Manual
injury and damage to components.
Call Meritor’s Commercial Vehicle Aftermarket at 888-725-9355 to
obtain tools and supplies.
Hazard Alert Messages and Torque
Symbols
WARNING
A Warning alerts you to an instruction or procedure that you
must follow exactly to avoid serious personal injury and
damage to components.
CAUTION
A Caution alerts you to an instruction or procedure that you
must follow exactly to avoid damage to components.
@ This symbol alerts you to tighten fasteners to a specified torque

value.
How to Obtain Additional Maintenance,

Service and Product Information
Publications
Refer to the following publications for more information on servicing
WABCO’s Hydraulic Power Brake (HPB) systems.
Information contained in this publication was in effect at the time the publication
was approved for printing and is subject to change without notice or liability.
WABCO reserves the right to revise the information presented or to discontinue the
production of parts described at any time.
WABCO Maintenance Manual MM-0401 (Revised 08-18)

Contents
pg. i Asbestos and Non-Asbestos Fibers pg. 68 Removal

Hydraulic Compact Unit (HCU) Relay Valve
1 Section 1: Introduction
69 Installation
Overview
Hydraulic Compact Unit (HCU) Relay Valve
System Components
70 Removal
3 How the HPB System Works
Hydraulic Compact Unit (HCU) Pump
5 Section 2: Wiring Diagram 71 Installation
HPB Wiring Diagram for Multiplex Vehicles Hydraulic Compact Unit (HCU) Pump
6 HPB Connector Diagram for Multiplex Vehicles 72 Removal
7 HPB Wiring Diagram for Non-Multiplexed Vehicles Master Cylinder Replacement Information
8 HPB Connector Diagram for Non-Multiplexed Vehicles Master Cylinder
9 Section 3: Troubleshooting and Testing 75 Installation
Testing the System Master Cylinder
WABCO TOOLBOX™ Software 77 Removal
Connecting TOOLBOX™ Software Master Cylinder Reservoir
10 Hydraulic Power Brake Menus and Toolbars 79 Installation
14 Standard Testing Master Cylinder Reservoir
Test Equipment: Volt-Ohm Meter (VOM) 81 Removal
System Requirements and Component Tests Master Cylinder Foot Brake Switch
Tire Size Range 82 Installation
Checking Power, Ground and Load Test Master Cylinder Foot Brake Switch
15 Standard Component Testing Removal
Indicator Lamps Master Cylinder Fluid Level Sensor Switch
Sensor Adjustment Installation
Vehicle Test Drive Master Cylinder Fluid Level Sensor
16 Safety Features 83 Removal
Towing Procedure for Navistar CE Buses Parking Brake Pressure Supply Valve
17 Warning Lamps 85 Installation
18 SPN, SID, FMI Diagnostic Trouble Code List Parking Brake Pressure Supply Valve
87 Removal
52 Section 4: Removal and Installation Low Pressure Hose
Removal 88 Installation
Hydraulic Compact Unit Low Pressure Hose
55 Installation 89 Lubrication
Hydraulic Compact Unit Wheel Speed Sensor Specification
56 Removal 90 Removal
HCU Reservoir Front Axle Wheel Speed Sensor
57 Installation Installation
HCU Reservoir Front Axle Wheel Speed Sensor
58 Removal 91 Removal
HCU Accumulators Rear Axle Wheel Speed Sensor
60 Installation Installation
HCU Accumulators Rear Axle Wheel Speed Sensor
62 Removal
Electronic Control Unit (ECU) 92 Section 5: Brake Bleeding Procedures
64 Installation 93 Brake Bleeding Procedures
Electronic Control Unit (ECU) Pressure Bleed Procedures
65 Parameter Downloading Master Cylinder Circuit
Contents
pg. 94 Brake Caliper Circuit pg.

97 Spring-Applied/Hydraulic Release Parking Brake Circuit
98 Changing Hydraulic Brake Fluid
99 Brake Fluid Replacement Requirement
Filling the Hydraulic Power Brake (HPB) Master Cylinder
Reservoir
101 Section 6: Appendix
Leak Check Procedure for WABCO HPB System
Check the HPB System for Brake Fluid Leaks
System Test
Asbestos and Non-Asbestos Fibers
ASBESTOS FIBERS WARNING NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce exposure to The following procedures for servicing brakes are recommended to reduce exposure to
asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are non-asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets
available from WABCO. are available from WABCO.
Hazard Summary Hazard Summary
Because some brake linings contain asbestos, workers who service brakes must understand the Most recently manufactured brake linings do not contain asbestos fibers. These brake linings may
potential hazards of asbestos and precautions for reducing risks. Exposure to airborne asbestos contain one or more of a variety of ingredients, including glass fibers, mineral wool, aramid fibers,
dust can cause serious and possibly fatal diseases, including asbestosis (a chronic lung disease) ceramic fibers and silica that can present health risks if inhaled. Scientists disagree on the extent
of the risks from exposure to these substances. Nonetheless, exposure to silica dust can cause
and cancer, principally lung cancer and mesothelioma (a cancer of the lining of the chest or
silicosis, a non-cancerous lung disease. Silicosis gradually reduces lung capacity and efficiency
abdominal cavities). Some studies show that the risk of lung cancer among persons who smoke and can result in serious breathing difficulty. Some scientists believe other types of non-asbestos
and who are exposed to asbestos is much greater than the risk for non-smokers. Symptoms of fibers, when inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic
these diseases may not become apparent for 15, 20 or more years after the first exposure to fiber dust are known to the State of California to cause lung cancer. U.S. and international
asbestos. agencies have also determined that dust from mineral wool, ceramic fibers and silica are potential
causes of cancer.
Accordingly, workers must use caution to avoid creating and breathing dust when servicing brakes.
Specific recommended work practices for reducing exposure to asbestos dust follow. Consult your Accordingly, workers must use caution to avoid creating and breathing dust when servicing brakes.
Specific recommended work practices for reducing exposure to non-asbestos dust follow. Consult
employer for more details. your employer for more details.
Recommended Work Practices Recommended Work Practices
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other
operations to reduce risks to unprotected persons. OSHA has set a maximum allowable level of 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other
operations to reduce risks to unprotected persons.
exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average and 1.0 f/cc averaged over
a 30-minute period. Scientists disagree, however, to what extent adherence to the maximum 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for silica of
allowable exposure levels will eliminate the risk of disease that can result from inhaling asbestos 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-asbestos brake
linings recommend that exposures to other ingredients found in non-asbestos brake linings be
dust. OSHA requires that the following sign be posted at the entrance to areas where exposures kept below 1.0 f/cc as an 8-hour time-weighted average. Scientists disagree, however, to what
exceed either of the maximum allowable levels: extent adherence to these maximum allowable exposure levels will eliminate the risk of disease
DANGER: ASBESTOS that can result from inhaling non-asbestos dust.
CANCER AND LUNG DISEASE HAZARD Therefore, wear respiratory protection at all times during brake servicing, beginning with the
AUTHORIZED PERSONNEL ONLY removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA) filter approved by
RESPIRATORS AND PROTECTIVE CLOTHING NIOSH or MSHA, if the exposure levels may exceed OSHA or manufacturers’ recommended
ARE REQUIRED IN THIS AREA. maximum levels. Even when exposures are expected to be within the maximum allowable levels,
wearing such a respirator at all times during brake servicing will help minimize exposure.
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter
approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, beginning 3. Procedures for Servicing Brakes.
with the removal of the wheels. a. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be
3. Procedures for Servicing Brakes. equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the
a. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be HEPA vacuum to loosen and vacuum residue from the brake parts.
equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the b. As an alternative procedure, use a catch basin with water and a biodegradable,
HEPA vacuum to loosen and vacuum residue from the brake parts. non-phosphate, water-based detergent to wash the brake drum or rotor and other brake
b. As an alternative procedure, use a catch basin with water and a biodegradable, parts. The solution should be applied with low pressure to prevent dust from becoming
non-phosphate, water-based detergent to wash the brake drum or rotor and other brake airborne. Allow the solution to flow between the brake drum and the brake support or the
parts. The solution should be applied with low pressure to prevent dust from becoming brake rotor and caliper. The wheel hub and brake assembly components should be thoroughly
airborne. Allow the solution to flow between the brake drum and the brake support or the wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake
brake rotor and caliper. The wheel hub and brake assembly components should be thoroughly parts clean with a cloth.
wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake c. If an enclosed vacuum system or brake washing equipment is not available, carefully clean
parts clean with a cloth. the brake parts in the open air. Wet the parts with a solution applied with a pump-spray bottle
c. If an enclosed vacuum system or brake washing equipment is not available, employers may that creates a fine mist. Use a solution containing water, and, if available, a biodegradable,
adopt their own written procedures for servicing brakes, provided that the exposure levels non-phosphate, water-based detergent. The wheel hub and brake assembly components
associated with the employer’s procedures do not exceed the levels associated with the should be thoroughly wetted to suppress dust before the brake shoes or brake pads are
enclosed vacuum system or brake washing equipment. Consult OSHA regulations for more removed. Wipe the brake parts clean with a cloth.
details. d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when grinding or
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use with machining brake linings. In addition, do such work in an area with a local exhaust ventilation
asbestos when grinding or machining brake linings. In addition, do such work in an area with system equipped with a HEPA filter.
a local exhaust ventilation system equipped with a HEPA filter. e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, flammable
filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, flammable solvents, or solvents that can damage brake components as wetting agents.
solvents, or solvents that can damage brake components as wetting agents.
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty vacuum
wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved by NIOSH
cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA, to minimize exposure. When you replace a HEPA filter, wet the filter with a fine mist of
or MSHA for use with asbestos. When you replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter with care.
water and dispose of the used filter with care.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA filter to
Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not shake or use
vacuum work clothes after they are worn. Launder them separately. Do not shake or use compressed air to remove dust from work clothes.
compressed air to remove dust from work clothes.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care, 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care,
such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste
disposal. disposal.
Regulatory Guidance Regulatory Guidance

References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States, References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States,
are made to provide further guidance to employers and workers employed within the United States. are made to provide further guidance to employers and workers employed within the United States.
Employers and workers employed outside of the United States should consult the regulations that Employers and workers employed outside of the United States should consult the regulations that
apply to them for further guidance. apply to them for further guidance.
WABCO Maintenance Manual MM-0401 (Revised 08-18) i

1 Introduction
Overview
1 Introduction
Figure 1.2
HCU WITH OPTIONAL POWER PARKING

WABCO’s Hydraulic Power Brake (HPB) is a braking and vehicle BRAKE PRESSURE SUPPLY VALVE
control system for Business Class trucks, Classes 4 through 7, and
buses that are equipped with hydraulic brakes. The HPB system PRESSURE
provides the following functions. SUPPLY
VALVE
앫 Full power brake performance
앫 Brake control functions including Anti-Lock Braking System
(ABS), Automatic Traction Control (ATC) and Electronic Brake
force Distribution (EBD)
앫 Optional parking brake control
4004474c
System Components
Figure 1.2
The HPB system consists of two main components — the Hydraulic
Compact Unit (HCU) and a dual circuit master cylinder. The HPB
Figure 1.3
system is also available with an optional parking brake pressure

supply valve. Figure 1.1 and Figure 1.2 illustrate the HPB system MASTER CYLINDER ASSEMBLY
with and without the park brake supply valve. Figure 1.3 illustrates
the master cylinder assembly.
Figure 1.1
HCU WITHOUT OPTIONAL POWER

PARKING BRAKE SUPPLY VALVE
4004475a
Figure 1.3
4004474b
Hydraulic Compact Unit
The HCU consists of an electronic control unit, two independent
Figure 1.1
electric motors driving two piston pumps, two accumulators, a dual
circuit fluid reservoir with integrated filters, pressure relief valves,
solenoid valves and a dual circuit relay valve. The HCU is mounted to
the vehicle frame rail with two brackets. Figure 1.4.
WARNING
Do not drive the vehicle if a HPB system failure has occurred.
Loss of braking ability may occur, resulting in an accident and
serious personal injury.
앫 The HCU generates the service brake pressure.
WABCO Maintenance Manual MM-0401 (Revised 08-18) 1

1 Introduction
앫 Two pump motors drive the piston pumps to build hydraulic Master Cylinder Assembly
pressure. The pressure is stored in accumulators. The motors
The dual circuit master cylinder in conjunction with a relay valve
are not serviceable. The motors cannot be replaced without
provides the translation of brake pedal force into hydraulic braking
replacing the entire HCU.
pressure, and sends the driver’s demand signal to the HCU.
앫 The accumulators are two gas-filled hydraulic accumulators. The Figure 1.5.
accumulators store energy supplied by the pumps. Accumulators
앫 The foot brake switch provides brake status to the ECU and
are sealed at the factory and are non-refillable. Accumulators
eliminates the need for a brake light switch.
may be replaced as a set without replacing the entire HCU.
앫 The master cylinder reservoir holds the additional hydraulic
앫 The ECU processes sensor signals and generates solenoid valve
brake fluid.
commands to reduce, maintain or increase brake pressure for
control function. The ECU constantly monitors the pressure in the 앫 The fluid sensor switch monitors fluid level in the master cylinder
accumulators, using one pressure sensor per brake circuit. The reservoir.
ECU may be replaced without replacing the complete HCU.
앫 The master cylinder reservoir and both master cylinder switches
앫 The optional pressure supply valve controls the Spring-Applied/ may be replaced without replacing the entire master cylinder.
Hydraulic Released (SAHR) parking brake. The pressure supply
앫 The master cylinder cap provided by WABCO contains a special
valve is mounted on the HCU. The pressure supply valve may be
gore material that allows the reservoir to breathe, and serves as
replaced without replacing the entire HCU.
a filter to help prevent contaminants from getting into the
앫 The dual circuit HCU reservoir holds the hydraulic brake fluid. reservoir. This is the only cap approved for use with WABCO
(The reservoir may be replaced without replacing the entire HPB.
HCU.)
NOTE: The ability of the master cylinder cap to breathe is critical
앫 The relay valve is mounted on the bottom of the HCU and may be to correct brake system function. If the cap becomes
replaced without replacing the entire HCU. contaminated, it will need to be replaced.
Figure 1.5
Figure 1.4
HYDRAULIC COMPACT UNIT MASTER CYLINDER ASSEMBLY

WITHOUT PRESSURE SUPPLY VALVE
MASTER
DUAL CIRCUIT CYLINDER
HCU RESERVOIR RESERVOIR VENTED
RESERVOIR CAP
ECU
RELAY
VALVE
FOOT
BRAKE
SWITCH
PRIMARY
FLUID LEVEL CIRCUIT
SENSOR (MF-FRONT
SWITCH SECONDARY AXLE)
CIRCUIT
PUMP (MR-REAR AXLE) 4004477a
MOTORS (2)
Figure 1.5
ACCUMULATORS 4004476b
Figure 1.4
2 WABCO Maintenance Manual MM-0401 (Revised 08-18)

1 Introduction
Wheel-End Sensors Spring-Applied Hydraulic Release (SAHR) Parking

A WABCO wheel speed sensor is installed at each wheel whose Brake Canister (Optional)
speed is to be monitored. These sensors generate electronic signals
NOTE: The SAHR canister is not produced by WABCO and is an
which are sent to the ECU. A sensor spring clip holds the wheel
optional feature. Please consult the OEM for maintenance and
speed sensor in place. Figure 1.6. The sensor and sensor clip must
service information. Refer to Navistar publication TSI-08-04-01.
be lubricated before installation and whenever wheel-end
maintenance is performed.
On vehicles equipped with hydraulic parking brakes, the SAHR
canister controls the force applied to the parking brake cable.
Figure 1.6
Internal springs are used to apply tension to the parking brake cable,
SENSOR
SPRING which applies the parking brake. When pressurized brake fluid is
CLIP routed to the SAHR canister, the hydraulic pressure overcomes the
internal springs to relax the parking brake cable, which releases the
parking brake. The SAHR parking brake canister is typically located
inside the driver’s side frame rail, forward of the rear axles.
Vehicles not equipped with hydraulic parking brakes have
mechanical or air (Spring Applied Air Released, SAAR) parking
brakes. Please consult the OEM for maintenance and service
WHEEL SPEED information.
SENSOR
4004479a WARNING
Never drive the vehicle if the parking brake cable is
Figure 1.6
disconnected or if the parking brake system is not operating
correctly. Driving the vehicle without a correctly functioning
TOOLBOX™ Software parking brake system can result in an accident and serious
TOOLBOX™ Software is a PC-based diagnostics program required personal injury.
to diagnose HPB system faults. For HPB, version 9.0 or higher is
recommended. TOOLBOX™ Software is available at Parking Brake Switch
www.wabco-auto.com. Figure 1.7.
The parking brake switch (optional) is a three-position electrical
Figure 1.7
switch (apply, neutral and release). It controls the driver-requested
operation of the parking brake.
How the HPB System Works

WABCO’s hydraulic power braking system provides the energy
required to actuate the brakes and control the electronic brake force
distribution (EBD), ABS and ATC functions. The HCU is activated
each time the ignition is turned on or whenever the driver steps on
the brake pedal. If the system is equipped with the optional power
park brake, the HCU also supplies the energy to release and control
4011996a the service and park brakes.
Figure 1.7 The WABCO HPB system for trucks is illustrated in Figure 1.8. A
complete HPB system layout, with hydraulic brake lines, appears in
Low Pressure Hose the Appendix.
The Removal and Installation section of this manual contains service
information for a low pressure hose which is not produced by
WABCO but is an integral part of the HPB system.

1 Introduction
Figure 1.8
HPB SYSTEM LAYOUT
HCU RESERVOIR
MASTER
CYLINDER
RESERVOIR HCU ASSEMBLY
PARKING
BRAKE
PRESSURE
SUPPLY
VALVE
MASTER ACCUMULATORS (2)

CYLINDER
ASSEMBLY
RELAY ECU
VALVES
WHEEL-END
SENSORS (4)
REAR AXLE
FRONT AXLE
4004478a
Figure 1.8
Functional Description For ABS, wheel pressure is individually modulated by eight

integrated ABS solenoid valves in the ECU/HCU.
Hydraulic energy is stored in the gas-filled hydraulic accumulators,
one for each circuit. When the vehicle’s ignition is turned on, For ATC, the normally closed ATC solenoid valve in the ECU is
internal pumps are activated and fill both accumulators with actuated and hydraulic energy is supplied to the sensed wheel. At
pressurized hydraulic brake fluid. Two internal sensors, one for each the same time, the normally open ATC valve is actuated to prevent
accumulator, measure pressure and the ECU continuously monitors fluid flow back into the reservoir. The brake pressure is then
and controls pressure. modulated by the corresponding ABS solenoid valves.
During normal operation, the ECU actuates two separate power
drivers for the electric motors, keeping the pressure level within the
WARNING
system at desired limits. Two pressure relief valves provide safety Do not install any “add-on” hydraulic devices to the HPB
against overpressurization. system. A loss of braking ability may occur, resulting in an
accident and serious personal injury.
When the brake pedal is applied, the master cylinder provides a
hydraulic signal to the relay valve. Proportional to that signal, the
accumulators release pressure to the brake calipers. When the
pedal is released, brake fluid returns from the brake calipers to the
reservoir, and line pressure is reduced to zero.

2 Wiring Diagram
HPB Wiring Diagram for Multiplex Vehicles

2 Wiring Diagram
The WABCO HPB electronic control unit interface wiring diagram for multiplex vehicles is shown in Figure 2.1.
Figure 2.1
SENSOR
27
RIGHT
REAR
OV
2x0.75 mm2 TWISTED
REAR RIGHT
22
SENSOR
IV
23 28
REAR
LEFT
2x0.75 mm2 TWISTED
SENSOR
25 30
FRONT
RIGHT
2x0.75 mm2 TWISTED
WHEEL PRESSURE MODULATION SOLENOIDS
OV
REAR LEFT
SENSOR
29
FRONT
LEFT
2x0.75 mm2 TWISTED
IV
24
FOR MULTIPLEX (MUX) VEHICLES WITH POWER BRAKE OPTION
BRAKE LIGHT SIGNAL

15
OV
CAN LOW
FRONT RIGHT
14
CAN HIGH ACC. SAE J1939

IV
26
DIAGNOSE "B"
31
31-PIN CONNECTOR
DIAGNOSE "A" ACC. SAE J1587

ELECTRONIC CONTROL UNIT
OV
FRONT LEFT
WIRING DIAGRAM
IV
2
9
LOW BRAKE FLUID

27K
680R
3
1
2
NO
ATC–SOLENOIDS
10
BRAKE SWITCH
5A
ATC
1K
3K
NC
560R
STUD 3
GRD
11
PARKING BRAKE SWITCH

6
REFERENCE GROUND
1
IGNITION
5A
MOTOR 2
PUMP–
19
* SOLENOID VALVE GROUND

30A
17
* SOLENOID VALVE SUPPLY

STUD 2
GRD
18
MOTOR 1
* PUMP MOTOR 2 GROUND

30A
PUMP–
16
* PUMP MOTOR 2 SUPPLY

7
IGNITION
SWITCH
5
30
STUD 1
BATTERY FEED
4
GRD
CONNECTOR
P
30A
1
2-PIN
+12V
* PUMP MOTOR 1 GROUND

P
* PUMP MOTOR 1 SUPPLY

+
CUTOFF SOLENOID
–
2
PARKING BRAKE
PRESSURE
1
SUPPLY
VALVE
1
2
PIN 7
B
GROUND
A
IGNITION
TRAVEL SWITCH 4004481a
Figure 2.1

2 Wiring Diagram
HPB Connector Diagram for Multiplex Vehicles

The WABCO HPB electronic control unit interface connector diagram for multiplex vehicles is shown in Figure 2.2.
Figure 2.2
PIN IDENTIFICATION FOR WIRE HARNESS CONNECTORS TO THE ECU
(9511)
1
16
IGNITION 12V PUMP MOTOR 2 SUPPLY 12V+
NOT USED
17
3
BRAKE SIGNAL SOLENOID VALVE SUPPLY 12V+
PRESSURE SUPPLY
4
VALVE (OPTIONAL)
18
5 PUMP MOTOR 2 GROUND –
CUT OFF SOLENOID
(OPTIONAL) REFERENCE GROUND
6
19
SAHR TRAVEL SOLENOID VALVE GROUND –
7
SWITCH (OPTIONAL)
ABS OFFROAD
8
20
SWITCH (OPTIONAL) NOT USED

LOW BRAKE
9
21
FLUID NOT USED

10
MASTER CYLINDER
22
BRAKE SWITCH 22 REAR RIGHT

11
PARKING BRAKE 27 WHEEL SPEED

23
DASH SWITCH 27 SENSOR

12
NOT USED 28
24
13
NOT USED 29
25
23 REAR LEFT
14
J1939 + HIGH 30 WHEEL SPEED

26
28 SENSOR
15
31
J1939 – LOW
24 FRONT LEFT
WHEEL SPEED
29 SENSOR
25 FRONT RIGHT
WHEEL SPEED
30 SENSOR
X2
26 J1587 DIAG. B
+ LOW
30A
URAT1
30
J1587 DIAG. A
31 + HIGH
4008946b
Figure 2.2

2 Wiring Diagram
HPB Wiring Diagram for Non-Multiplexed Vehicles

The WABCO HPB electronic control unit interface wiring diagram for non-multiplexed vehicles is shown in Figure 2.3.
Figure 2.3
4011904a
Figure 2.3

2 Wiring Diagram
HPB Connector Diagram for Non-Multiplexed Vehicles

The WABCO HPB electronic control unit interface connector diagram for multiplex vehicles is shown in Figure 2.4.
Figure 2.4
X1
A-LINE
CAN-L 15 31 B-LINE SAE J1587
26 GM
SAE J1939 CAN-L 14 30 IG SENSOR FR
25 IGM
ATC-L 13 29 IG SENSOR FL
15 24 IGM
BUZZER-RELAY 12 28
15 IG SENSOR RL
23 IGM
11 27
PARKING BRAKE SWITCH IG SENSOR RR
22
BRAKE ACUATION SWITHC 10
ABS WARNING
21
LAMP RELAY
15
FLUID LEVEL SWITHC 9
BRAKE WARNING
20
LAMP RELAY 15
8
19
PARKING BRAKE MONITOR SWITCH 7
REF-GND
6
18
PB-CUTOFF
5
PB-SUPPLY 4 15A UBAT

17 30
BLR-RELAY 3
15
DBR-RELAY 2 30A UBAT2
15 16 30
5A 1
UIGN
15
X2
30A
URAT1
30
4011905a
Figure 2.4

3 Troubleshooting and Testing
Testing the System Connecting TOOLBOX™ Software

This section contains information for testing the HPB system with To connect TOOLBOX™ Software to the vehicle, a RP1210A
TOOLBOX™ Software, and for performing standard component and compliant device will be needed. Once TOOLBOX™ Software is
electrical tests. connected and open, verify the adapter settings are correct.
To access “Adapter Selection” for TOOLBOX™ Software 11 or
WARNING newer, click on “Utilities” from the main TOOLBOX™ page or under
To prevent serious eye injury, always wear safe eye protection “System Setup” in “J1707 TOOLBOX” from the main TOOLBOX
when you perform vehicle maintenance or service. page.
Exhaust gas contains poison. When testing a vehicle with the To access “Comport Settings” for TOOLBOX™ Software versions
engine running, test in a well-ventilated area or route the prior to TOOLBOX™ Software 11 click on “System Setup” from the
exhaust hose outside. main TOOLBOX™ page.
Make sure the “Vendor:” and “Adapter:” drop-downs are set for the
To avoid serious personal injury, keep away, and keep test device being used and set the “Protocol:” drop-down to J1708, and
equipment away, from all moving or hot engine parts. click “OK”. Figure 3.1.
To avoid unwanted vehicle movement when testing, set the Figure 3.1
parking brake and place the gear selector in NEUTRAL (manual

transmission), or PARK (automatic transmission) unless
otherwise directed. Failure to do so may result in serious
personal injury.
Never drive the vehicle if the parking brake cable is

disconnected or if the parking brake system is not operating
correctly. Driving the vehicle without a correctly functioning
parking brake system can result in an accident and serious
personal injury.
Refer to, and follow, the vehicle manufacturer’s Warnings, Cautions

and service procedures.
WABCO TOOLBOX™ Software 4011997a

NOTE: The HPB system does not have blink code capability and
Figure 3.1
WABCO TOOLBOX™ Software is needed to communicate with the
system.
NOTE: When switching between J1939 and J1708
Use TOOLBOX™ Software to obtain DTCs and verify the activation communications, vehicle ignition must be cycled between sessions
of various system components. to correctly communicate with ECU.
앫 Turn valves, pump and retarder relay (if available) on and off NOTE: TOOLBOX™ Software must be connected to the vehicle and
(Valve Activation Menu) the vehicle ignition must be ON in order to display information. If
앫 Turn indicator lamps on and off (Miscellaneous Output Activation unable to communicate with the ECU:
Menu) 앫 Verify device and data link connections are secure.
NOTE: To obtain TOOLBOX™ Software, go to 앫 Verify the device is RP1210A compliant and that the comport
www.wabco-auto.com. settings (Vendor, Protocol, Adapter) in TOOLBOX™ Software are
correct.

앫 Verify the device software and firmware is up to date. Figure 3.3
앫 Check all the powers and grounds coming to the ECU including WABCO HPB
load testing.
앫 Check J1587 circuit at the ECU and the data link connector.
Hydraulic Power Brake Menus and Toolbars

Select Hydraulic ABS from the TOOLBOX™ Software Main Menu.
TOOLBOX™ Software senses the type of ECU being used and
displays the HPB Main Screen.
4008958a
Main HPB Screen
Figure 3.3
This screen provides icons and pull-down menu task selections. It
also provides information about the current status of WABCO HPB.
Figure 3.2. Faults
Figure 3.2
WARNING
WABCO HPB Do not drive the vehicle if active faults are present. Driving the
vehicle with active faults present can result in an accident and
Select Faults to display the Fault Information screen. Figure 3.4.
NOTE: The Fault Information screen is also accessible from the

HPB Main Menu.
Figure 3.4
1222 1438
4006207a
Figure 3.2
ECU information is read once from the ECU and does not change. All
other information (e.g., wheel sensors, voltages and fault
information) is read and updated continuously.
Display 4004460a
Select Display from the HPB Main Screen. A pull-down menu will Figure 3.4
appear. Figure 3.3.
The Fault Information screen contains a description of each fault,
including the type of fault (Active or Stored), SID and FMI number.
Repair instructions for the fault appear at the bottom of the screen.

Faults that occur after the screen is displayed will not appear until a Figure 3.6
screen update is requested. Use the Update button at the bottom of

the screen to refresh the fault information table and display a new
list of faults.
After making any required repairs, use the Clear Faults button to
clear the fault. Clear each fault as it is repaired. The Update button
should be used after all faults are repaired. Cycle the ignition after
clearing the faults.
NOTE: When all faults are cleared, you need to drive the vehicle
above 5 mph before the ABS light will go out.
Use the Save or Print button to save or print the fault information
data. Select Exit to close this section.
4004462a
Wheel Speed Figure 3.6
Select Wheel Speed to display the Wheel Speed screen.
Figure 3.5. The Counters screen provides an overview of HPB component
performance (pump hours, brake events, etc.) as well as general
Figure 3.5
vehicle activity such as ignition cycles. Occurrences displayed on
this screen accumulate until the Clear button is selected.
Component Tests
Select Component Tests from the HPB Main Screen. A pull-down
menu will appear. Figure 3.7.
Figure 3.7
4004461a
Figure 3.5
Use the Wheel Speed screen to verify that sensors are connected
at each wheel. Speed at a sensed wheel (FL, FR, RL, RR) indicates 4008959a
sensors are installed, but does not verify correct sensor installation.
Wheel speed sensor installation information is available in the Figure 3.7
Removal and Installation section.
Counters
Select Counters to display the Counters screen. Figure 3.6.

Valves Figure 3.9
Select Valves to display the Valve Activation test screen.

Figure 3.8.
Figure 3.8
4004465a
Figure 3.9
As each lamp is tested, check the actual lamp to verify correct

operation. Select Close to exit this screen.
Parking Brake
WARNING
Park the vehicle on a level surface. Block the front and rear
wheels to prevent vehicle movement. Failure to do so can
result in unwanted vehicle movement causing serious
personal injury.
Select Parking Brake to display the Parking Brake test screen.

Figure 3.10.
Figure 3.10
4004464a
Figure 3.8
The Valve Activation test screen lets you activate the HPB valves to
check for correct activation and to verify correct brake line
installation.
Click on the valve you wish to test, then click the Send button to
actuate the component. Component activation status appears in the
Status box field. Select Close to exit this screen.
Lamps
Select Lamps to display the Lamp Test screen. Figure 3.9.
4004466a
Figure 3.10

Select Release or Apply, then select Send to test the parking Figure 3.12
brake. Select Close to exit this screen.
Relay (Only on Non-Multiplex Vehicles)

Select Relay to display the Activate Relay test screen. Figure 3.11.
Figure 3.11
4004468a
Figure 3.12
This screen allows you to send a “limit engine torque” command to

the engine or a “disable retarder” command to the retarder.
Select the data link destination (engine or retarder), then select
Send to test. Use the Stop button to end testing. Select Close to
exit this screen. The vehicle must be running with the engine RPM
increased (1000-1500 RPM) in order for this function to work.
Disable ATC
Select Disable ATC to send a command to the ECU to disable
automatic traction control. ATC will remain disabled until the enable
command is sent, or until the vehicle ignition is cycled. ATC must be
disabled for dynamometer testing.
Enable ATC
Select Enable ATC to send a command to the ECU to enable
4004467a
automatic traction control. This is the normal state of the ECU.
Figure 3.11 Figure 3.7.
This screen allows you to turn the retarder relay on or off. This is NOTE: The status bar on the HPB Main Menu reflects the current
helpful in verifying correct operation, installation and wiring of the ATC status (enabled, disabled or not available).
unit under test. Select Close to exit this screen.
Miscellaneous Outputs
Engine Data Link Select Miscellaneous Outputs to display the Activate
Select Engine Data Link to display the Data Link test screen. Miscellaneous Outputs test screen. Figure 3.13.
Figure 3.12.
NOTE: Use TOOLBOX™ Software to test the following components:
Retarder Relay (if available), Brake Light Relay (if available), Supply
Valve, Cut-Off Valve, ABS Lamp, Traction Lamp, Brake Warning,
Pump Front, Pump Rear, Buzzer.

Figure 3.13
Standard Testing
Test Equipment: Volt-Ohm Meter (VOM)
Use of a VOM with automatic polarity sensing is recommended. This
eliminates the concern of the polarity of the meter leads during
voltage measurements.
System Requirements and Component

Tests
Tire Size Range
WARNING
For correct hydraulic ABS operation, front and rear tire sizes
must be within 16% of each other. Do not use a tire size range
4005142a that exceeds 16%. Failure to do so may cause reduced braking
force and result in serious personal injury.
Figure 3.13
Calculate the tire size with the following equation:

This screen provides a check of several HPB components, as well as
a way to check either inlet or outlet activity of the valves, pump or
retarder relay.
RPM Steer
% Difference = {  1} x 100
Highlight the component you wish to test, then select the Send RPM Drive
button to actuate the component. Component activation status
RPM = tire revolutions per mile
appears in the Status Box field. Select Close to exit this screen.
Reset Memorized Checking Power, Ground and Load Test

Select Reset Memorized to display the Learned Component
screen. Figure 3.14. CAUTION
When troubleshooting or testing the ABS, be careful not to
Figure 3.14 damage the connector terminals. If connector terminals are
damaged, they must be replaced.
There are 2 connectors at the HPB ECU, a 2-pin connector and a

31-pin connector. When checking power and ground for any of the
4004471a
ECU circuits, it is recommended to check all the power and ground
Figure 3.14 circuits as there are redundant powers and grounds.
Disconnect the 2-pin and 31-pin connectors and verify all the lock
Relay is an automatic default and cannot be de-selected. It indicates tabs are there and good, check for any signs of damage, moisture or
the ECU has memorized the installed retarder relay. Once the ECU corrosion.
has seen a retarder, it expects to see it every time the vehicle is
powered up.

Ground Checks On drive axles, the sensor is typically accessible on the in-board
side of the rear axle spindle.
Check all the ground wire circuits, with the key off, disconnect the
2-pin and 31-pin connectors and in the 2-pin harness connector To adjust the sensor, push the sensor in until it contacts the tooth
check resistance to ground pin 1 and in the 31-pin harness wheel.
connector check resistance to ground pins 6, 18, 19. All readings
앫 Do not pry or push sensors with sharp objects.
should be less than 1 ohm, if the readings are not in spec, may need
to review wiring diagnostics and repair with the OEM. 앫 Sensors will self-adjust during wheel rotation.
Voltage Checks NOTE: No gap is allowed at installation. During normal operation,

Check all the power wire circuits, with the key off, disconnect the the gap should not be greater than 0.04-inch (1.02 mm).
2-pin and 31-pin connectors. In the 2-pin harness connector, check
voltage to ground pin 2 and in the 31-pin harness connector, check Vehicle Test Drive
voltage to ground pins 1, 16, 17. All readings should be
After replacing an HPB component, use TOOLBOX™ Software to
approximately 12 volts, except pin 17. There should be no voltage
ensure there are not active faults, then test drive the vehicle as
key off. With the key on, recheck voltage at pin 2 of the 2-pin
follows:
connector and pins 1, 16, 17 of the 31-pin connector. All readings
should be approximately 12 volts. If the readings are not in spec, 1. Turn ignition ON.
may need to review wiring diagnostics and repair with the OEM.
NOTE: Depending on the vehicle, the ATC lamp may be
Load Test labeled differently and some vehicles may not have an ATC
lamp. Refer to the vehicle specification sheet for label
A compromised wire or circuit may still be able to provide resistance
designation.
and voltage readings that would be within specification for a Digital
Volt Ohm Meter or test light, but might not be capable of handling
2. Check the vehicle dash lamps:
enough current to allow the system to function correctly. To make
sure of the integrity of the wire or circuit, a load test is necessary. 앫 Most of the dash lamps for HPB come on briefly
With the key on load, test across pins 1-2 of the 2-pin harness (approximately three seconds) for a bulb check, then go off.
connector and pins 1-6, 16-18, 17-19 of the 31-pin harness This indicates the system is O.K.
connector with a device that will draw about 5 amps (such as a
앫 If the ABS and ATC lamps do not go off within 3 seconds
Sealed Beam headlight) for approximately 10 seconds. The
after turning the ignition ON, the system is looking for a
headlamp should be bright, if the lamp does not light, is dim or
wheel speed test. Drive the vehicle at speeds of 5-10 mph
flickers, it would indicate an issue with the wiring, may need to
(8-16 km/h). The ABS and ATC lamps will then go off if the
review wiring diagnostics and repair with the OEM.
system is O.K.
Standard Component Testing 앫 If the ABS and ATC lamps do not go off after the vehicle
reaches a speed of 5-10 mph (8-16 km/h), this indicates
Indicator Lamps there is a system fault. Perform vehicle diagnostics and
make all of the necessary repairs, including appropriate
If the indicator lamps do not come on after the ignition is turned on, bleed procedures, before returning the vehicle to service.
or it comes on but does not go out after three seconds, check all
ABS fuses or circuit breakers and replace if necessary. After WARNING
checking the indicator lamps, make repairs as necessary. Do not drive the vehicle if active faults are present. Driving the
vehicle with active faults present can result in an accident and
Sensor Adjustment serious personal injury.
On steering axles, the sensor is typically accessible on the in-board
side of the steering knuckle. 3. Drive the vehicle for a short distance. Make gentle brake
applications to verify brake performance.

Safety Features 3. While using the 15 mm wrench to hold the canister shaft,
unscrew the threaded rod using an 8 mm wrench. The rod
Limp Mode must be unscrewed approximately 2.5 inches before the cable
The HPB system has a feature known as “Limp Mode” In the event disconnects. The cable will exhibit some resistance while being
that power is lost at the 31-pin ECU connector or the 31-pin unscrewed because it is under tension.
connector has become dislodged, power for emergency foundation
Towing Vehicle with Front Wheels Suspended
braking can still be provided through the 2 pin ECU connector.
When it is necessary to tow a vehicle with the front wheels
Dynamic Park Brake Application, If Equipped with suspended, extra precautions must be taken to avoid transmission
the Hydraulic Park Brake System or differential damage.
In the event that the HPB system should lose all power and Disconnect the axle shafts at the rear axle to prevent the wheels
pressure, the park brake will automatically apply, while moving or at from driving the differential and the transmission. If axle shaft is not
rest. disconnected, remove the rear axle shafts from the axle assembly.
Cover the wheel hub ends to prevent loss of axle lubricant and
Interlocks, If Equipped with the Hydraulic Park entrance of contaminants.
Brake System
The HPB system with the hydraulic park brake feature may not allow Towing Vehicles with Rear Wheels Suspended
the park brake to be release unless certain interlock messages are Whenever possible, it is preferable to tow a disabled vehicle from
received, such as a door being left open or a wheel chair lift that is the rear by raising the rear of the chassis. When towing a vehicle
not seated correctly in the stored position. Review interlock with the rear of the chassis suspended, the front wheels must be
operation and diagnostics with the OEM. locked in the straight ahead position.
Towing Procedure for Navistar CE Buses

Towing Preparation: Hydraulic Powered Parking
Brakes
If battery power is available:
1. Place the transmission in “N” Neutral and turn the ignition
switch to the ON position.
2. While depressing the brake pedal, push and hold the Parking
Brake knob to release the parking brake. If battery power has
been lost, the Parking Brake cable will have to be disconnected
by following the steps below.
If battery power has been lost:
Use the following procedure to disconnect the Parking Brake cable.
CAUTION
While removing the parking brake cable, only the threaded rod
should rotate. If the cable is to be reused, do not allow the
cable to twist during removal.
1. Block the wheels, place the transmission in “N” Neutral, and

turn the ignition switch to the OFF position.
2. While using a 15 mm wrench to hold the SAHR canister shaft,
loosen the jam nut on the threaded rod with a 16 mm wrench.

Warning Lamps
Indicator Lamp Lamp Status System Condition Being Indicated Recommendation
BRAKE/BRAKE STEADY ON and Half brake system failure. One of the two Immediately find a location to safely park the vehicle.
PRESSURE buzzer on brake circuits is not generating pressure or is When safely off the road and stopped, turn off ignition
Note: Indicator not generating pressure at the proper rate. and ensure the vehicle transmission is in the park
differs by model Braking force from the Hydraulic Power Brake position. Apply Parking Brake. Do not drive until the
year may be reduced or impaired. Use Parking failure has been repaired.
Brake if necessary.
FLASHING or Full brake system failure. Both brake circuits Immediately find a location to safely park the vehicle.
STEADY ON* and are not generating pressure or are not When safely off the road and stopped, turn off ignition
buzzer on generating pressure at the proper rate. and ensure the vehicle transmission is in the park
(*depending on Braking force from the Hydraulic Power Brake position. Apply Parking Brake. Do not drive until the
model) may be reduced or impaired. Use Parking failure has been repaired.
Brake if necessary.
OFF System pressures are in normal operating —
range.
BRAKE FLUID STEADY ON Low brake fluid level in the Master Cylinder Immediately find a location to safely park the vehicle.
Reservoir. Braking force from the Hydraulic When safely off the road and stopped, turn off ignition
Power Brake may be reduced or impaired. and ensure the vehicle transmission is in the park
Use parking brake if necessary. position. Apply Parking Brake. Do not drive until the
failure has been repaired.
OFF Brake fluid level detected in the Master —
Cylinder is at or above MIN mark.
ABS STEADY ON An ABS related fault has been detected by the Have vehicle repaired as soon as possible.
ECU. The advantages provided by ABS may
not be fully available
OFF No ABS related faults detected. —
TRAC CTRL STEADY ON A Traction Control related fault has been If the lamp remains on for over 10 seconds, there is a
detected – OR- A Traction Control event is high likelihood of a fault in the traction control system.
occurring due to spinning wheels and the Have vehicle repaired as soon as possible.
system is operating correctly.
FLASHING Mud and Snow mode was selected using the —
traction control switch (switch indicator lit)
OFF ATC is operating correctly, the Mud and Snow —
mode has not been selected and the vehicle
is not experiencing an ATC event.
PARK BRAKE STEADY ON Park Brake is applied. —
OFF Park Brake is not applied. —
SERVICE PARK FLASHING/ A Park Brake related fault has been detectedImmediately find a location to safely park the vehicle.
BRAKE STEADY ON by the ECU. Braking force from Park Brake When safely off the road and stopped, turn off ignition
may be reduced or impaired. and ensure the vehicle transmission is in the park
position. Apply Parking Brake. Do not drive until the
failure has been repaired.
OFF No Park Brake related faults detected. —
NOTE: If the ABS and/or ATC lamps are flashing after the parameters have been downloaded, verify the System Check Status has been set.
See “System Check Status” in “Parameter Downloading” section of this manual.

Figure 3.15
18
System
SPN SID FMI Description Warning Light Cause Action
Figure 3.15
Reaction
Main Controller, Safety Controller
ABS Warning Lamp – ON
Brake Warning Lamp – ON
There are multiple
ATC Lamp – ON
causes. Valves
Audible Warning – ON
may have been • Reset ECU by cycling the ignition or by using the reset option in
Parking Brake Service
ABS, ATC, activated too TOOLBOX™ Software.
Lamp (1939) – ON
629 254 12 Internal Error and EBD long during • If fault persists, check ABS ECU powers, grounds and load test.
Parking Brake Indicator
Disabled diagnostic testing. • If all powers, grounds and load testing checks pass, if fault still
Lamp – ON (if applied)
Internal ECU persists, may indicate the ECU has failed.
OFF (if released).
communication is
not correct.
Lamp (1939) according to
SAHR status.
Left Front Wheel Speed Sensor

Brake Warning Lamp – OFF
ATC Lamp – ON
Audible Warning – OFF
• Check air gap. The gap should not be greater than 0.040-inch
Parking Brake Service ABS Wheel Sensor air gap is
(1.02 mm).
Lamp (1939) – OFF Disabled too large, sensor
789 1 1 Air Gap • Check bearing play and tone ring run out. Eliminate root cause
Parking Brake Indicator ATC output voltage is
for air gap extension and push sensor back in afterwards.
Lamp – ON (if applied) Disabled too low.
• Check tone ring for damage (missing teeth, corrosion).
OFF (if released).
SPN, SID, FMI Diagnostic Trouble Code List

SAHR status.
ATC Lamp – ON
An open circuit or
short to ground
Parking Brake Service ABS Wheel • Check sensor impedance and sensor wiring and connectors for
has been detected.
Lamp (1939) – OFF Disabled intermittent contact.
789 1 5 Impedance i.e ECU detects
Parking Brake Indicator ATC • Check harness and/or sensor for open circuit or short to ground.
a disconnected
Lamp – ON (if applied) Disabled Sensor resistance should measure between 900-2000 ohms.
wheel speed
OFF (if released).
sensor.
SAHR status.
ATC Lamp – ON
Wheel speed
Parking Brake Service ABS Wheel
signal drops out
Lamp (1939) – OFF Disabled • Check tone ring for damage/missing teeth/corrosion.
789 1 7 Tone Ring periodically at
Parking Brake Indicator ATC • Check bearing play and tone ring run out.
speeds higher than
Lamp – ON (if applied) Disabled
10 kph.
OFF (if released).
SAHR status.
4011920a
Figure 3.16
Figure 3.16
System
Reaction
Left Front Wheel Speed Sensor
ATC Lamp – ON
(1.02 mm).
Wheel speed • Check bearing play and tone ring and run out. Eliminate root
No Trigger Lamp (1939) – OFF Disabled
789 1 8 sensor signal not cause for air gap extension and push sensor back in afterwards.
Detected Parking Brake Indicator ATC
detected • Check tone ring for damage (missing teeth, corrosion).
• Check sensor impedance and sensor wiring and connectors for
OFF (if released).
intermittent contact.
SAHR status.
ABS Warning Lamp - ON
Brake Warning Lamp - OFF
ATC Lamp - ON
Audible Warning - OFF Temporary
Parking Brake Service ABS Wheel Brake drags or
Lamp (1939) - OFF Disabled chatters. Abnormal • Check foundation brakes; condition may occur even without
789 1 11 Brake Chatter
Parking Brake Indicator Temporary vibrations system failure.
Lamp - ON (if applied) ATC detected.
OFF (if released) Disabled
SAHR status
ATC Lamp – ON
Incorrect tire size. •
Check foundation and change wrong tire.
Tire Lamp (1939) – OFF Disabled
789 1 13 brakes. Condition • Check tone ring for correct tooth count.
Combination Parking Brake Indicator ATC
may occur without • Check tone ring for damage/missing teeth/corrosion.
system failure. • Clear fault from memory.
OFF (if released).
SAHR status.
ATC Lamp - ON
Inlet valve Audible Warning - OFF
(1.02 mm).
actuation time Parking Brake Service ABS Wheel An ABS modulator
• Check bearing play and tone ring run out. Eliminate root cause
not plausible Lamp (1939) - OFF Disabled was activated for
629 254 9 for air gap extension and push sensor back in afterwards.
(75% switch Parking Brake Indicator ATC an abnormally long
• Check tone ring for damage/missing teeth/corrosion.
on time within Lamp - ON (if applied) Disabled time.
5 minutes) OFF (if released)
SAHR status
4011921a

19
Figure 3.17
20
Figure 3.17
System
Reaction
Right Front Wheel Speed Sensor
ATC Lamp – ON
Parking Brake Service ABS Wheel Sensor air gap is
(1.02 mm).
Lamp (1939) – OFF Disabled too large, sensor
Parking Brake Indicator ATC output voltage is
Lamp – ON (if applied) Disabled too low.
OFF (if released).
SAHR status.

ATC Lamp – ON
An open circuit or
short to ground
Parking Brake Service ABS Wheel • Check sensor impedance and sensor wiring and connectors for
has been detected.
Lamp (1939) – OFF Disabled intermittent contact.
Parking Brake Indicator ATC • Check harness and/or sensor for open circuit or short to ground.
a disconnected
Lamp – ON (if applied) Disabled Sensor resistance should measure between 900-2000 ohms.
wheel speed
OFF (if released).
sensor.
SAHR status.
ATC Lamp – ON
Wheel speed
signal drops out
Lamp (1939) – OFF Disabled • Check tone ring for damage/missing teeth/corrosion.
Parking Brake Indicator ATC • Check bearing play and tone ring run out.
speeds higher than
10 kph.
OFF (if released).
SAHR status.
ATC Lamp – ON
(1.02 mm).
Wheel speed • Check bearing play and tone ring run out. Eliminate root cause
No Trigger Lamp (1939) – OFF Disabled
790 2 8 sensor signal not for air gap extension and push sensor back in afterwards.
Detected Parking Brake Indicator ATC
detected. • Check tone ring for damage (missing teeth, corrosion).
OFF (if released).
SAHR status.
4011922a
Figure 3.18
System
Figure 3.18
Reaction
Right Front Wheel Speed Sensor
ATC Lamp – ON
Audible Warning – OFF Temporary
Lamp (1939) – OFF Disabled chatters. Abnormal • Check foundation brakes; condition may occur even without
Lamp – ON (if applied) ATC detected.
OFF (if released). Disabled
SAHR status.
ATC Lamp – ON
Audible Warning – OFF •
Incorrect tire size.
Parking Brake Service ABS Wheel and change wrong tire.
Check foundation
Tire Lamp (1939) – OFF Disabled • Check air gap and push sensor back in afterward.
790 2 13 brakes. Condition
Combination Parking Brake Indicator ATC • Check tone ring for correct tooth count.
may occur without
Lamp – ON (if applied) Disabled • Check tone ring for damage/missing teeth/corrosion.
system failure.
OFF (if released). • Clear fault from memory.
SAHR status.
ATC Lamp – ON
Inlet valve Audible Warning – OFF
(1.02 mm).
actuation time Parking Brake Service ABS Wheel An ABS modulator
not plausible Lamp (1939) – OFF Disabled was activated for
(75% switch Parking Brake Indicator ATC an abnormally long
on time within Lamp – ON (if applied) Disabled time.
5 minutes) OFF (if released).
SAHR status.
Left Rear Wheel Speed Sensor
ATC Lamp – ON
Audible Warning – OFF Speed
Parking Brake Service Signal Taken Sensor air gap is
(1.02 mm).
Lamp (1939) – OFF From Other too large, sensor
Parking Brake Indicator Rear Wheel output voltage is
Lamp – ON (if applied) ATC too low.
SAHR status.

4011923a
21
Figure 3.19
22
Figure 3.19
System
Reaction
ATC Lamp – ON
An open circuit
or short to ground
Parking Brake Service Signal Taken • Check sensor impedance and sensor wiring and connectors for
has been detected.
Lamp (1939) – OFF From Other intermittent contact.
Parking Brake Indicator Rear Wheel • Check harness and/or sensor for open circuit or short to ground.
a disconnected
Lamp – ON (if applied) ATC Sensor resistance should measure between 900-2000 ohms.
wheel speed
sensor.
SAHR status.

ATC Lamp – ON
Wheel speed
Parking Brake Service Signal Taken
signal drops out
Lamp (1939) – OFF From Other • Check tone ring for damage/missing teeth/corrosion.
Parking Brake Indicator Rear Wheel • Check bearing play and tone ring run out.
speeds higher than
Lamp – ON (if applied) ATC
10 kph.
SAHR status.
ATC Lamp – ON
(1.02 mm).
No Trigger Lamp (1939) – OFF From Other
Detected Parking Brake Indicator Rear Wheel
SAHR status.
ATC Lamp – ON
SAHR status.
4011924a
Figure 3.20
System
Figure 3.20
Reaction
ATC Lamp – ON
Audible Warning – OFF Speed •
Parking Brake Service Signal Taken and change wrong tire.
Check foundation
Tire Lamp (1939) – OFF From Other • Check air gap and push sensor back in afterward.
Combination Parking Brake Indicator Rear Wheel • Check tone ring for correct tooth count.
may occur without
Lamp – ON (if applied) ATC • Check tone ring for damage/missing teeth/corrosion.
system failure.
OFF (if released). Disabled • Clear fault from memory.
SAHR status.
ATC Lamp – ON
Inlet valve Audible Warning – OFF Speed
(1.02 mm).
actuation time Parking Brake Service Signal Taken An ABS modulator
not plausible Lamp (1939) – OFF From Other was activated for
(75% switch Parking Brake Indicator Rear Wheel an abnormally long
on time within Lamp – ON (if applied) ATC time.
5 minutes) OFF (if released). Disabled
SAHR status.
Right Rear Wheel Speed Sensor
ATC Lamp – ON
Parking Brake Service Signal Taken Sensor air gap is
(1.02 mm).
Lamp (1939) – OFF From Other too large, sensor
Parking Brake Indicator Rear Wheel output voltage is
Lamp – ON (if applied) ATC too low.
SAHR status.
ATC Lamp – ON
An open circuit or
short to ground
Parking Brake Service Signal Taken • Check sensor impedance and sensor wiring and connectors for
has been detected.
Lamp (1939) – OFF From Other intermittent contact.
Parking Brake Indicator Rear Wheel • Check harness and/or sensor for open circuit or short to ground.
a disconnected
Lamp – ON (if applied) ATC Sensor resistance should measure between 900-2000 ohms.
wheel speed
sensor.
SAHR status.

4011925a
23
Figure 3.21
24
System
Figure 3.21
Reaction
ATC Lamp – ON
Wheel speed
signal drops out
Lamp (1939) – OFF From Other • Check tone ring for damage/missing teeth/corrosion.
Parking Brake Indicator Rear Wheel • Check bearing play and tone ring run out.
speeds higher than
10 kph.
SAHR status.
ATC Lamp – ON

(1.02 mm).
No Trigger Lamp (1939) – OFF From Other
Detected Parking Brake Indicator Rear Wheel
SAHR status.
ATC Lamp – ON
SAHR status.
ATC Lamp – ON
Audible Warning – OFF Speed •
Parking Brake Service Signal Taken and change wrong tire.
Check foundation
Tire Lamp (1939) – OFF From Other • Check air gap and push sensor back in afterward.
Combination Parking Brake Indicator Rear Wheel • Check tone ring for correct tooth count.
may occur without
Lamp – ON (if applied) ATC • Check tone ring for damage/missing teeth/corrosion.
system failure.
OFF (if released). Disabled • Clear fault from memory.
SAHR status.
4011926a
Figure 3.22
System
Figure 3.22
Reaction
ATC Lamp – ON
Inlet valve Audible Warning – OFF Speed
(1.02 mm).
actuation time Parking Brake Service Signal Taken An ABS modulator
not plausible Lamp (1939) – OFF From Other was activated for
(75% switch Parking Brake Indicator Rear Wheel an abnormally long
on time within Lamp – ON (if applied) ATC time.
5 minutes) OFF (if released). Disabled
SAHR status.
Power Amp. In Valve Left Front
ATC Lamp – ON
ABS, ATC
and EBD
Parking Brake Service • Disconnect and inspect ECU connectors for any sign of damage,
Disabled
Shorted to Lamp (1939) – OFF Inlet (IV) short to moisture or corrosion, clean connectors if necessary.
932 42 3 No Service
Battery Parking Brake Indicator BATT detected. • Check all ECU powers and grounds including load test.
brake
Lamp – ON (if applied) • If DTC persists, may indicate ECU has failed.
intervention
OFF (if released).
(power park)
SAHR status.
ATC Lamp – ON
Parking Brake Service ABS Wheel • Disconnect and inspect ECU connectors for any sign of damage,
Lamp (1939) – OFF Disabled Inlet (IV) open moisture or corrosion, clean connectors if necessary.
932 42 5 Open Circuit
Parking Brake Indicator ATC circuit detected. • Check all ECU powers and grounds including load test.
Lamp – ON (if applied) Disabled • If DTC persists, may indicate ECU has failed.
OFF (if released).
SAHR status.
ATC Lamp – ON
Short to Lamp (1939) – OFF Disabled Inlet (IV) short to moisture or corrosion, clean connectors if necessary.
932 42 6
Ground Parking Brake Indicator ATC ground detected. • Check all ECU powers and grounds including load test.
OFF (if released).
SAHR status.

4011927a
25
Figure 3.23
26
Figure 3.23
System
Reaction
Power Amp. Out Valve Left Front
ATC Lamp – ON
ABS, ATC
and EBD
Disabled
Shorted to Lamp (1939) – OFF Outlet (OV) short moisture or corrosion, clean connectors if necessary.
938 48 3 No Service
Battery Parking Brake Indicator to BATT detected. • Check all ECU powers and grounds including load test.
brake
intervention
OFF (if released).

(power park)
SAHR status.
ATC Lamp – ON
Lamp (1939) – OFF Disabled Outlet (OV) open moisture or corrosion, clean connectors if necessary.
OFF (if released).
SAHR status.
ATC Lamp – ON
Outlet (OV)
Short to Lamp (1939) – OFF Disabled moisture or corrosion, clean connectors if necessary.
938 48 6 short to ground
Ground Parking Brake Indicator ATC • Check all ECU powers and grounds including load test.
detected.
OFF (if released).
SAHR status.
4011928a
Figure 3.24
System
Figure 3.24
Reaction
Power Amp. Out Valve Left Front
ATC Lamp – ON
ABS, ATC
and EBD
Disabled
933 43 3 No Service
brake
intervention
OFF (if released).
(power park)
SAHR status.
ATC Lamp – ON
OFF (if released).
SAHR status.
ATC Lamp – ON
933 43 6
OFF (if released).
SAHR status.
Power Amp. Out Valve Right Front
ATC Lamp – ON
ABS, ATC
and EBD
Disabled
939 49 3 No Service
brake
intervention
OFF (if released).
(power park)
SAHR status.

4011929a
27
Figure 3.25
28
System
Figure 3.25
Reaction
Power Amp. Out Valve Right Front
ATC Lamp – ON
OFF (if released).
SAHR status.
ATC Lamp – ON

Outlet (OV)
detected.
OFF (if released).
SAHR status.
Power Amp. In Valve Left Rear
ATC Lamp – ON
ABS, ATC
and EBD
Disabled
934 44 3 No Service
brake
intervention
OFF (if released).
(power park)
SAHR status.
ATC Lamp – ON
OFF (if released).
SAHR status.
4011931a
Figure 3.26
System
Figure 3.26
Reaction
Power Amp. In Valve Left Rear
ATC Lamp – ON
934 44 6
OFF (if released).
SAHR status.
Power Amp. Out Valve Left Rear
ATC Lamp – ON
ABS, ATC
and EBD
Disabled
940 50 3 No Service
brake
intervention
OFF (if released).
(power park)
SAHR status.
ATC Lamp – ON
OFF (if released).
SAHR status.
ATC Lamp – ON
Outlet (OV)
detected.
OFF (if released).
SAHR status.

4011932a
29
Figure 3.27
30
System
Figure 3.27
Reaction
Power Amp. In Valve Right Rear
ATC Lamp – ON
ABS, ATC
and EBD
Disabled
935 45 3 No Service
brake
intervention
OFF (if released).
(power park)
SAHR status.
ATC Lamp – ON

OFF (if released).
SAHR status.
ATC Lamp – ON
935 45 6
OFF (if released).
SAHR status.
Power Amp. Out Valve Right Rear
ATC Lamp – ON
ABS, ATC
and EBD
Disabled
941 51 3 No Service
brake
intervention
OFF (if released).
(power park)
SAHR status.
4011933a
Figure 3.28
System
Figure 3.28
Reaction
Power Amp. Out Valve Right Rear
ATC Lamp – ON
OFF (if released).
SAHR status.
ATC Lamp – ON
Outlet (OV)
detected.
OFF (if released).
SAHR status.
Power Amp. ATC Normally Closed
ATC Lamp – ON
ABS, ATC
and EBD
Disabled
Shorted to Lamp (1939) – OFF ATC short to BATT moisture or corrosion, clean connectors if necessary.
806 18 3 No Service
Battery Parking Brake Indicator detected. • Check all ECU powers and grounds including load test.
brake
Lamp – ON (if applied) • If DTC, verify correct ECU part number.
intervention
OFF (if released).
(power park)
SAHR status.
ATC Lamp – ON
Lamp (1939) – OFF Disabled ATC open circuit moisture or corrosion, clean connectors if necessary.
Parking Brake Indicator ATC detected. • Check all ECU powers and grounds including load test.
OFF (if released).
SAHR status.

4011934a
31
Figure 3.29
32
System
Figure 3.29
Reaction
Power Amp. ATC Normally Closed
ATC Lamp – ON
Short to Lamp (1939) – OFF Disabled ATC short to moisture or corrosion, clean connectors if necessary.
806 18 6
OFF (if released).
SAHR status.
Power Amp. ATC Normally Open

ATC Lamp – ON
ABS, ATC
and EBD
Disabled
Shorted to Lamp (1939) – OFF ATC short to BATT moisture or corrosion, clean connectors if necessary.
807 19 3 No Service
Battery Parking Brake Indicator detected. • Check all ECU powers and grounds including load test.
brake
intervention
OFF (if released).
(power park)
SAHR status.
ATC Lamp – ON
Lamp (1939) – OFF Disabled ATC open circuit moisture or corrosion, clean connectors if necessary.
Parking Brake Indicator ATC detected. • Check all ECU powers and grounds including load test.
OFF (if released).
SAHR status.
ATC Lamp – ON
Short to Lamp (1939) – OFF Disabled ATC short to moisture or corrosion, clean connectors if necessary.
807 19 6
OFF (if released).
SAHR status.
4011935a
Figure 3.30
System
Figure 3.30
Reaction
Power Amp. Endurance Brake Relay
ATC Lamp – ON
Endurance brake
Shorted to Lamp (1939) – OFF EBD • Check wiring and connections from the ECU to the EBR.
801 13 3 relay output short
Battery Parking Brake Indicator Disabled • If DTC persists, may indicate ECU has failed.
to BATT detected.
OFF (if released).
SAHR status.
ATC Lamp – ON
Endurance brake
Lamp (1939) – OFF EBD • Check wiring and connections from the ECU to the EBR.
801 13 5 Open Circuit relay output open
Parking Brake Indicator Disabled • If DTC persists, may indicate ECU has failed.
detected.
OFF (if released).
SAHR status.
ATC Lamp – ON
Endurance brake
Short to Lamp (1939) – OFF EBD • Check wiring and connections from the ECU to the EBR.
801 13 6 relay short to
Ground Parking Brake Indicator Disabled • If DTC persists, may indicate ECU has failed.
ground detected.
OFF (if released).
SAHR status.
Power Amp. Brake Light Signal
ATC Lamp – ON
• Disconnect and inspect connectors for any sign of damage,
Brake light signal moisture or corrosion, clean connectors if necessary.
Shorted to Lamp (1939) – OFF
3541 100 3 N/A short to BATT • Check wiring and connectors of Brake Light Signal relay circuit
Battery Parking Brake Indicator
detected. from ABS ECU to dash module for short to voltage.
• Pin 3 should have 4-5 volts key off and 12 volts key on.
OFF (if released).
SAHR status.

4011936a
33
Figure 3.31
34
System
Figure 3.31
Reaction
Power Amp. Brake Light Signal
ATC Lamp – ON
moisture or corrosion, clean connectors if necessary.
Lamp (1939) – OFF Brake light signal
3541 100 5 Open Circuit N/A • Check wiring and connectors of Brake Light Signal relay circuit
Parking Brake Indicator open detected.
from ABS ECU to dash module for open circuit.
OFF (if released).
SAHR status.
ATC Lamp – ON

Brake light signal moisture or corrosion, clean connectors if necessary.
Short to Lamp (1939) – OFF
3541 100 6 N/A short to ground • Check wiring and connectors of Brake Light Signal relay circuit
Ground Parking Brake Indicator
detected. from ABS ECU to dash module for short to ground.
OFF (if released).
SAHR status.
Power Amp. Parking Brake Pressure Supply Valve
ABS Warning Lamp - OFF
ATC Lamp - OFF
• Check wiring and connectors of Pressure Supply Valve circuit
Audible Warning - OFF
from ABS ECU to Pressure Supply Valve for short to voltage.
SAHR • Check resistance of Pressure Supply Valve, should be 12 ohms.
Shorted to Lamp (1939) - ON Short to BATT
617 234 3 Backup (If not in spec, indicates the Pressure Supply Valve may have
Battery Parking Brake Indicator detected.
Mode 2 failed.)
Lamp - ON (if applied)
• Review Pressure Supply Valve harness diagnostics with the
FLASHING (if released)
OEM.
• If the Pressure Supply Valve and harness pass all checks, and if
DTC persists, may indicate ECU has failed.
SAHR status.
ATC Lamp - OFF
from ABS ECU to Pressure Supply Valve for open circuit.
Lamp (1939) - ON
617 234 5 Open Circuit Backup Open detected. (If not in spec, indicates the Pressure Supply Valve may have
Mode 2 failed.)
OEM.
SAHR status.
4011937a
Figure 3.32
System
Figure 3.32
Reaction
Power Amp. Parking Brake Pressure Supply Valve
ATC Lamp - OFF
from ABS ECU to Pressure Supply Valve for short to ground.
Short to Lamp (1939) - ON Short to ground
617 234 6 Backup (If not in spec, indicates the Pressure Supply Valve may have
Ground Parking Brake Indicator detected.
Mode 2 failed.)
OEM.
SAHR status.
Power Amp. Parking Brake Pressure Cut-Off Valve
ATC Lamp - OFF • Disconnect and inspect connectors for any sign of damage,
Audible Warning - OFF moisture or corrosion, clean connectors if necessary.
Parking Brake Service Park Brake • Check wiring and connectors of Pressure Cut-off Valve circuit
Shorted to Lamp (1939) - ON cannot be Short to BATT from ABS ECU to Pressure Cut-off Valve for short to voltage.
618 235 3
Battery Parking Brake Indicator Applied if detected. • Review Pressure Cut-off valve and harness diagnostics and
Lamp - ON (if applied) Released repair following OEM diagnostic TSI-08-04-01.
FLASHING (if released) • If the Pressure Cut-off Valve and harness pass all checks, and if
Parking Brake Indicator DTC persists, may indicate ECU has failed.
SAHR status.
ATC Lamp - OFF • Disconnect and inspect connectors for any sign of damage,
Parking Brake Service • Check wiring and connectors of Pressure Cut-off Valve circuit
SAHR
Lamp (1939) - ON from ABS ECU to Pressure Cut-off Valve for an open.
618 235 5 Open Circuit Backup Open detected.
Parking Brake Indicator • Review Pressure Cut-off valve and harness diagnostics and
Mode 1
Lamp - ON (if applied) repair following OEM diagnostic TSI-08-04-01.
SAHR status.
ATC Lamp - OFF • Disconnect and inspect ECU connector for any sign of damage,
Parking Brake Service • Check wiring and connectors of Pressure Cut-off Valve circuit
SAHR
Short to Lamp (1939) - ON Short to ground from ABS ECU to Pressure Cut-off Valve for a short to ground.
618 235 6 Backup
Ground Parking Brake Indicator detected. • Review Pressure Cut-off valve and harness diagnostics and
Mode 1
Lamp - ON (if applied) repair following OEM diagnostic TSI-08-04-01.
SAHR status.

4011938a
35
Figure 3.33
36
System
Reaction
Figure 3.33
Internal Valve Relay (provides supply voltage for ABS pressure control valves)
ATC Lamp - ON
Audible Warning - OFF • Disconnect and inspect connectors for any sign of damage,
Parking Brake Service moisture or corrosion, clean connectors if necessary.
ABS, ATC Internal valve relay
Cannot switch Lamp (1939) - OFF • Check all ECU powers and grounds including load test, may
818 30 3 and EBD is unable to switch
off Parking Brake Indicator need to review wiring diagnostics and repair with OEM.
Disabled off.
Lamp - ON (if applied) • If connectors and harness pass all checks, and if DTC persists,
Flashing (if released) may indicate ECU has failed.
SAHR status.
ATC Lamp - ON
Audible Warning - OFF ABS, ATC • Disconnect and inspect connectors for any sign of damage,

Valve supply
Parking Brake Service and EBD moisture or corrosion, clean connectors if necessary.
voltage Internal valve relay
Lamp (1939) - ON Disabled • Check all ECU powers and grounds including load test, may
818 30 4 missing or unable to switch
Parking Brake Indicator No Service need to review wiring diagnostics and repair with OEM.
cannot switch on.
Lamp - ON (if applied) Brake • If connectors and harness pass all checks, and if DTC persists,
on
Flashing (if released) Intervention may indicate ECU has failed.
SAHR status.
ABS Warning Light Relay (if available)
ABS Warning Lamp – N/A
ATC Lamp – ON
Activation
Audible Warning – OFF • Check wiring and connections of the ABS warning lamp circuit
of blink
Parking Brake Service pin 21 of 31-pin connector.
code switch
Open or Lamp (1939) – OFF No load detected • With ECU disconnected, with key ON, the voltage level shall
1438 23 5 longer than
Grounded Parking Brake Indicator or grounded. be ~12 volts at Pin 21 to Ground. May need to review wiring
16 seconds
Lamp – ON (if applied) diagnostics and repair with OEM.
causes fault
Flashing (if released). • Replace relay if necessary.
detection
SAHR status.
Brake Warning Light Relay (if available)
Brake Warning Lamp – N/A
ATC Lamp – ON
Activation
Audible Warning – OFF • Check wiring and connections of the Brake warning lamp circuit
of blink
Parking Brake Service pin 20 of 31-pin connector.
code switch
Open or Lamp (1939) – OFF No load detected • With ECU disconnected, with key ON, the voltage level shall
1439 101 5 longer than
Grounded Parking Brake Indicator or grounded. be ~12 volts at Pin 20 to Ground. May need to review wiring
16 seconds
Lamp – ON (if applied) diagnostics and repair with OEM.
causes fault
Flashing (if released). • Replace relay if necessary.
detection
SAHR status.
4011939a
Figure 3.34
Figure 3.34
System
Reaction
Buzzer (if available)
ATC Lamp – ON • Disconnect and inspect connectors for any sign of damage,
Audible Warning – Status moisture or corrosion, clean connectors if necessary.
per failure mode • Check wiring and connections of the Buzzer circuit pin 12 of
Parking Brake Service 31-pin connector.
Buzzer circuit
920 224 5 Buzzer Lamp (1939) – OFF Parking N/A • With ECU disconnected, with key ON, the voltage level shall
problem detected.
Brake Indicator Lamp – ON be ~12 volts at Pin 12 to Ground. May need to review wiring
(if applied) diagnostics and repair with OEM.
OFF (if released). • Current-measurement with Pin12/31 short or open.
Parking Brake Indicator • Replace buzzer relay if necessary.
SAHR status.
ECU Main Ground or Reference Ground Connection
ATC Lamp – ON
Audible Warning – OFF ABS, ATC • Check all ECU powers and grounds including load test, may
Parking Brake Service and EBD ECU Main or need to review wiring diagnostics and repair with OEM.
ECU Main or
Lamp (1939) – ON Disabled Reference • Shake harness while checking ground for any loss of ground
3540 98 2 Reference
Parking Brake Indicator Park Brake Ground missing or issues.
Ground
Lamp – ON (if applied) Status interrupted. • Even if no issues were found during inspection, disconnect,
OFF (if released). Maintained inspect and clean connectors, reinstall per OEM guidelines.
SAHR status.
No Ignition Voltage Although Engine Speed Is Higher than 300 rpm for 5s
ATC Lamp – OFF
Audible Warning – OFF • Disconnect and inspect connectors for any sign of damage,
Parking Brake Service moisture or corrosion, clean connectors if necessary.
ECU Ignition
No Ignition Lamp (1939) – ON • Check voltage at pin 1 shall be ~ battery voltage.
158 158 4 N/A missing or
Voltage Parking Brake Indicator • Check fuse, chassis connector and ignition relay.
interrupted.
Lamp – ON (if applied) • Shake harness while checking voltage for any voltage
OFF (if released). interruptions.
SAHR status.
4011940a

37
Figure 3.35
38
System
Figure 3.35
Reaction
ECU Voltage
ATC Lamp – ON
• Check alternator and battery.
High Voltage Lamp (1939) – OFF ATC ECU supply
2597 251 3 moisture or corrosion, clean connectors if necessary.
(>16.5 V) Parking Brake Indicator Disabled voltage too high.
• Check all ECU powers and grounds including load test, may
need to review wiring diagnostics and repair with OEM.
OFF (if released).
SAHR status.
Brake Warning Lamp – ON ABS enabled
ATC Lamp – ON during

Audible Warning – OFF cycling
• Check alternator and battery.
Parking Brake Service ATC
Low Voltage Lamp (1939) – ON Disabled ECU supply
2597 251 4 moisture or corrosion, clean connectors if necessary.
(<10.0 V) Parking Brake Indicator ECU voltage too low.
Lamp – ON (if applied) attempts
OFF (if released). to maintain
Parking Brake Indicator park brake
Lamp (1939) according to functionality
SAHR status.
Accumulator Pressure Sensing Front Axle
Level 1
Audible Warning – ON moisture or corrosion, clean connectors if necessary.
Warning
Parking Brake Service • Check all ECU powers and grounds including load test, may
ABS
Shorted to Lamp (1939) – OFF Signal short to need to review wiring diagnostics and repair with OEM.
1049 59 3 Disabled
Battery Parking Brake Indicator BATT detected. • Remove ECU and check Pressure Sensor both ECU and HCU
(Front Axle)
Lamp – ON (if applied) sides and check for signs of damage, moisture or corrosion.
ATC
OFF (if released). • If pressure sensor, connectors and wiring pass all checks, and if
Disabled
Parking Brake Indicator DTC persists, may indicate ECU/HCU has failed.
SAHR status.
Brake Warning Lamp – ON • Disconnect and inspect connectors for any sign of damage,
ATC Lamp – ON moisture or corrosion, clean connectors if necessary.
Level 1
Audible Warning – ON • Check all ECU powers and grounds including load test, may
Warning
Parking Brake Service need to review wiring diagnostics and repair with OEM.
ABS
Short to Lamp (1939) – OFF Signal short to • Remove ECU and check Pressure Sensor both ECU and HCU
1049 59 4 Disabled
Ground Parking Brake Indicator ground detected. sides and check for signs of damage, moisture or corrosion.
(Front Axle)
Lamp – ON (if applied) • If pressure sensor, connectors and wiring pass all checks, and if
ATC
OFF (if released). DTC persists, may indicate ECU has failed.
Disabled
Parking Brake Indicator • If after replacing the ECU, the DTC persists, may indicate the
Lamp (1939) according to HCU has failed.
SAHR status.
4011941a
Figure 3.36
System
Figure 3.36
Reaction
Accumulator Pressure Sensing Front Axle
ABS Warning Lamp – ON • Check accumulator pre-charge level using TOOLBOX™
Brake Warning Lamp – ON Software diagnostics.
ATC Lamp – ON - Deplete accumulators with ignition off, wait approximately 5
Level 1
Audible Warning – ON seconds then turn ignition on. Do not apply the brakes, then
Abnormal Warning
Parking Brake Service under Display, select Pre-Charge Pressure.
High Pressure ABS Abnormal high
Lamp (1939) – OFF - If the pressure is below 430 psi or 30 bar, replace the ac-
1049 59 10 Gradient Disabled pressure gradient
Parking Brake Indicator cumulator.
(Short Charge (Front Axle) detected.
Lamp – ON (if applied) • If pressure increases rapidly, may indicate the accumulator has
Time) ATC
OFF (if released). failed.
Disabled
Parking Brake Indicator • Disconnect and inspect connectors for any sign of damage,
Lamp (1939) according to moisture or corrosion, clean connectors if necessary.
SAHR status. • Replace accumulator if necessary.
Accumulator Pressure Sensing Rear Axle
Level 1
Audible Warning – ON moisture or corrosion, clean connectors if necessary.
Warning
Parking Brake Service • Check all ECU powers and grounds including load test, may
ABS
Shorted to Lamp (1939) – OFF Signal short to need to review wiring diagnostics and repair with OEM.
1052 62 3 Disabled
Battery Parking Brake Indicator BATT detected. • Remove ECU and check Pressure Sensor both ECU and HCU
(Front Axle)
Lamp – ON (if applied) sides and check for signs of damage, moisture or corrosion.
ATC
OFF (if released). • If pressure sensor, connectors and wiring pass all checks, and if
Disabled
Parking Brake Indicator DTC persists, may indicate ECU/HCU has failed.
SAHR status.
Brake Warning Lamp – ON • Disconnect and inspect connectors for any sign of damage,
ATC Lamp – ON moisture or corrosion, clean connectors if necessary.
Level 1
Audible Warning – ON • Check all ECU powers and grounds including load test, may
Warning
Parking Brake Service need to review wiring diagnostics and repair with OEM.
ABS
Short to Lamp (1939) – OFF Signal short to • Remove ECU and check Pressure Sensor both ECU and HCU
1052 62 4 Disabled
Ground Parking Brake Indicator ground detected. sides and check for signs of damage, moisture or corrosion.
(Front Axle)
Lamp – ON (if applied) • If pressure sensor, connectors and wiring pass all checks, and if
ATC
OFF (if released). DTC persists, may indicate ECU has failed.
Disabled
Parking Brake Indicator • If after replacing the ECU the DTC persists, may indicate the
Lamp (1939) according to HCU has failed.
SAHR status.
ABS Warning Lamp – ON • Check accumulator pre-charge level using TOOLBOX™
Brake Warning Lamp – ON Software diagnostics.
ATC Lamp – ON - Deplete accumulators with ignition off, wait approximately 5
Level 1
Audible Warning – ON seconds then turn ignition on. Do not apply the brakes, then
Abnormal Warning
Parking Brake Service under Display, select Pre-Charge Pressure.
High Pressure ABS Abnormal high
Lamp (1939) – OFF - If the pressure is below 430 psi or 30 bar, replace the ac-
1052 62 10 Gradient Disabled pressure gradient
Parking Brake Indicator cumulator.
(Short Charge (Front Axle) detected.
Lamp – ON (if applied) • If pressure increases rapidly, may indicate the accumulator has
Time) ATC
OFF (if released). failed.
Disabled
Parking Brake Indicator • Disconnect and inspect connectors for any sign of damage,
Lamp (1939) according to moisture or corrosion, clean connectors if necessary.
SAHR status. • Replace accumulator if necessary.

4011942a
39
Figure 3.37
40
System
Figure 3.37
Reaction
Electronic Pressure Control Front Axle
ATC Lamp – ON
Level 1 • Disconnect and inspect the ECU 2-pin and 31-pin connectors for
Warning any sign of damage, moisture or corrosion, verify all lock tabs
Pump motor Parking Brake Service
ABS Pump motor are in good condition and, clean connectors if necessary.
does not Lamp (1939) – OFF
2580 57 3 Disabled current draw less • Check all ECU powers and grounds including load test, may
operate when Parking Brake Indicator
(Front Axle) than expected. need to review wiring diagnostics and repair with OEM.
expected Lamp – ON (if applied)
ATC & EBD • If connectors and wiring pass all checks, and if DTC persists,
OFF (if released).
Disabled may indicate ECU/HCU has failed.
SAHR status.
ATC Lamp – ON
Level 1

Warning • Disconnect and inspect the ECU 2-pin and 31-pin connectors for
Supply Parking Brake Service
ABS any sign of damage, moisture or corrosion, verify all lock tabs
voltage for Lamp (1939) – OFF
2580 57 5 Disabled Pump power. are in good condition and, clean connectors if necessary.
pump motor Parking Brake Indicator
(Front Axle) • Check all ECU powers, grounds and corresponding pump motor
missing Lamp – ON (if applied)
ATC & EBD fuse and related wiring and repair per OEM guidelines.
OFF (if released).
Disabled
SAHR status.
• Disconnect and inspect the ECU 2-pin and 31-pin connectors for
any sign of damage, moisture or corrosion, verify all lock tabs
are in good condition and, clean connectors if necessary.
• Check accumulator pre-charge level using Toolbox™ Software
ABS Warning Lamp – ON diagnosis.
Brake Warning Lamp – ON - Deplete accumulators with ignition off, wait approximately 5
ATC Lamp – ON seconds then turn ignition on. Do not apply the brakes, then
Level 1
Audible Warning – ON under Display, select Pre-Charge Pressure.
Warning
Pump motor Parking Brake Service - If the pressure is below 430 psi or 30 bar, replace the ac-
ABS Pump motor
operates Lamp (1939) – OFF cumulator.
2580 57 4 Disabled unexpected
when not Parking Brake Indicator • Verify reservoir cap is venting correctly using below procedure:
(Front Axle) operation.
expected Lamp – ON (if applied) - If a hissing noise is heard when removing the cap, replace
ATC & EBD
OFF (if released). the cap.
Disabled
Parking Brake Indicator - If no noise is heard, deplete accumulators using Toolbox™
Lamp (1939) according to Software, or disconnect the battery or pull the pump fuses
SAHR status. and press the brake pedal a minimum of 30 times.
- Remove the cap.
- Reconnect the battery or fuses, if pulled, and measure the
time it takes for the pumps to run and shut off.
- If the pumps run longer than 60 seconds, replace the unit.
- If the pumps shut off before 60 seconds is achieved and the
failure disappears, replace the cap.
4011943a
Figure 3.38
Figure 3.38
System
Reaction
diagnosis.
ABS Warning Lamp – ON - Deplete accumulators with ignition off, wait approximately 5
Brake Warning Lamp – ON seconds then turn ignition on. Do not apply the brakes, then
ATC Lamp – ON under Display, select Pre-Charge Pressure.
Level 1
Audible Warning – ON - If the pressure is below 430 psi or 30 bar, replace the ac-
Warning
Pump motor Parking Brake Service cumulator.
ABS Motor runs after
operates Lamp (1939) – OFF • Verify reservoir cap is venting correctly using below procedure:
2580 57 6 Disabled cut out pressure
when not Parking Brake Indicator - If a hissing noise is heard when removing the cap, replace
(Front Axle) reached.
expected Lamp – ON (if applied) the cap.
ATC & EBD
OFF (if released). - If no noise is heard, deplete accumulators using Toolbox™
Disabled
Parking Brake Indicator Software, or disconnect the battery or pull the pump fuses
Lamp (1939) according to and press the brake pedal a minimum of 30 times.
SAHR status. - Remove the cap.
- Check pressure in accumulators, if pressure exceeds 2435
psi, replace unit.
diagnosis.
- Deplete accumulators with ignition off, wait approximately 5
seconds then turn ignition on. Do not apply the brakes, then
under Display, select Pre-Charge Pressure.
ATC Lamp – ON
Level 1 - If the pressure is below 430 psi or 30 bar, replace the ac-
Warning cumulator.
Master ABS • Check master cylinder function.
Lamp (1939) – OFF Brake circuit failure
2580 57 7 cylinder brake Disabled - Inspect master cylinder for leaks. Replace master cylinder if
Parking Brake Indicator detected.
circuit failure (Front Axle) any leaks are found.
ATC & EBD - Press and hold the brake pedal down. If the pedal starts to
OFF (if released).
Disabled move lower, replace the master cylinder.
- Crack the bleeder screws on the relay valve of the HPB unit.
With the bleeder screws cracked open, have someone press
SAHR status.
screws, replace the master cylinder.
4011944a

41
Figure 3.39
42
Figure 3.39
System
Reaction
Diaphragm
ATC Lamp – ON
accumulator Level 1 • Check accumulator pre-charge level using TOOLBOX™
precharge Warning Software diagnostics.
level too low ABS Accumulator pre- - Deplete accumulators with ignition off, wait approximately 5
Lamp (1939) – OFF
2580 57 8 (detected Disabled charge low level seconds then turn ignition on. Do not apply the brakes, then
by short run (Front Axle) detected. under Display, select Pre-Charge Pressure.
time and high ATC & EBD - If the pressure is below 430 psi or 30 bar, replace the ac-
OFF (if released).
switch on Disabled cumulator.

frequency)
SAHR status.
ATC Lamp – ON
Level 1 • Check pump motor for external leakage.
Warning • Count frequency of pump actuations less than 30 seconds apart
ABS with no demand from brakes or park brakes. If frequency of
Leakage too Lamp (1939) – OFF Too high of
2580 57 9 Disabled activation is greater than 30 seconds, decrease count by one. If
high Parking Brake Indicator leakage detected.
(Front Axle) count is greater than 20, failure is logged.
ATC & EBD • If all checks pass, and if DTC persists, may indicate ECU has
OFF (if released).
Disabled failed or HCU has failed.
SAHR status.
• Verify reservoir cap is venting correctly using below procedure:
- If a hissing noise is heard when removing the cap, replace
the cap.
- If no noise is heard, deplete accumulators using Toolbox™
ATC Lamp – ON
Level 1 Software, or disconnect the battery or pull the pump fuses
Warning and press the brake pedal a minimum of 30 times.
Extended ABS Long accumulator - Remove the cap.
Lamp (1939) – OFF
2580 57 10 accumulator Disabled charging time - Reconnect the battery or fuses, if pulled, and measure the
charging time (Front Axle) detected. time it takes for the pumps to run and shut off.
ATC & EBD - If the pumps run longer than 60 seconds, replace the unit.
OFF (if released).
Disabled • If the pumps shut off before 60 seconds is achieved and the
failure disappears, replace the cap
•
SAHR status.
• Verify there is no air in the system, Bleed system if necessary.
• If all checks pass, may indicate a pump or motor has failed.
4011945a
Figure 3.40
Figure 3.40
System
Reaction
Electronic Pressure Control Rear Axle
ATC Lamp – ON
Level 1 • Disconnect and inspect the ECU 2-pin and 31-pin connectors for
Warning any sign of damage, moisture or corrosion, verify all lock tabs
ABS Pump motor are in good condition and, clean connectors if necessary.
does not Lamp (1939) – OFF
2581 60 3 Disabled current draw less • Check all ECU powers and grounds including load test, may
operate when Parking Brake Indicator
(Front Axle) than expected. need to review wiring diagnostics and repair with OEM.
ATC • If connectors and wiring pass all checks, and if DTC persists,
OFF (if released).
Disabled may indicate ECU/HCU has failed.
SAHR status.
ATC Lamp – ON
Level 1
Audible Warning – ON • Disconnect and inspect the ECU 2-pin and 31-pin connectors for
Warning
Supply Parking Brake Service any sign of damage, moisture or corrosion, verify all lock tabs
ABS
voltage for Lamp (1939) – OFF are in good condition and, clean connectors if necessary.
2581 60 5 Disabled Pump power.
pump motor Parking Brake Indicator • Check all ECU powers and grounds including load test, may
(Front Axle)
missing Lamp – ON (if applied) need to review wiring diagnostics and repair with OEM.
ATC
OFF (if released).
Disabled
SAHR status.
ATC Lamp – ON
Level 1
Warning • Disconnect and inspect the ECU 2-pin and 31-pin connectors for
ABS Pump motor any sign of damage, moisture or corrosion, verify all lock tabs
operates Lamp (1939) – OFF
2581 60 4 Disabled unexpected are in good condition and, clean connectors if necessary.
when not Parking Brake Indicator
(Front Axle) operation. • Check all ECU powers, grounds and corresponding pump motor
ATC fuse and related wiring. Repair or replace per OEM guidelines.
OFF (if released).
Disabled
SAHR status.
4011946a

43
Figure 3.41
44
System
Reaction
Figure 3.41
Electronic Pressure Control Rear Axle
diagnosis.
ABS Warning Lamp – ON - Deplete accumulators with ignition off, wait approximately 5
Brake Warning Lamp – ON seconds then turn ignition on. Do not apply the brakes, then
ATC Lamp – ON under Display, select Pre-Charge Pressure.
Level 1
Audible Warning – ON - If the pressure is below 430 psi or 30 bar, replace the ac-
Warning
Pump motor Parking Brake Service cumulator.
ABS Pump motor
operates Lamp (1939) – OFF • Verify reservoir cap is venting correctly using below procedure:
2581 60 6 Disabled runs after cut-out
when not Parking Brake Indicator - If a hissing noise is heard when removing the cap, replace
(Front Axle) pressure reached.
expected Lamp – ON (if applied) the cap.
ATC
OFF (if released). - If no noise is heard, deplete accumulators using Toolbox™
Disabled
Parking Brake Indicator Software, or disconnect the battery or pull the pump fuses

Lamp (1939) according to and press the brake pedal a minimum of 30 times.
SAHR status. - Remove the cap.
- Check pressure in accumulators. If pressure exceeds 2435
psi, replace unit.
diagnosis.
- Deplete accumulators with ignition off, wait approximately 5
seconds then turn ignition on. Do not apply the brakes, then
under Display, select Pre-Charge Pressure.
ATC Lamp – ON
Level 1 - If the pressure is below 430 psi or 30 bar, replace the ac-
Warning cumulator.
Master ABS • Check master cylinder function.
Lamp (1939) – OFF Brake circuit failure
2581 60 7 cylinder brake Disabled - Inspect master cylinder for leaks. Replace master cylinder if
circuit failure (Front Axle) any leaks are found.
ATC - Press and hold the brake pedal down. If the pedal starts to
OFF (if released).
Disabled move lower, replace the master cylinder.
- Crack the bleeder screws on the relay valve of the HPB unit.
With the bleeder screws cracked open, have someone press
SAHR status.
bleeder screws, replace the master cylinder.

Diaphragm
ATC Lamp – ON
accumulator Level 1 • Check accumulator pre-charge level using TOOLBOX™
precharge Warning Software diagnostics.
level too low ABS Accumulator pre- - Deplete accumulators with ignition off, wait approximately 5
Lamp (1939) – OFF
2581 60 8 (detected Disabled charge low level seconds then turn ignition on. Do not apply the brakes, then
by short run (Front Axle) detected. under Display, select Pre-Charge Pressure.
time and high ATC - If the pressure is below 430 psi or 30 bar, replace the ac-
OFF (if released).
switch on Disabled cumulator.
frequency)
SAHR status.
4011947a
Figure 3.42
Figure 3.42
System
Reaction
ATC Lamp – ON
Level 1 • Check pump motor for external leakage.
Warning • Count frequency of pump actuations less than 30 seconds apart
ABS with no demand from brakes or park brakes. If frequency of
Leakage too Lamp (1939) – OFF Too high of
2581 60 9 Disabled activation is greater than 30 seconds, decrease count by one. If
high Parking Brake Indicator leakage detected.
(Front Axle) count is greater than 20, failure is logged.
ATC • If all checks pass, and if DTC persists, may indicate ECU has
OFF (if released).
Disabled failed or HCU has failed.
SAHR status.
• Verify reservoir cap is venting correctly using below procedure:
- If a hissing noise is heard when removing the cap, replace
the cap.
- If no noise is heard, deplete accumulators using Toolbox™
ATC Lamp – ON
Level 1 Software, or disconnect the battery or pull the pump fuses
Warning and press the brake pedal a minimum of 30 times.
Extended ABS Long accumulator - Remove the cap.
Lamp (1939) – OFF
2581 60 10 accumulator Disabled charging time - Reconnect the battery or fuses, if pulled, and measure the
charging time (Front Axle) detected. time it takes for the pumps to run and shut off.
ATC - If the pumps run longer than 60 seconds, replace the unit.
OFF (if released).
Disabled - If the pumps shut off before 60 seconds is achieved and the
•
SAHR status.
• Verify there is no air in the system. Bleed system if necessary.
• If all checks pass, may indicate a pump or motor has failed.
Foot Brake Switch
• Check in TOOLBOX™ Software to see if switch positions are
recognized.
ABS Warning Lamp – OFF • Disconnect and inspect connectors for any sign of damage,
Brake Warning Lamp – ON moisture or corrosion, clean connectors if necessary.
ATC Lamp – OFF • Check pin 10 of 31-pin harness connector circuit for open, short
Audible Warning – OFF to voltage or ground.
Cruise
Parking Brake Service • Check resistance of circuit and check resistance of switch
control
Lamp (1939) – OFF Brake switch range (27680 ohms at rest and 680 ohms depressed).
597 246 3 Out of range disabled
Parking Brake Indicator error detected. • If switch reading is out of range, may indicate switch failure. If
ATC & EBD
Lamp – ON (if applied) circuit readings are out of range, may indicate a wiring issue.
disabled
OFF (if released). (Review wiring diagnostics and repairs with OEM.)
Parking Brake Indicator • Verify battery voltage at pin 2 of switch harness connector. If
Lamp (1939) according to no voltage detected or out of range, may indicate wiring or fuse
SAHR status. issue.
•
has failed.
4011948a

45
Figure 3.43
46
System
Reaction
Figure 3.43
Foot Brake Switch
• Determine if switch was being held in position too long.
recognized.
ABS Warning Lamp – OFF
ATC Lamp – OFF
• Check pin 10 of 31-pin harness connector circuit for open, short
Cruise to voltage or ground.
control Excessive switch • Check resistance of circuit and check resistance of switch at rest
Long Switch Lamp (1939) – OFF
597 246 10 disabled activation time (27680 ohms at rest and 680 ohms depressed).
Time Detected Parking Brake Indicator
ATC & EBD detected. • If switch reading is out of range, may indicate switch failure. If
disabled circuit readings are out of range, may indicate a wiring issue.
OFF (if released).
(Review wiring diagnostics and repairs with OEM.)
• Verify battery voltage at pin 2 of switch harness connector. If
no voltage detected or out of range, may indicate wiring or fuse
SAHR status.
issue.
•
has failed.

Parking Brake Switch
recognized.
• Verify parameters are correct in ECU if issue occurs after
replacing the ECU.
ATC Lamp – OFF
Park brake to voltage or ground.
Lamp (1939) – OFF Brake switch range
70 70 3 Out of range status • Check resistance of circuit and check resistance of switch.
Parking Brake Indicator error detected.
maintained Switch readings that are out of spec indicate a failed switch.
- Gen 2 switch: pushed in (560 ohms), Neutral (1560 ohms),
FLASHING (if released).
pulled out (4560 ohms).
SAHR status.
• If switch reading is out of range, may indicate switch failure. If
circuit readings are out of range, may indicate a wiring issue.
recognized.
• Verify parameters are correct in ECU if issue occurs after
replacing the ECU.
ATC Lamp – OFF
Park brake Excessive switch to voltage or ground.
Long switch Lamp (1939) – OFF
70 70 10 status activation time • Check resistance of circuit and check resistance of switch.
time detected Parking Brake Indicator
maintained detected. Switch readings that are out of spec indicate a failed switch.
SAHR status.
• If switch reading is out of range, may indicate switch failure. If
circuit readings are out of range, may indicate a wiring issue.
4011949a
Figure 3.44
Figure 3.44
System
Reaction
Parking Brake System
ATC Lamp – OFF
Park brake Parking Brake Service Parking brake • Follow OEM diagnostic TSI-08-04-01.
SAHR
travel Lamp (1939) – ON travel switch • Check SAHR for correct mechanical functionality.
619 61 3 backup
switch out Parking Brake Indicator position error • Check parking brake adjustment.
mode 1
implausible Lamp – ON (if applied) detected. • Check functionality of travel switch.
SAHR status.
ATC Lamp – OFF
Parking Brake Service • Follow OEM diagnostic TSI-08-04-01.
SAHR
Could not be Lamp (1939) – OFF Park brake could • Check SAHR for correct mechanical functionality.
619 61 4 backup
released Parking Brake Indicator not be released. • Check parking brake adjustment.
mode 1
Lamp – ON (if applied) • Check functionality of travel switch.
SAHR status.
ATC Lamp – OFF
Parking Brake Service Parking brake • Follow OEM diagnostic TSI-08-04-01.
SAHR
Lamp (1939) – OFF travel switch • Check SAHR for correct mechanical functionality.
619 61 13 Overtravel backup
Parking Brake Indicator overtravel • Check parking brake adjustment.
mode 1
Lamp – ON (if applied) detected. • Check functionality of travel switch.
SAHR status.
4011950a

47
Figure 3.45
48
Figure 3.45
System
Reaction
J1939 Communication
• Check electrical system of J1939 bus (connections, wiring).
• Disconnect and inspect the 31-pin connector for any sign of
damage, moisture or corrosion, clean connectors if necessary.
• At the 31-pin harness connector, check resistance across pins
ATC Lamp – ON Audible
14,15 with the key off (should be 60 ohms).
Warning – OFF Parking
J1939 data • At the 31-pin harness connector pin 14, check voltage to ground
Brake Service Lamp J1939 high(+) or
J1939 Data errors or with key on (should be 2.5 to 5 volts).
639 231 5 (1939) – ON Parking Brake low (-) open or
Bus Error J1939 time • At the 31-pin harness connector pin 15, check voltage to ground
Indicator Lamp - ON (if shorted.
out with key on (should be 2.5 volts or less).
applied) OFF (if released).
•
but they should never be the same and the total voltage of pins 14
and 15 should equal approximately 5 volts.
SAHR status.
• May need to review J1939 circuit diagnostics and repair with the
OEM.

• Disconnect and inspect the 31-pin connector for any sign of
ABS Warning Lamp – ON damage, moisture or corrosion, clean connectors if necessary.
Brake Warning Lamp – OFF • At the 31-pin harness connector, check resistance across pins
ATC Lamp – ON 14,15 with the key off (should be 60 ohms).
Audible Warning – OFF • At the 31-pin harness connector pin 14, check voltage to ground
Parking Brake Service with key on (should be 2.5 to 5 volts).
J1939 Internal Lamp (1939) – ON • At the 31-pin harness connector pin 15, check voltage to ground
639 231 12 N/A Internal fault.
Error Parking Brake Indicator with key on (should be 2.5 volts or less).
Lamp – ON (if applied) •
OFF (if released). but they should never be the same and the total voltage of pins 14
Parking Brake Indicator and 15 should equal approximately 5 volts.
Lamp (1939) according to • May need to review J1939 circuit diagnostics and repair with the
SAHR status. OEM.
• If all J1939 checks pass, may indicate a failed ECU.
ABS Warning Lamp – (ON
if engine retarder time out. • Check electrical system of J1939 bus (connections, wiring).
Else OFF) • Disconnect and inspect the 31-pin connector for any sign of
Brake Warning Lamp - OFF damage, moisture or corrosion, clean connectors if necessary.
ATC Lamp – (ON if Engine • At the 31-pin harness connector, check resistance across pins
Controller (EEC1) or 14,15 with the key off (should be 60 ohms).
System Controller message • At the 31-pin harness connector pin 14, check voltage to ground
time out. Else OFF) Incorrect with key on (should be 2.5 to 5 volts).
J1939 Audible Warning - OFF message • At the 31-pin harness connector pin 15, check voltage to ground
639 231 9 Message Parking Brake Service N/A received or Time with key on (should be 2.5 volts or less).
Time Out Lamp (1939) – (ON if Out detected •
transmission ECU, selected fault. but they should never be the same and the total voltage of pins 14
gear (ETC2). Else OFF) and 15 should equal approximately 5 volts.
Parking Brake Indicator • May need to review J1939 circuit diagnostics and repair with the
Lamp - ON (if applied) OFF OEM.
(if released) • May have unusual or erratic sensor readings for 2 or more
Parking Brake Indicator sensors, check sensor adjustment, wheel end play and tone rings
Lamp (1939) according to for issues.
SAHR status
4011951a
Figure 3.46
Figure 3.46
System
Reaction
J1939 Communication
ATC Lamp – ON
Parking Brake Service Problem with the
• Check electrical system of J1939 bus (connections, wiring), and
ATC Switches Lamp (1939) – OFF ATC switch or
639 231 2 N/A review ATC switch circuit diagnostics and repair, with the OEM.
(EBC1) Parking Brake Indicator circuit has been
• Verify the ECU parameters are correct.
Lamp – ON (if applied) OFF detected.
(if released).
SAHR status.
Special System Conditions
(for hardwired systems) ATC
Lamp – OFF Brake Fluid
Audible Warning – ON Indicator
Parking Brake Service Lamp • Inspect and repair leaks.
Low Fluid
N/A N/A N/A Lamp (1939) – OFF Enabled •
Level detected.
Parking Brake Indicator (on non- Brake (HPB) Master Cylinder Reservoir“ section in this manual).
Lamp – ON (if applied) hardwired
OFF (if released). systems)
SAHR status.
ABS, ATC
& EBD
ATC Lamp – ON
disabled
PB release
Pressure level Parking Brake Service Low pressure
request
below 1525 Lamp (1939) – OFF level in circuit
N/A N/A N/A postponed N/A
PSI in circuit 1 Parking Brake Indicator 1 or circuit 2
until both
or circuit 2 Lamp – ON (if applied) detected.
pressure
OFF (if released).
levels
exceed 1525
psi.
SAHR status.
Engine
torque
limited to
ATC Lamp – OFF
50% auto
Parking brake Audible Warning – ON Application of
N/A N/A N/A trans/20% N/A
applied (500 ms) Parking Brake park brake.
manual trans
Service Lamp (1939) – OFF
if engine
intervention
Lamp – ON
possible.
4011952a

49
Figure 3.47
50
Figure 3.47
System
Reaction
Park brake
release
rejected due Pressure level
to following: ABS Warning Lamp – OFF below 1525 psi
Pressure Brake Warning Lamp – OFF in any circuit
level below ATC Lamp – OFF detected. Shift
1525 psi in Audible Warning – ON inhibit active
any circuit. (500 ms) detected. Foot
PB release
Shift inhibit Parking Brake Service brake switch
N/A N/A N/A request N/A
active. Foot Lamp (1939) – OFF not actuated
rejected
brake switch Parking Brake Indicator on auto trans

not actuated Lamp – ON vehicle detected.

on auto trans Parking Brake Indicator Transmission
vehicle. Lamp (1939) according to in park on auto
Transmission SAHR status. trans vehicle
in park on detected.
auto trans
vehicle.
ATC Lamp – OFF
Service brake Service brake
Audible Warning – OFF Actuate
intervention intervention
Parking Brake Service brake signal
due to due to parking
Lamp (1939) – OFF output in
N/A N/A N/A parking brake brake application N/A
Parking Brake Indicator order to
application request during
Lamp – ON (if applied) illuminate
request during vehicle driving
OFF (if released). brake lights
vehicle driving detected.
SAHR status.
ATC Lamp – FLASHING at
• During a vehicle acceleration event where wheel slip is detected,
0.33 Hz Audible Warning
the ABS ECU may derate the engine or modulate the rear brakes
– OFF
ATC as needed in order to improve traction.
Parking Brake Service ATC off-road
ATC off-road enabled with • In some road and or off-road conditions more wheel slip is
N/A N/A N/A Lamp (1939) – OFF switch activation
switch applied increased desired, by activating the “Off-Road” (or Deep Mud and Snow)
thresholds switch, more wheel slip is allowed. While the system is in the “Off-
OFF (if released).
switch off or cycle the key.
SAHR status.
4013079a
Figure 3.48
Figure 3.48
System
Reaction
ATC Lamp – ON
• During a vehicle acceleration event where wheel slip is detected,
Lamp (1939) – OFF ATC ATC event
N/A N/A N/A ATC Event the ABS ECU may derate the engine or modulate the rear brakes
Parking Brake Indicator activation detected.
as needed in order to improve traction.
OFF (if released).
SAHR status.
(until all wheels speeds
pass sensor test) Brake
Warning Lamp – OFF
ATC Lamp – ON (until all
Sensor failure wheels speeds pass sensor ABS & ATC
Sensor failure
detected test) Audible Warning – OFF disabled until
detected during
N/A N/A N/A during Parking Brake Service all wheel • Repair wheel end sensor failure.
previous drive
previous drive Lamp (1939) – OFF Parking speeds pass
cycle.
cycle Brake Indicator Lamp – sensor test
ON (if applied) OFF (if
released).
SAHR status.
4013080a

51
4 Removal and Installation
Hazard Alert Messages Before disposing of used components, verify the warranty
status. Contact WABCO North America Customer Care at

Read and observe all Warning and Caution hazard alert messages in 855-228-3203 for instructions.
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
Removal
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
WARNING
The full power brake system is a pressurized system that
Park the vehicle on a level surface. For vehicle equipped with
manual parking brakes, apply the parking brakes. Ensure that achieves pressures of up to 2320 psi. This pressure is not
the ignition is turned off. Block the front and rear wheels to reduced by switching the ignition off or removing battery
power. Prior to servicing this system, the depressurization
prevent the vehicle from moving. Failure to do so can result in
unwanted vehicle movement causing serious personal injury. procedures must be performed exactly as presented. Failure to
depressurize the system may result in serious personal injury.
Release all air from the air systems before you remove any
NOTE: The following general guidelines are provided to facilitate
components. Pressurized air can cause serious personal
injury. the safe removal of the HCU from the vehicle.
The full power brake system is a pressurized system that 앫 Two people are needed to perform this procedure.
achieves pressures of up to 2320 psi. This pressure is not 앫 For the HCU drain procedure in Step 11, TOOLBOX™ Software
reduced by switching the ignition off or removing battery version 9.0 or higher is required. If you do not have this version
power. Prior to servicing this system, the depressurization of TOOLBOX™ Software, go to wabco-na.com.
procedures must be performed exactly as presented. Failure to
앫 In some vehicles it may be necessary to move non-HPB system
depressurize the system may result in personal injury or
components, such as the air tank, in order to access the HPB
death.
part. If this is necessary, refer to the vehicle manufacturer’s
manual for information before moving the component.
Thoroughly clean the area around the HCU fittings before
beginning the removal procedure to avoid contaminating the 앫 HPB systems may include automatic parking brakes. If your
system. As hoses and brake lines are removed, plug all open vehicle is equipped with manual parking brakes, refer to the
ports and lines. Contamination may cause loss of braking force manual parking brake procedures. To determine the type of
or brake failure, and result in serious personal injury. parking brake on the vehicle, refer to the vehicle specification
sheet.
CAUTION
앫 Bleed the brake and master cylinder circuits. Bleed procedures
The HPB hydraulic power brake system is a complex device
appear in Section 5 of this manual.
that provides optimum efficiency and operation. If the system
sustains damage, or a component malfunctions and requires 앫 After installing HPB components or making system repairs, use
replacement, the replacement procedures provided by WABCO TOOLBOX™ Software to remove the error code from the ECU
must be followed exactly with the associated steps performed memory. Instructions for using TOOLBOX™ Software appear in
in the order presented. Section 3 of this manual.
1. Park the vehicle on a level surface. Apply the parking brake.
Hydraulic brake fluid is a caustic substance. Contact with the
Ensure that the ignition is turned OFF.
hydraulic brake fluid can cause skin irritation. Do not let
hydraulic brake fluid touch any painted surfaces, as it will 2. Block the front and rear tires to prevent the vehicle from
remove the paint. Hydraulic brake fluid may also damage moving. Failure to do so can result in unwanted vehicle
certain non-metal surfaces. Do not let fluid contact brake movement causing serious personal injury.
pads, shoes, rotors or discs.
3. Disconnect the battery.

4. Use a clean rag to carefully clean the surface of the HCU and 6. Repeat Steps A-E for the second axle.
the surrounding area.
NOTE: Be careful not to damage the HCU reservoir inlet when
5. Apply the brake pedal a minimum of 30 times to decrease
attaching the pinch clamp. If damaged, it will need to be
pressure in the system. As an alternate method, connect the
replaced.
vehicle to a computer that has TOOLBOX™ Software version
9.0 or higher installed. From the HPB Main menu, select EOL
7. Attach hose clamp pliers to the low pressure hose at the HCU
to enable the end of line test. From the pull-down options, reservoir inlet. Clamp the rubber hose at least 3 inches
select Deplete Accumulators to start the procedure. To (76 mm) away from the entrance to the HCU reservoir. Use
ensure the system is depressurized, perform the following
care to avoid damage to the plastic reservoir nipple inside the
check on both the front and rear axles. hose. Figure 4.2.
A. Remove the protective cover from the end of the bleeder
fitting on one brake caliper. Figure 4.2
Do not damage
B. Attach a bleeder bottle hose to the bleeder fitting at the the reservoir inlet.
wheel end. Submerge the free end of the bleeder hose LOW
into the bleeder bottle. Both the tubing and container PRESSURE HCU RESERVOIR
HOSE
must be able to withstand the effects of hydraulic brake
fluid.
C. Use a wrench to open the bleeder fitting screw.
Figure 4.1.
Figure 4.1
4004438a
Figure 4.2
8. Loosen the two support brackets and any retaining hardware

that holds the middle section of the low pressure hose to the
chassis. The bolts must be loose enough to allow movement of
the hose during the HCU removal.
9. To help prevent brake fluid from damaging the vehicle or floor
paint, or from seeping into the ground, position a container
beneath the work area to collect any drained or spilled brake
4004437a
fluid.
Figure 4.1
10. Disconnect the low pressure hose from the HCU reservoir. Plug
both the low pressure hose and the HCU reservoir inlet to
D. Apply and hold the brake pedal down until no more brake
prevent system contamination.
fluid runs out. Do not release the brake pedal.
11. Before removing the HCU assembly from the vehicle, drain the
E. With the brake pedal still applied, use a torque wrench to
fluid from the HCU reservoir. To do this:
tighten the bleeder fitting screw to the torque value
specified by the component manufacturer. A. Reconnect the battery.

B. Attach a bleeder bottle to one wheel end at the front axle. Figure 4.4
C. Connect the vehicle to a computer that has TOOLBOX™

Software, version 9.0 or higher, installed.
D. From the HPB Main Menu, select EOL to enable the End
of Line test. The pull-down option, Drain Reservoir, will
appear. Click on Drain Reservoir to start the drain
procedure. Figure 4.3.
Figure 4.3
WABCO HPB
4005017a 31-PIN
2-PIN POWER
HARNESS
Figure 4.3 CONNECTOR 4004436a
Figure 4.4
E. Open the bleeder screw.
F. Apply and hold the brake pedal down until no more fluid NOTE: If space does not permit removing the HCU with the
runs out. mounting brackets attached, skip Step 15 and proceed to Step
16.
G. Tighten the bleeder screw.
Attach a bleeder bottle to one wheel end at the rear axle. 15. While supporting the HCU, loosen and remove the four nuts
Repeat Steps D-G for the rear axle. (two per side) that hold the HCU mounting brackets to the
frame rail of the vehicle. Remove the HCU, with mounting
brackets attached, from the vehicle. Figure 4.5.
13. Disconnect the brake lines from the HCU. There are at least six
brake lines; seven if the system is equipped with power parking Figure 4.5
brakes. Plug the brake lines and ports on the HCU to prevent
system contamination. Mark the brake lines to ensure correct
positioning during reassembly.
14. Open the latches on the two-pin power connector and the
31-pin harness attached to the ECU. After the latch is released,
remove the connectors from the ECU. Figure 4.4.
If the vehicle is equipped with hydraulic parking brakes,
disconnect the pressure supply valve electrical connector on
the HCU. Refer to the Parking Brake Pressure Supply Valve
removal and installation procedures in this section.
FRAME RAIL
MOUNTING
BRACKETS 4004440a
Figure 4.5

16. Loosen and remove the two bolts that hold the HCU to the front 4. Connect the brake lines. Remove the protective cover before
mounting bracket. Then, loosen and remove the two bolts that attaching the line. Check the line markers to ensure correct
hold the HCU to the rear mounting bracket. installation on the HCU. Figure 4.6 and Figure 4.7.
17. Remove the mounting brackets from the HCU. 앫 Four lines leading to the wheel ends
18. Examine the four bushings inside the brackets for potential 앫 Two lines leading to the master cylinder
deformations. Replace if necessary.
앫 One line leading to the parking brake (if equipped)
19. Verify the warranty status. If the HCU is under warranty, return
it to WABCO. Figure 4.6
TO REAR
BRAKE CIRCUIT
Installation
TO
CAUTION PARKING
BRAKE
The replacement HCU is pre-charged with brake fluid to (SAHR)
ensure successful bleeding. To prevent fluid loss, do not CIRCUIT
remove the protective caps until you are ready to connect the
brake lines. Damage to components can result.
PARKING BRAKE
PRESSURE SUPPLY
NOTE: Before installation, the replacement HCU must be fitted with VALVE
the HCU reservoir. Refer to the HCU reservoir installation information BLEEDERS
in this section. FROM MASTER
CYLINDER 4004441a
NOTE: WABCO recommends that you install the replacement HCU Figure 4.6
in the same location as the old one.
Figure 4.7
NOTE: Bleeding the master cylinder, brake caliper and

TO FRONT
spring-applied/hydraulic release (SAHR) circuits is required during BRAKE CIRCUIT
installation of the HCU. Refer to Section 5.
NOTE: Examine the four bushings inside the brackets for potential
deformations before attaching the HCU to the brackets. Replace if
necessary.
NOTE: If space does not permit installing the HCU with the
mounting brackets attached, perform Step 2 first, then perform Step
1.
1. Ensure that the ignition is off and the battery is disconnected.

2. Position the HCU between the mounting brackets. While
supporting the HCU, install the four replacement bolts that
attach the HCU to the mounting brackets. Tighten the bolts to 4004442a
32-34 ft-lb (43-46 N폷m). @
Figure 4.7
3. Attach the two mounting brackets to the frame rail of the
vehicle. Tighten the nuts to 79.7-99.6 ft-lb (108-135 N폷m). @

5. Connect the low pressure hose from the master cylinder Figure 4.8
reservoir to the HCU reservoir and secure the connection with a

hose clamp. Once the connection is secure, remove the pinch
clamp installed during the removal of the old HCU.
6. Tighten the two support brackets (hose clamps) that secure the
low pressure hose to the vehicle chassis.
7. Fill the brake system with new brake fluid from a sealed
container until the fluid level in the master cylinder reservoir
stabilizes at the Max mark. Use DOT 3 or DOT 4 hydraulic
brake fluid. Refer to the vehicle specifications sheet to
determine which fluid to use.
NOTE: Temporarily open one caliper bleeder screw or the

SAHR bleeder screw, if applicable, to expedite the filling
process. The open bleeder screw facilitates the expelling of the
air from the system. Close the bleeder screw when filling is
complete.
4004443a
WARNING Figure 4.8
Electrical connectors must be correctly installed with the latch

pushed in to lock the connection to prevent them from coming 9. Proceed with pressure filling and bleeding the brake caliper
loose or disconnecting. Failure to securely connect and circuits, and the SAHR circuit, if applicable. Refer to Section 5
correctly latch the connectors could result in loss of braking for procedures.
functions during vehicle operation. Serious personal injury can 10. If a new complete ECU/HCU assembly was installed, it will be
result. necessary to download the parameters into the ECU.
8. Attach the 31-pin harness and then the two-pin power NOTE: To make sure of correct ABS performance, the correct
connector to the ECU. Push the latch into position to lock the parameters must be downloaded into the ECU. Parameters are
connection. Figure 4.8. OEM and VIN number specific and should not be swapped
vehicle to vehicle.
If the vehicle is equipped with a hydraulic parking brake, attach
the pressure supply valve connector. Refer to the Parking Refer to the “Parameter Downloading” section in this manual.
Brake Pressure Supply Valve removal and installation
procedures in this section. Removal
HCU Reservoir
NOTE: The removal of the entire HCU assembly is necessary in
order to remove the HCU reservoir. Refer to the hydraulic compact
unit removal procedure in this section.
1. Remove the HCU assembly from the vehicle. Refer to the

hydraulic compact unit removal procedure in this section.
2. Inspect the area between the body of the HCU and the HCU
reservoir to ensure the area is free from any dirt or other
contaminants. Clean if necessary. Do not allow any
contaminants to enter the HCU ports.

3. Use a number 4 Phillips-head screwdriver to remove the four 7. With the ports plugged, clean the top of the HCU.
HCU reservoir mounting screws. Then, remove the reservoir
from the HCU. Figure 4.9. Installation
Figure 4.9
HCU Reservoir
WARNING
To ensure correct assembly, use only the four seals and four
screws included in the HCU reservoir replacement kit. Do not
reuse the seals or screws from the old reservoir. Failure to do
so may cause reduced braking force and result in serious
personal injury.
NOTE: Bleeding the master cylinder, brake caliper and

spring-applied/hydraulic release (SAHR) circuits is required during
installation of the HCU. Refer to Section 5.
1. Inspect the top of the HCU to ensure it is clean and free from
debris or other contaminants.
4004447a
2. Remove the plugs from the reservoir ports on the HCU.
Figure 4.9
3. Install the four new black rubber grommets from the
replacement kit into the ports on the top of the HCU.
4. Verify the warranty status. If the reservoir is under warranty,
Figure 4.11.
return it to WABCO.
5. Remove the old rubber grommets from the four ports. Do not Figure 4.11
allow any dirt or other contaminants from these grommets to

enter the HCU ports. If contaminated, the unit must be
replaced.
6. Seal the HCU reservoir ports. Figure 4.10.
Figure 4.10
4004448a
Figure 4.11
4. Use new, clean brake fluid from a sealed container to lubricate

the reservoir grommets. Use DOT 3 or DOT 4 hydraulic brake
fluid. Refer to the vehicle specification sheet to determine
4004446a which fluid to use.
Figure 4.10

5. Position the reservoir on the HCU and verify orientation: The 7. Use the four new mounting screws to attach the reservoir to
mounting screw holes must line up and the inlet port for the the HCU. Using a number 4 Phillips-head screwdriver, tighten
low pressure hose must face the front of the HCU. Figure 4.12. the screws to 43-60 in-lb (5-7 N폷m). @
Figure 4.12
8. Reinstall the HCU assembly on the vehicle. Refer to the
hydraulic compact unit installation procedure in this section.
Removal
HCU Accumulators
WARNING

manual parking brakes, apply the parking brakes. Block the
front and rear wheels to prevent the vehicle from moving.
Failure to do so can result in unwanted vehicle movement
causing serious personal injury.
4004449a
Figure 4.12 components. Pressurized air can cause serious personal
injury.
6. Install the new reservoir by pressing it carefully and completely
into the grommets in the ports. Figure 4.13. It is possible for the removed accumulator to retain an internal
pressure of up to 1087 psi. To eliminate any removed
Figure 4.13
accumulator from posing a safety hazard, depressurize the
accumulator and disable its pressure chamber.

achieves pressures of up to 2320 psi. This pressure is not
reduced by switching the ignition off or removing battery
death.
Thoroughly clean the area around the HCU fittings before

beginning the removal procedure to avoid contaminating the
system. As hoses and brake lines are removed, plug all open
ports and lines. Contamination may cause loss of braking force
or brake failure, and result in serious personal injury.
4004450a
Figure 4.13

2. Block the front and rear tires to prevent vehicle movement.

CAUTION
sustains damage, or a component malfunctions and requires 3. Disconnect the battery.
replacement, the vehicle owner is strongly advised to contact
4. Use a clean rag to carefully wipe the surface of the HCU and
the nearest dealer for professional assistance and repair. If
location and circumstances prevent consulting the dealer, and
components must be replaced, the replacement procedures 5. Apply the brake pedal a minimum of 30 times to decrease
provided by WABCO must be followed exactly with the pressure in the system. To ensure the system is depressurized,
associated steps performed in the order presented. perform the following check on both the front and rear axles.
fitting on one brake caliper.
hydraulic brake fluid touch any painted surfaces, as it will B. Attach a bleeder bottle hose to the bleeder fitting at the
remove the paint. Hydraulic brake fluid may also damage wheel end. Submerge the free end of the bleeder hose
certain non-metal surfaces. Do not let fluid contact brake into the bleeder bottle. Both the tubing and container
pads, shoes, rotors or discs. must be able to withstand the effects of hydraulic brake
fluid.
the safe removal of the accumulators from the HPB.
Figure 4.14.
앫 Accumulators are precharged with gas pressure to 1087 psi and Figure 4.14
have a limited shelf life. When replacing an accumulator, note

and record the expiration date of the replacement accumulator.
앫 Used accumulators must be depressurized before disposal.
Follow Steps 10A-10D to perform this procedure.
앫 WABCO recommends replacing both accumulators at the same
time.
앫 It is not necessary to remove the entire HCU to replace the
accumulators.
앫 Replacing the accumulators does not require any brake bleed
procedures.
앫 Accumulators still under warranty must be returned
without depressurizing. Drilling accumulators will void the
warranty.
앫 Two people are needed to perform this procedure.
4004437a
앫 After installing HBP components or making system repairs, use
TOOLBOX™ Software to remove the error code from the ECU Figure 4.14
memory. Instructions for using TOOLBOX™ Software appear in

Section 3 of this manual. D. Apply and hold the brake pedal down until no more brake
1. Park the vehicle on a level surface. For vehicles with manual
parking brakes, apply the parking brakes. E. With the brake pedal still applied, use a torque wrench to
specified by the component manufacturer.

6. Repeat Steps A-E for the second axle. A. Securely position the accumulator on a drill press table.
Use a vise or clamp that will allow the accumulator to be
correctly positioned. The drilling point will be on the
opposite side of the welded seam from the threaded port.
fluid. B. Center punch the accumulator.
8. Use a strap wrench to remove the accumulator. The C. Use a 3 mm or 1/8-inch drill bit to slowly and carefully
accumulator has a right-hand thread. Figure 4.15. drill approximately 1/2-inch (12.7 mm) into the
accumulator. Figure 4.16.
Figure 4.15
Figure 4.16
Center punch
prior to drilling.
WELDED
SEAM
4004444a
Figure 4.15
THREADED
PORT
9. Use a clean rag to clean the counterbore on the HCU. Inspect
4004451a
the counterbore to ensure that the O-ring seal was removed.
Plug the counterbore to prevent contamination from entering Figure 4.16
the HCU.
D. After releasing the internal pressure, correctly dispose of
10. Determine the warranty status of the accumulators. If the
the accumulator.
accumulators are under warranty, do not perform Step 11
(depressurizing the accumulators). Return the accumulators to 앫 Repeat Steps A-D to depressurize the second
WABCO. If the accumulators are not under warranty, the accumulator.
accumulators MUST be depressurized before disposal (Step
11). Installation
WARNING HCU Accumulators
A slight hissing sound may be heard when the wall of the
accumulator is pierced. Metal shavings may be blown away WARNING
from the hole during this procedure. Wear protective goggles, Failure to bleed the system whenever any hydraulic system
not glasses, to protect the eyes. fitting is loosened or disconnected will allow air to remain in
the system. This will prevent the hydraulic pressure in the
11. Use the following steps to depressurize the accumulator and brake system from rising enough to apply the brakes correctly.
disable the internal pressure chamber before disposing of the This will cause the stopping distance to increase and can
accumulators. Figure 4.16. result in serious personal injury.

Correctly discard hydraulic brake fluid that is removed from Figure 4.17
the brake system. Hydraulic brake fluid that is removed can be

contaminated and, if used, can cause damage, loss of braking
and serious personal injury.
Use only the type of hydraulic brake fluid specified by the

equipment manufacturer. Do not use or mix different types of
hydraulic brake fluid. The incorrect hydraulic brake fluid will
damage the rubber parts of the brake caliper and can cause
damage, loss of braking and serious personal injury.
A new accumulator is precharged to a pressure of 1087 psi. Do

not puncture or pierce the accumulator. Puncturing or piercing
the accumulator may result in personal injury or death.
4004445a
CAUTION
Figure 4.17
Hydraulic brake fluid is a caustic substance. Contact with
4. Repeat Steps 1-3 to replace the second accumulator.
hydraulic brake fluid touch any painted surfaces, as it will
remove the paint. Hydraulic brake fluid may also damage 5. Check the fluid level in the master cylinder reservoir. Fluid level
certain non-metal surfaces. Do not let fluid get on brake pads, should be at the MAX mark. If not, fill the reservoir to the MAX
shoes, rotors or disks. mark with new brake fluid from a sealed container. Use only
DOT 3 or DOT 4 brake fluid. Refer to the vehicle specification
NOTE: Use DOT 3 or DOT 4 hydraulic brake fluid. Refer to the sheet to determine which fluid to use.
vehicle specification sheet to determine which fluid to use.
NOTE: Never add fluid above the MAX mark regardless of the
1. Remove the plug from the accumulator counterbore on the state of the accumulator.
HCU. Clean the counterbore and the surrounding area. The old
accumulator O-rings should have been removed from the 6. Connect the battery.
counterbore during removal of the accumulators. Verify that the
7. Turn the ignition to ON. The HCU pump motors will start up and
O-ring was removed.
fill the accumulators. Approximate running time is 45 seconds.
2. Use clean brake fluid from a sealed container to lubricate the
If the HCU pump motors fail to deliver a sufficient amount of
O-ring on the new accumulator. Use DOT 3 or DOT 4 hydraulic
fluid, the ECU module will control the HCU pump motors in a
brake fluid. Refer to the vehicle specification sheet to
self priming procedure. The HCU pump motors should stop
within three minutes, with the brake warning light and the
3. Place the new accumulator and O-ring into the counterbore. buzzer OFF. If there are problems building pressure after
After positioning, use a torque wrench with a strap wrench bleeding and powering up the system, increase the pressure
attachment to tighten to 43.4-50 ft-lb (60-70 N폷m). Do not setting of the pressure bleeder equipment to 29-40 psi
overtighten. Figure 4.17. @ (2-2.75 bar), and cycle the ignition off for 10 seconds, then
back on.
NOTE: Pressure should be left on the system during the first

key-on (attempt to build pressure).
8. When the pumps stop running and the system is fully charged,
the fluid level in the master cylinder reservoir should be
between MIN and MAX marks.

9. Check the accumulator connections for leaks. If there are no 앫 Repeat Steps A-E for the second axle.
leaks, go to Step 11.
10. After making the repairs, check the fluid level in the master
If there are leaks, depressurize the system before making the cylinder reservoir to make sure it is at the MAX mark when
necessary repairs. Use the following procedure to depressurize both accumulators are fully depleted. Refill as necessary, using
the system: only the recommended DOT 3 or DOT 4 hydraulic brake fluid,
as described above. Refer to Section 5 for detailed instructions
앫 Apply the brake pedal a minimum of 30 times to decrease
on how to correctly fill the master cylinder reservoir.
pressure in the system. To ensure that the system is
depressurized, perform the following check on both the
NOTE: Never add fluid above the MAX mark regardless of the
front and rear axles:
state of the accumulator.
fitting on one brake caliper. 11. Use TOOLBOX™ Software to cancel the diagnostic code for
the accumulator. Refer to Section 3 for TOOLBOX™ Software
B. Attach a bleeder bottle hose to the bleeder fitting at the
instructions.
wheel end. Submerge the free end of the bleeder hose
into the bleeder bottle. Both the tubing and container 12. Perform the Deplete Accumulators function two times. Refer to
must be able to withstand the effects of hydraulic brake the procedure in this section.
fluid.
13. Remove the wheel blocks.
14. Test drive the vehicle. Refer to the test drive procedure in
Figure 4.18.
Section 3 of this manual.
Figure 4.18
Removal
Electronic Control Unit (ECU)
WARNING

manual parking brakes, apply the parking brakes. Block the
front and rear wheels to prevent vehicle movement. Failure to
do so can result in unwanted vehicle movement causing
components. Pressurized air can cause serious personal
4004437a
injury.
Figure 4.18 The full power brake system is a pressurized system that
D. Apply and hold the brake pedal down until no more brake reduced by switching the ignition off or removing battery
fluid runs out. Do not release the brake pedal. power. Prior to servicing this system, the depressurization
death.

CAUTION Figure 4.19

sustains damage, or a component malfunctions and requires
replacement, the replacement procedures provided by WABCO
must be followed exactly with the associated steps performed
in the order presented.

hydraulic brake fluid touch any painted surfaces, as it will
remove the paint. Hydraulic brake fluid may also damage
certain non-metal surfaces. Do not let fluid contact brake
pads, shoes, rotors or discs.
31-PIN
2-PIN POWER
HARNESS
CONNECTOR 4004436a
NOTE: Do not open the ECU. Opening the ECU to gain access to the
internal components will void the warranty.
Figure 4.19

6. Use a 4 mm Allen wrench to loosen and remove the four
the safe removal of the ECU module from the HCU assembly.
mounting screws that attach the ECU module to the HCU.
Remove the screws in the sequence shown. Figure 4.20.
앫 It is not necessary to remove the entire HCU to replace the
Electronic Control Unit (ECU). Figure 4.20
앫 After replacing the ECU, new system parameters must be

entered. Refer to Section 3 of this manual for parameter entry
procedures.
앫 When only the ECU is replaced, bleeding the system is not 4
necessary. 1
parking brakes, apply the parking brakes.
2
3
4. Use a clean rag to carefully wipe the surface of the HCU and 4004452a
5. Open the latches on the two-pin power connector and the Figure 4.20
31-pin harness attached to the ECU. After the latch is released,
remove the connectors from the ECU. Figure 4.19. 7. Carefully remove the ECU by lifting straight out. To avoid
damaging the HCU, do not twist the ECU during removal.
Determine the warranty status of the ECU. If the ECU is under
warranty, return it to WABCO. If it is not under warranty,
discard the used ECU.

2. Position the ECU onto the HCU valves. Apply gentle pressure to
CAUTION
seat the ECU. Motor connectors must achieve full depth into
Do not touch the pressure sensor connectors. The connectors
the housing. The gap between the HCU and ECU must not
are sensitive and can be damaged by static electrical shock.
exceed 0.08-inch (2 mm). Figure 4.22.
8. Use a clean rag to carefully clean the area around the valves
Figure 4.22
formerly covered by the ECU. Do not touch the two pressure

sensor connectors. Figure 4.21.
Figure 4.21
4004455a
Figure 4.22
Do not touch
pressure sensor 3. Use a 4 mm Allen wrench to tighten the four mounting screws
connectors. that attach the ECU to the HCU. Tighten to 14 in-lb (1.5 N폷m).
4004453a
Do not exceed this torque. The metal sleeves on the ECU
Figure 4.21 housing must rest flat on the body of the HCU. Tighten the
screws using the correct sequence. Figure 4.23. @
9. Remove and discard the orange seals from the two pressure
sensors. Do not touch the two pressure sensor connectors.
Figure 4.23
Installation
Electronic Control Unit (ECU) 4
1
CAUTION
Do not touch the pressure sensor connectors. The connectors
are sensitive and can be damaged by static electrical shock. 2
1. Remove the replacement orange seals from the ECU

replacement kit. Install the seals onto the replacement ECU.
3
CAUTION
Excessive force in positioning the ECU onto the HCU will 4004452a
damage the ECU housing. Do not force the ECU into position.
Use a gentle, even pressure when positioning the ECU. Figure 4.23

4. When the ECU is correctly installed with the metal sleeves flat Parameter Downloading
on the HCU, tighten the bolts to 21-30 in-lb (2.5-3.5 N폷m). @
After Installing a new ECU or a new ECU/HCU assembly, it will be
necessary to download the parameters into the ECU.
WARNING
Electrical connectors must be correctly installed with the latch NOTE: To make sure of correct ABS performance, the correct
pushed in to lock the connection to prevent them from coming parameters must be downloaded into the ECU. Parameters are OEM
loose or disconnecting. Failure to securely connect and and VIN number specific and should not be swapped vehicle to
correctly latch the connectors could result in loss of braking vehicle.
functions during vehicle operation. Serious personal injury can
NOTE: TOOLBOX™ Software will be needed to enter the HPB
result.
system parameters into the ABS ECU.
5. Attach the 31-pin harness and then the two-pin power For Navistar vehicles, it is recommended to go to the Navistar ISIS
connector to the ECU. Push the latch into position to lock the website to download the parameters per VIN using the TOOLBOX™
connection. Figure 4.24. Software. Contact Navistar for assistance.
Figure 4.24
For Non-Navistar vehicles, the parameters may be entered
manually. To manually enter the parameters, it will be necessary to
save a parameter file to the computer and then using TOOLBOX™
Software extract the parameters from the computer and download
them into the ABS ECU.
When downloading parameters, it should be noted that there are 2
series of ABS ECUs, Release 1 and Release 2.
Release 1: These ECUs were original equipment on most vehicles
built prior to 2009 and only have a 5-parameter capability.
TOOLBOX™ Software versions prior to 8.7 may be used.
Release 2: These ECUs are original equipment on most vehicles
built 2009 to present and have a 10-parameter capability.
TOOLBOX™ Software versions 8.7 or newer must be used.
Manual Downloading
Obtain Parameter Data Set Numbers
4004443a To create a parameter file, you must obtain the correct VIN-specific
parameter data set numbers using the following procedure.
Figure 4.24
If you are able to communicate with the original ECU, try to obtain
6. Connect the battery. the parameter data set numbers as follows.
7. If the original ECU was just reinstalled, test drive the vehicle. 1. Open TOOLBOX™ Software and go to the HPB main page and
Refer to the “Test Drive Procedure” in this manual. click on “Parameters” in the toolbar.
8. If a new ECU was installed, it will be necessary to download the 2. Select “read parameters” from the drop-down menu and write
parameters into the ECU. down the “10” settings; i.e. Data 1: “1”, Data 2: “15.
NOTE: To make sure of correct ABS performance, the correct If you are unable to communicate with the original ECU, it will
parameters must be downloaded into the ECU. Parameters are be necessary to contact the OEM or WABCO to obtain the
OEM and VIN number specific and should not be swapped parameter data set numbers.
vehicle to vehicle. Refer to the “Parameter Downloading”
Section.

Create a New File to Calibrate ECU Parameters Extract the File and Save It to the ABS ECU
Once the parameter data set numbers have been obtained, you Use the following procedure to extract the file from the computer
must create a new file to calibrate the ECU parameters using the and save it to the ABS ECU.
following procedure.
1. Turn the ignition on.
1. Open “Notepad” as follows.
2. Connect the computer to the vehicle.
A. Click the computer “Start” icon and type “run” into the
3. Open TOOLBOX™ Software and go to the HPB main page and
search window.
click on “Parameters” in the toolbar.
B. Click “run” and enter “Notepad” into the search window
4. A drop-down menu will appear. Click on “Write Parameters”
and click “OK”. This will bring up a blank “Notepad” page.
5. A window will appear displaying the VIN, verify the VIN number
2. Once the Notepad page has been brought up, type the VIN on
is correct.
the first line and press enter to move down to the next line.
6. Click the Download button. Once the process is complete, a
3. Type the 10 data set numbers on each line below (example:
message of “Success” will appear.
1<enter>15<enter>) do not hit enter after the 10th (last)
entry. Use the data sets that were saved from the original ECU. 7. Close out of TOOLBOX™ Software and turn the ignition off for
If the 10 data set numbers could not be obtained from the a few minutes.
original ECU, it will be necessary to contact the OEM or WABCO
Verify the Parameters
to obtain the correct parameter data set numbers.
Use the following procedure to verify the parameters were saved
NOTE: If the parameter file was obtained from the OEM, it may correctly.
be necessary to remove the underscores from the file name for
TOOLBOX™ Software to recognize it. 1. Turn the ignition on.
4. Once the VIN and data set numbers have been entered, click 2. Connect the computer to the vehicle.
“File” and “Save as”. In the File Save window, save the file as 3. Open TOOLBOX™ Software and go to the HPB main page and
follows. click on “Parameters” in the toolbar.
Save in: 4. Click on “Read Parameters” and compare the parameters that
For TOOLBOX™ Software 10 or lower are displayed with the parameters that were entered. They
should be identical.
Windows XP or Vista: “C:\ Program Files\WABCO\WINNT\HPB”
5. Test drive the vehicle. Refer to the Test Drive procedure in
Windows 7:“ C:\ Program Files (x86)\WABCO\WINNT\HPB” Section 3 of this manual.
For TOOLBOX™ Software 11
Password Failed
Windows XP or Vista: “C:\ Program Files\
If during the Parameter download process a “Password Failed”
WABCO\TOOLBOX\HPB”
message should appear, it indicates several attempts have been
Windows 7: “C:\ Program Files (x86)\WABCO\TOOLBOX\HPB” made on the same key cycle. To correct this issue, close out of
TOOLBOX™ Software and cycle the key off for a few minutes and
File name: “MW ABS Param.dat”
reattempt downloading the parameters.
Save As Type: “All files”
System Check Status (ABS and or ATC Lamps
Encoding: “ANSI” This is usually the default setting.
Flashing after Downloading the Parameters)
5. Click Save. The parameter file will now be saved to the After downloading the parameters, there may be no active or stored
computer. DTC listed but the ABS lamp may start flashing. If the vehicle also
has ATC, the ABS and ATC lamps will flash alternately, commonly
referred to as Railroading. To correct this issue, perform the
following.

1. Open the TOOLBOX™ Software and bring up the opening/ Figure 4.25
main HPB page

2. Press and hold down the Ctrl, Alt and Shift keys, then tap the
F12 key. Observe the upper toolbar and the word “Utility” will
appear. Release the keys.
3. Click on the word “Utility” and a drop-down menu will appear.
4. Scroll through the menu and click on “System Check Status”.
5. The System Check Status window will appear showing the
Current Status which will display Status Not Set. 4011930a
6. Click on the “Set Status” button and the lights will stop Figure 4.25
flashing. The lamps may remain on solid until the vehicle sees
wheel speed above 4 mph. Run the HPB Programmer
7. Close out of TOOLBOX™ Software and cycle the key off for a 1. Once the correct HPB programmer has been installed on to the
few minutes. computer, determine if the vehicle has an ammeter.
8. Test drive the vehicle. Refer to the Test Drive procedure in 앫 If the vehicle has an ammeter: Refer to the OEM
Section 3 of this manual. schematics and remove the fuse for the ammeter.
Using the HPB Programmer 앫 If the vehicle does not have an ammeter: Continue to
the next step.
The HPB programmer is a software tool that is used to “reflash” or
“update” an ECU that has already had the parameters set. Do NOT 2. Connect the computer to the vehicle.
use the HPB Programmer on a brand new ECU that has not had the 3. Click on the HPB Programmer icon on your desktop and run the
parameters downloaded into it yet. The HPB Programmer is not a HPB Programmer.
part of TOOLBOX™ Software. It has its own Icon and is a separate
stand-alone software program. The HPB Programmer has several 4. When the window opens, verify that the correct
versions based on the OEM, vehicle and issue. If you need the HPB “Communications Adapter” is selected.
Programmer to resolve an issue, contact the OEM or WABCO to 5. Click the “Start Download” button.
obtain the correct version.
6. Follow the screen prompts to reflash the ECU. During the
Obtaining and Installing the HPB Programmer reflash the ignition should be off and the brake pedal must be
To obtain the HPB Programmer, you must contact the OEM or depressed through the entire process, which may take several
WABCO. minutes.
Once the file has been obtained, use the following procedure to 7. When the process is complete, a message will appear stating
install it. “Flashing Complete”.
1. Save the “.piz” file to your computer. 8. Release the brake pedal and wait three seconds.
2. Rename the extension from “.piz” to “.zip”. 9. Re-apply the brake pedal and verify that the “ECU” and
Software ID is correct.
3. Unzip the “.zip” file.
10. A message stating the “Flashing is complete and Software ID
4. Once the files are extracted, run the “setup.exe”. Once the
verified” will appear when flashing is complete.
setup is complete, the “HPB Programmer” icon will appear on
your desktop. Figure 4.25. 11. Release the brake pedal and turn the ignition on. If the ABS
lamp stays on longer than three seconds, check for active
DTCs. If TOOLBOX™ Software is unable to communicate with
the ECU, repeat the download procedure.

12. Connect TOOLBOX™ Software, note and clear any DTCs. Figure 4.26
13. Close out of TOOLBOX™ Software and disconnect from the

vehicle.
14. If the ammeter fuse was removed, reinstall the fuse.
15. Depending on the version of the HPB Programmer that was
used, it may be necessary to download new parameters.
Review with the OEM or WABCO.
16. Test drive the vehicle. Refer to the Test Drive procedure in
4006216a
Removal Figure 4.26
Hydraulic Compact Unit (HCU) Relay Valve NOTE: Avoid bending or kinking the brake lines while
1. Wear safe eye protection. disconnecting and handling other components.
2. Park the vehicle on a level surface. Block the wheels to prevent 8. Disconnect the two master cylinder brake lines from the relay
the vehicle from moving. Failure to do so can result in valve. Plug the two lines to prevent contamination.
unwanted vehicle movement causing serious personal injury.
9. Use a 4 mm socket wrench to loosen and remove the five
3. Disconnect the battery. Allen-head screws that secure the relay valve to the hydraulic
4. Apply the brake pedal a minimum of 30 times to decrease compact unit (HCU). Figure 4.27.
pressure in the system. To ensure the system is depressurized,
perform the following check on both the front and rear axles. Figure 4.27

into the bleeder bottle. Both the tubing and container
fluid.
C. Use a wrench to open the bleeder fitting screw. 4006217a
Figure 4.27
E. With the brake pedal still applied, use a torque wrench to 10. Carefully lower and remove the relay valve.
close the bleeder fitting screw.
11. Remove and discard the rubber-coated seal plate. Do not
5. Use a torque wrench to tighten the bleeder fitting screw to the reuse this plate. During installation, use the new seal plate
torque value specified by the component manufacturer. included with the relay valve replacement kit. Figure 4.28.
6. Repeat Step 4 and Step 5 for the other axle.
7. Use hose clamp pliers to clamp the rubber hose at least
three-inches (76 mm) away from the entrance to the HCU
reservoir. Use care to avoid damage to the plastic reservoir
nipple inside the hose. Figure 4.26.

Figure 4.28 Figure 4.30
8 9
3 4
SEAL PLATE
IDENTIFICATION
2 5
10
7 1
4006218a 6
Tightening sequence.
Figure 4.28 Tighten each bolt twice.
4006221a
12. Use denatured alcohol and lint-free rags to clean the valve
Figure 4.30
mounting surface. Ensure there is no rubber sticking to the
HCU. Do not allow rubber or other debris to fall into the HPB
2. Place the remaining four screws into the mounting holes on the
bore holes. Figure 4.29.
relay valve. Hand tighten all five screws.
Figure 4.29
3. Use a torque wrench to tighten all five screws to 71 in-lb
(8 N폷m) following the numbered sequence illustrated in
Figure 4.30. @
4. Attach the master cylinder brake lines. Remove the hose clamp
from the low pressure hose.
5. Fill the brake system with new brake fluid from a sealed
container until the fluid level in the master cylinder reservoir
stabilizes at the MAX mark. Use DOT 3 or DOT 4 hydraulic
brake fluid. Refer to the vehicle specifications sheet to
4006219a
Figure 4.29 NOTE: Temporarily open one caliper bleeder screw or the
SAHR bleeder screw, if applicable, to expedite the filling
Installation process. The open bleeder screw facilitates the expelling of the
air from the system. Close the bleeder screw when filling is
Hydraulic Compact Unit (HCU) Relay Valve complete.
1. Place a screw into the center mounting hole of the relay valve. 6. Proceed with pressure filling and bleeding the master cylinder
Use a hex-head socket tool for positioning. Place the new relay circuit. Refer to Section 5 for procedures.
valve seal onto the relay valve using the screw to align the seal.
The orientation should match Figure 4.30. Position the relay 7. Proceed with pressure filling and bleeding the brake caliper
valve against the HCU. Thread the screw into the HCU. circuits, and the SAHR circuit if applicable. Refer to Section 5
for procedures.

Removal Figure 4.31
Hydraulic Compact Unit (HCU) Pump

Before removing the pump, ensure the replacement pump is readily
accessible.
1. Wear safe eye protection.
2. Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Failure to do so can result in
4006216a
4. Apply the brake pedal a minimum of 30 times to decrease Figure 4.31

perform the following check on both the front and rear axles. NOTE: Avoid bending or kinking the brake lines while
disconnecting and handling other components.
fitting on one brake caliper. 8. For a rear axle pump, proceed to Step 9. For a front axle pump,
B. Attach a bleeder bottle hose to the bleeder fitting at the carefully remove the relay valve from the HCU to gain access to
wheel end. Submerge the free end of the bleeder hose the pump. Do not kink or bend the brake lines while
into the bleeder bottle. Both the tubing and container removing the relay valve.
must be able to withstand the effects of hydraulic brake 9. Prepare the replacement pump. Lubricate both pump O-rings
fluid. with brake fluid. Actuate the pump several times by depressing
C. Use a wrench to open the bleeder fitting screw. the spring-loaded pump button by hand. The initial force
required to actuate the pump and depress the pump button
D. Apply and hold the brake pedal down until no more brake may be high at first. However, after the first actuation, the force
fluid runs out. Do not release the brake pedal. should be reduced.
E. With the brake pedal still applied, use a torque wrench to 10. Use a 6 mm hex-head socket wrench to remove the pump
close the bleeder fitting screw. retaining plug from the HCU cavity. To minimize fluid spill, keep
5. Use a torque wrench to tighten the bleeder fitting screw to the the replacement pump within reach and prepared for
torque value specified by the component manufacturer. installation. Figure 4.32.
6. Repeat Step 4 and Step 5 for the other axle. Figure 4.32
7. Use hose clamp pliers to clamp the rubber hose at least

three-inches (76.2 mm) away from the entrance to the HCU
reservoir. Use care to avoid damage to the plastic reservoir
nipple inside the hose. Figure 4.31.
4006203a
Figure 4.32

CAUTION Figure 4.34
Use care when removing the pump to prevent damage to the

O-rings.
11. Use needle nose pliers with a good grip to remove the pump
from the bore. Use care to prevent damage to the O-rings.
Avoid sliding the needle nose pliers on the pump. This can
produce metal filings or contaminants which can enter the
pump bore. Do not leave any foreign material in the pump
bore. Figure 4.33.
4006205a
Figure 4.33
Figure 4.34
2. Insert the pump retaining plug into the threaded hole. Use a
6 mm hex-head socket wrench to tighten the plug to
195  18 in-lb (22  2 N폷m). Figure 4.35. @
Figure 4.35
4006204a
Figure 4.33
12. Inspect the bore holes to verify that no foreign material such as
rubber, rag lint or metal filings have entered the bore holes. If
necessary, remove foreign material with a lint-free swab.
4006206a
13. Install the replacement pump. Refer to the installation
procedure. If you are replacing both pumps, do not remove Figure 4.35
the second pump before installing the first replacement
pump. 3. Repeat the procedure for removing and installing the second
pump (if replacing both pumps).
Installation 4. If the front axle pump was replaced, install the relay valve.
Refer to TP-0672, Hydraulic Compact Unit (HCU) Pump Relay
Hydraulic Compact Unit (HCU) Pump Valve Replacement, for the correct procedures.
CAUTION 5. Remove the hose clamp from the rubber hose.

Use care when installing the pump to prevent damage to the 6. Proceed with pressure filling and bleeding the master cylinder
O-rings. circuit. Refer to Section 5 for procedures.
1. Use light hand pressure to slowly seat the pump into the bore. 7. Proceed with pressure filling and bleeding the brake caliper
Use care not to damage the O-rings. Figure 4.34. circuits, and the SAHR circuit if applicable. Refer to Section 5
for procedures.

Removal NOTE: Removing the master cylinder involves removing the master
cylinder reservoir. If the old reservoir is going to be installed onto the
Master Cylinder Replacement Information new master cylinder, care must be taken during the removal
process not to damage the reservoir. Do not install a damaged
Before removing the master cylinder assembly or the master reservoir.
cylinder reservoir, verify the components to be replaced:
앫 Master cylinder and reservoir 1. Park the vehicle on a level surface. For vehicles with manual
앫 Master cylinder only, reusing reservoir
앫 Master cylinder reservoir only, reusing master cylinder Failure to do so can result in unwanted vehicle movement
Replacement kits specific to each of these three replacements are causing serious personal injury.
available from WABCO. Make sure the replacement kit is available 3. Disconnect the battery.
before you begin the removal.
4. Use a clean rag to carefully clean the outside of the master
If the current reservoir is to be reused, you will need to be careful cylinder and master cylinder reservoir.
when removing the master cylinder and reservoir assembly from the
vehicle, and when you separate the components. If the reservoir is NOTE: Both the foot brake switch and the fluid level sensor
damaged in any way, it is not reusable. switch can be replaced without draining the brake fluid. If you
앫 The master cylinder replacement kit contains a master cylinder are replacing either of these switches, follow the procedures
travel switch, grommets and roll pins. It does not include the given in this manual.
master cylinder reservoir.
5. Disconnect the foot brake switch on the master cylinder and
앫 The master cylinder reservoir replacement kit contains a master the fluid level switch on the master cylinder reservoir.
cylinder reservoir with a fluid level switch and four rubber
grommets.
perform the following check on both the front and rear axles.
Master Cylinder
CAUTION fitting on one brake caliper.
To avoid damage to the system while working on the brake
system, do not apply the foot pedal unless instructed to do so.
앫 In some vehicles it may be necessary to move non-HPB system fluid.
Figure 4.36.
앫 Bleeding the master cylinder circuit is required during installation
of the master cylinder. Bleed procedures appear in Section 5 of
this manual.
앫 After installing HPB components or making system repairs, use
TOOLBOX™ Software to remove the error code from the ECU

MASTER
CYLINDER
HOSE RESERVOIR
CLAMP
LOW PRESSURE
HOSE (TO HCU
RESERVOIR)
BRAKE TUBES
(TO HCU
ASSEMBLY)
4004975a
4004437a
Figure 4.37
Figure 4.36
D. Apply and hold the brake pedal down until no more brake paint, or from seeping into the ground, position a container
fluid runs out. Do not release the brake pedal. beneath the work area to collect any drained or spilled brake
fluid.
9. Remove the hose clamp.
specified by the component manufacturer. 10. Disconnect the low pressure hose from the master cylinder
reservoir. All of the fluid coming out of the master cylinder
Repeat Steps A-E for the second axle. reservoir, approximately one gallon (3.4 liters), should drain
7. Attach a pinch clamp to the low pressure hose near the outlet into the container. Remove the cap from the master cylinder
of the master cylinder reservoir. Do not damage the reservoir reservoir to improve the draining process. Plug the low
outlet. Figure 4.37. pressure hose to prevent system contamination. Figure 4.38.
NOTE: Be careful not to damage the HCU reservoir outlet when

replaced.

MASTER
CYLINDER PORT PLUGS
MASTER
RESERVOIR CYLINDER
RESERVOIR
HOSE
CLAMP
BRAKE TUBES
(TO HCU
ASSEMBLY)
LOW PRESSURE
HOSE (TO HCU
RESERVOIR)
4004976a
Figure 4.38 BRAKE TUBES

(TO HCU
ASSEMBLY) 4004977a
NOTE: Some brake fluid may remain in protected areas of the
master cylinder reservoir. Figure 4.39
11. When the reservoir is empty, replace the cap on the master 13. Disconnect the master cylinder pushrod clevis pin from the
cylinder reservoir and plug the reservoir outlet to prevent any brake pedal. Figure 4.40.
excess fluid from spilling during removal.
Figure 4.40
12. Disconnect the two brake tubes from the master cylinder. Plug
COTTER PIN
the brake tubes and the master cylinder ports to protect them
PUSHROD
from contamination. Figure 4.39. CLEVIS PIN
CLEVIS
BRAKE
PEDAL
ARM 4004979a
Figure 4.40

14. Loosen and remove the two bolts that hold the master cylinder A. Install two new rubber grommet seals into the inlet ports
assembly to the bracket on the fire wall. Remove the master of the master cylinder. Use new brake fluid from a sealed
cylinder and master cylinder reservoir assembly from the container to lubricate the seals. Use DOT 3 or DOT 4
vehicle. brake fluid. Refer to the vehicle specification sheet to
15. If the master cylinder reservoir is undamaged and is going to
be reused, follow these steps to remove the undamaged B. Install the original or replacement reservoir by carefully
reservoir from the old master cylinder. pressing it fully into the grommets.
A. Remove the nut from the front bolt. Use a punch to drive C. Install two new roll pins from the replacement kit. Drive
out the two roll pins. Use care and support the tabs while the pins through the holes in the master cylinder boss and
you drive out the pins. the reservoir mounting tab holes. Support the back of the
tabs as you install each pin. Figure 4.41.
B. Lift the reservoir off the master cylinder.
D. Install the nut on the front bolt.
C. Pour any fluid remaining in the reservoir into a suitable
container. Figure 4.41
D. Plug the reservoir outlet ports to prevent contamination to MASTER

the system. CYLINDER
RESERVOIR
16. Verify the warranty status. If the master cylinder is under
warranty, return it to WABCO.
Installation
Master Cylinder
WARNING

ROLL PINS
앫 In some vehicles it may be necessary to move non-HPB system 4004978a
part. If this is necessary, refer to the vehicle manufacturer’s Figure 4.41
2. Use the two mounting nuts included in the replacement kit to
attach the master cylinder assembly to the bracket on the fire
of the master cylinder. Bleed procedures appear in Section 5 of
wall. Tighten the bolts to 50 ft-lb (70 N폷m). @
this manual.
앫 After installing HPB components or making system repairs, use WARNING
TOOLBOX™ Software to remove the error code from the ECU Failure to correctly install the clevis pin as described may
memory. Instructions for using TOOLBOX™ Software appear in result in damage to the pushrod, abnormal brake pedal feel
Section 3 of this manual. and/or loss of brakes during vehicle operation.
1. Attach the original or replacement reservoir to the new master
3. Connect the master cylinder pushrod clevis pin to the pedal
cylinder, as follows.
assembly. The clevis pin must be installed into the same hole
on the brake pedal as it was before the old master cylinder was
removed. Secure the cotter pin. Figure 4.42.

Figure 4.42 9. Fill the master cylinder reservoir to the MAX mark with new
brake fluid from a sealed container. Use DOT 3 or DOT 4
hydraulic brake fluid. Refer to the vehicle specification sheet to
COTTER determine which fluid to use.
PIN
10. Connect the battery.
11. Turn the ignition ON. The HCU pump motors will start up and
CLEVIS If the HCU pump motors fail to deliver a sufficient amount of
PUSHROD
CLEVIS PIN
BRAKE
PEDAL within three minutes, with the brake warning light and the
ARM buzzer OFF. If there are problems building pressure after
4004980a bleeding and powering up the system, increase the pressure
Figure 4.42
setting of the pressure bleeder equipment to 29-40 psi
(2-2.75 bar), and cycle the ignition off for 10 seconds, then
4. Connect the brake tubes to the master cylinder. Tighten the back on.
fittings to 10.8-14.4 ft-lb (15-20 N폷m). @
NOTE: Pressure should be left on the system during the first
5. Connect the low pressure hose to the master cylinder reservoir key-on (attempt to build pressure).
and secure the connection with a hose clamp.
12. Depress the brake pedal rapidly four times to activate both HCU
6. Remove the pinch clamp from the low pressure hose.
pump motors.
7. Connect the foot brake switch on the master cylinder and the
13. After the pumps stop running and the system is completely
fluid level sensor switch under the reservoir. Figure 4.43.
charged, the brake fluid level in the master cylinder reservoir
Figure 4.43
should be between the MIN and MAX marks. Adjust if
necessary. Refer to Section 5 for detailed instructions on how
MASTER CYLINDER ASSEMBLY
to correctly fill the master cylinder reservoir.
MASTER
CYLINDER
RESERVOIR VENTED 14. Check the system for leaks. If there are no leaks, go to Step
RESERVOIR CAP 17.
If there are leaks, depressurize the system before making the
necessary repairs. Use the following procedure to depressurize
the system.
앫 Remove the two maxi-fuses for the pump motors or
disconnect the battery.
FOOT
BRAKE 앫 Apply the brake pedal a minimum of 30 times to decrease
SWITCH pressure in the system. To ensure that the system is
PRIMARY depressurized, perform the following check on both the
FLUID LEVEL CIRCUIT
SENSOR (MF-FRONT
CIRCUIT A. Remove the protective cover from the end of the bleeder
(MR-REAR AXLE) 4004477a fitting on one brake caliper.
Figure 4.43
8. Bleed the master cylinder circuit. Refer to Section 5.

B. Attach a bleeder bottle hose to the bleeder fitting at the 19. Test drive the vehicle. Refer to the test drive procedure in
wheel end. Submerge the open end of the bleeder hose Section 3 of this manual.
must be able to withstand the effects of hydraulic brake Removal
fluid.
C. Use a wrench to open the bleeder fitting screw. Master Cylinder Reservoir
Figure 4.44.
WARNING
Figure 4.44 The full power brake system is a pressurized system that
death.
CAUTION
To avoid damage to the system while working on the brake
system, do not apply the foot pedal unless instructed to do so.
NOTE: It is not necessary to remove the complete master cylinder

assembly when replacing the reservoir.

4004437a
Figure 4.44 part. If this is necessary, refer to the vehicle manufacturer’s
D. Apply and hold the brake pedal down until no more brake 앫 Bleeding the master cylinder circuit is required during installation
fluid runs out. Do not release the brake pedal. of the master cylinder reservoir. Bleed procedures appear in
E. With the brake pedal still applied, use a torque wrench to Section 5 of this manual.
tighten the bleeder fitting screw to the torque value 앫 After installing HPB components or making system repairs, use
specified by the component manufacturer. TOOLBOX™ Software to remove the error code from the ECU
앫 Repeat Steps A-E for the second axle. memory. Instructions for using TOOLBOX™ Software appear in
cylinder reservoir to make sure it is at the MAX mark. Refill as
WARNING
necessary, using only the recommended DOT 3 or DOT 4
Park the vehicle on a level surface. For vehicles with manual
hydraulic brake fluid, as described above.
parking brakes, apply the parking brakes. Block the front and
16. Reinstall the two maxi-fuses for the pump motors or reconnect rear tires to prevent vehicle movement. Failure to do so can
the battery. result in unwanted vehicle movement causing serious
personal injury.
17. Use TOOLBOX™ Software to clear the diagnostic code for the
master cylinder. Refer to Section 3 for TOOLBOX™ Software
instructions.

2. Block the front and rear tires to prevent vehicle movement. E. With the brake pedal still applied, use a torque wrench to
Failure to do so can result in unwanted vehicle movement tighten the bleeder fitting screw.
Repeat Steps A-E for the second axle.
3. Remove the two maxi-fuses for the pump motors or disconnect
6. Attach a pinch clamp to the low pressure hose near the outlet
the battery.
to the master cylinder reservoir. Do not damage the reservoir
4. Use a clean rag to carefully clean the outside of the master outlet. Figure 4.46.
cylinder and master cylinder reservoir.
NOTE: Be careful not to damage the HCU reservoir outlet when
5. Apply the brake pedal a minimum of 30 times to decrease attaching the pinch clamp. If damaged, it will need to be
pressure in the system. To ensure the system is depressurized, replaced.
perform the following check on both the front and rear axles.
Figure 4.46

MASTER
fitting on one brake caliper. CYLINDER
HOSE RESERVOIR
B. Attach a bleeder bottle hose to the bleeder fitting at the CLAMP
into the bleeder bottle. Both the tubing and container LOW PRESSURE
HOSE (TO HCU
must be able to withstand the effects of hydraulic brake RESERVOIR)
fluid.
C. Use a wrench to open the bleeder fitting screw to the
torque value specified by the component manufacturer.
Figure 4.45.
Figure 4.45
BRAKE TUBES
(TO HCU
ASSEMBLY)
4004975a
Figure 4.46

fluid.
8. Remove the hose clamp from the low pressure hose.
9. Disconnect the low pressure hose from the master cylinder
reservoir. All of the fluid coming out of the master cylinder
reservoir, approximately one gallon (3.4 liters), should drain
into the container. Remove the cap from the master cylinder
4004437a
reservoir to improve the draining process. Plug the low
Figure 4.45 pressure hose to prevent system contamination.
10. Remove the reservoir from the master cylinder assembly, as
follows.
A. Disconnect the fluid level switch.

B. Remove the nut from the front bolt. Use a punch to drive B. Install the replacement reservoir by carefully pressing it
out the two roll pins. fully into the grommets.
C. Lift the reservoir off the master cylinder. C. Install the two new roll pins from the replacement kit.
Drive the pins through the holes in the master cylinder
D. Plug the reservoir outlet ports to prevent contamination to
boss and the reservoir mounting tab holes. Support the
the system.
back of the tabs as you install each pin. Figure 4.47.
E. Pour any remaining fluid into a container that can
D. Install the nut on the front bolt.
withstand the effects of brake fluid.
F. Close the reservoir outlet ports to prevent spillage. Figure 4.47
MASTER
11. Verify the warranty status. If the master cylinder reservoir is CYLINDER
under warranty, return it to WABCO. RESERVOIR
Installation
Master Cylinder Reservoir
WARNING
Do not install a damaged reservoir. A damaged reservoir will

result in loss of hydraulic brake fluid which can lead to loss of
braking force. Serious personal injury can result.
ROLL PINS
앫 Two people are needed to perform this procedure. 4004978a
앫 In some vehicles it may be necessary to move non-HPB system Figure 4.47

part. If this is necessary, refer to the vehicle manufacturer’s 2. Connect the low pressure hose to the reservoir.
4. Connect the fluid level switch on the master cylinder reservoir.
of the master cylinder reservoir. Bleed procedures appear in
Figure 4.48.
1. Attach the replacement reservoir to the new master cylinder,
as follows.
A. Install the new rubber grommets in the two inlet ports of
the master cylinder. Use new brake fluid from a sealed
container to lubricate the seals. Use DOT 3 or DOT 4
brake fluid. Refer to the vehicle specification sheet to

Figure 4.48 NOTE: Pressure should be left on the system during the first
MASTER CYLINDER ASSEMBLY key-on (attempt to build pressure).
MASTER
CYLINDER
VENTED
10. Depress the brake pedal rapidly four times to activate both HCU
RESERVOIR
RESERVOIR CAP pump motors.
11. With the system fully charged, the brake fluid level will be
between the MIN and MAX marks on the master cylinder
reservoir. Adjust if necessary. Refer to Section 5 for detailed
instructions on how to correctly fill the master cylinder
reservoir.
FOOT 12. Check the system for leaks. If there are no leaks, go to Step
BRAKE 15.
SWITCH
PRIMARY
FLUID LEVEL CIRCUIT necessary repairs. Use the following procedure to depressurize
SENSOR (MF-FRONT the system.
CIRCUIT
(MR-REAR AXLE) 4004477a 앫 Remove the two maxi-fuses for the pump motors or
disconnect the battery.
Figure 4.48
5. Fill the master cylinder reservoir to the MAX mark with new pressure in the system. To ensure that the system is
brake fluid from a sealed container. Use DOT 3 or DOT 4 depressurized, perform the following check on both the
hydraulic brake fluid. Refer to the vehicle specification sheet to front and rear axles:
determine which fluid to use. A. Remove the protective cover from the end of the bleeder
6. Bleed the master cylinder circuit. Follow the instructions for fitting on one brake caliper.
bleeding the master cylinder circuit that appear in Section 5 of B. Attach a bleeder bottle hose to the bleeder fitting at the
this manual. wheel end. Submerge the free end of the bleeder hose
7. After bleeding, ensure that the fluid level in the master cylinder into the bleeder bottle. Both the tubing and container
is at the MAX mark. If brake fluid in the reservoir is above or must be able to withstand the effects of hydraulic brake
below the MAX mark, remove or add brake fluid as necessary fluid.
until the MAX mark level is achieved. Never add fluid above the C. Use a wrench to open the bleeder fitting screw to the
MAX mark. torque value specified by the component manufacturer.
8. Install the two maxi fuses or connect the battery. Figure 4.49.
If the HCU pump motors fail to deliver a sufficient amount of
within three minutes, with the brake warning light and the
buzzer OFF. If there are problems building pressure after
bleeding and powering up the system, increase the pressure
setting of the pressure bleeder equipment to 29-40 psi (2-2.75
bar), and cycle the ignition off for 10 seconds, then back on.

Figure 4.49
Removal
Master Cylinder Foot Brake Switch
WARNING
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
1. Park the vehicle on a level surface.

2. Apply the parking brake and block the wheels.
3. Disconnect the foot brake switch.
4. Remove the two machine screws securing the foot brake
switch to the base of the master cylinder.
4004437a
5. Remove the foot brake switch.
Figure 4.49
6. Remove and discard the paper gasket (models built prior to
D. Apply and hold the brake pedal down until no more brake 2006) from the master cylinder, or O-ring (models built in
fluid runs out. Do not release the brake pedal. 2006 and after) from the foot brake switch.
E. With the brake pedal still applied, use a torque wrench to 7. Verify the warranty status. If the switch is under warranty,
tighten the bleeder fitting screw. return it to WABCO.
앫 Repeat Steps A-E for the second axle. NOTE: When removing and inspecting the foot brake travel
switch, if brake fluid from the master cylinder is found in the
switch or switch cavity, it indicates that the master cylinder has
cylinder reservoir to make sure it is at the MAX mark. Refill as
failed.
necessary with new brake fluid from a sealed container. Use
only the recommended DOT 3 or DOT 4 hydraulic brake fluid.
Refer to the vehicle specification sheet to determine which fluid
to use.
14. Reinstall the two maxi-fuses for the pump motors or reconnect
the battery.
15. Use TOOLBOX™ Software to cancel the diagnostic code for
the master cylinder reservoir. Refer to Section 3 for
TOOLBOX™ Software instructions.

Installation Removal
Master Cylinder Foot Brake Switch Master Cylinder Fluid Level Sensor Switch
If the master cylinder tag displays a build date prior to
01.01.2006 as shown on the tag in Figure 4.50, replace the
WARNING
entire master cylinder with the current design used in vehicles Park the vehicle on a level surface. Block the wheels to
built after 01.01.2006. prevent the vehicle from moving. Support the vehicle with
Figure 4.50
BUILD
DATE 1. Park the vehicle on a level surface.
171 2. Apply the parking brake and block the wheels.
6 J08
1 / 0 3 4 005 0
1 3. Remove the electrical connector from the fluid level sensor.
411
468
PART 4. Squeeze the tabs together to remove the fluid level sensor from
NUMBER
its mounting location on the master cylinder reservoir.
4008216a
5. Verify the warranty status. If the switch is under warranty,
return it to WABCO.
Figure 4.50
Installation
1. Clean the surface of the master cylinder base and install the
O-ring seal on the foot brake switch.
Master Cylinder Fluid Level Sensor
2. Install the foot brake switch to the base of the master cylinder. 1. Install the fluid level sensor in the same direction as the switch
Tighten the two screws to 26.5-35.4 in-lb (3-4 N폷m). you removed. Figure 4.52.
Figure 4.51. @
Figure 4.52
Figure 4.51
FILL CAP FLUID LEVEL

RESERVOIR
SENSOR
CONNECTOR
MASTER O-RING
CYLINDER SEAL
MOUNTING
FOOT BRAKE SCREWS LOW
SWITCH PRESSURE
4008215b HOSE
RESERVOIR MASTER
Figure 4.51 MOUNTING CYLINDER
NUT BODY
4005145a
3. Connect the foot brake switch.
4. Remove the safety stands and wheel blocks. Figure 4.52
5. Test drive the vehicle. Refer to the test drive procedure in 2. Connect the fluid level sensor connector.
3. Remove the safety stands and wheel blocks.

4. Test drive the vehicle. Refer to the test drive procedure in NOTE: For convenience, Step 5 may be performed one axle at
Section 3 of this manual. a time.
Removal 5. Apply the brake pedal a minimum of 30 times to decrease

Parking Brake Pressure Supply Valve depressurized, perform the following check on both the front
and rear axles:
WARNING A. Remove the protective cover from the end of the bleeder
The full power brake system is a pressurized system that fitting on one brake caliper.
fluid.
death.
C. Use a wrench to open the bleeder fitting screw to the
NOTE: It is not necessary to remove the entire HCU assembly from torque value specified by the component manufacturer.
the vehicle when replacing the parking brake valve. Figure 4.53.
앫 Two people are needed to perform this procedure. Figure 4.53

앫 Bleeding the SAHR circuit is required during installation of the
parking brake pressure supply valve. Bleed procedures appear in
WARNING
Park the vehicle on a level surface. Block the front and rear
tires to prevent vehicle movement. Failure to do so can result
4004437a
in unwanted vehicle movement causing serious personal
injury. Figure 4.53
1. Park the vehicle on a level surface. D. Apply and hold the brake pedal down until no more brake
2. Block the front and rear tires to prevent vehicle movement. fluid runs out. Do not release the brake pedal.
Failure to do so can result in unwanted vehicle movement E. With the brake pedal still applied, use a torque wrench to
causing serious personal injury. tighten the bleeder fitting screw.
3. Disconnect the battery. 앫 Repeat Steps A-E for the second axle.
4. Use a clear rag to carefully wipe the surface of the HCU and the 6. Disconnect the electrical connection from the parking brake
surrounding area. pressure supply valve.

7. Attach a pinch clamp to the low pressure hose at the HCU NOTE: Do not use a 17 mm wrench to remove the pressure
reservoir. Figure 4.54. supply valve. The Snap-On Tool specified in Step 10 must be
used.
NOTE: Be careful not to damage the HCU reservoir inlet when
10. Use a socket, Snap-On Tools part number A121, to remove the
replaced.
pressure supply valve from the hydraulic compact unit.
Figure 4.54
Figure 4.56.
Figure 4.56
PARKING BRAKE TO REAR TO PARKING

VALVE BODY BRAKE BRAKE (SAHR)
CIRCUIT CIRCUIT
4005143a
Figure 4.54
TO REAR
8. To help prevent brake fluid from damaging the vehicle or floor BRAKE
CIRCUIT
beneath the work area to collect any drained or spilled brake BLEEDERS
fluid. 4004853a
FROM MASTER
9. Unscrew the black plastic nut by hand from the pressure CYLINDER
supply valve. Remove the coil and O-ring. Figure 4.55.
Figure 4.56
Figure 4.55
ELECTRICAL 11. Plug the open port to prevent contaminants from entering the
CONNECTOR system.
12. Verify the warranty status. If the pressure supply valve is under
warranty, return it to WABCO.
PARKING
BRAKE
COIL VALVE
O-RING BODY
HCU
PLASTIC
NUT 4004854a
Figure 4.55

Installation Figure 4.57
PARKING O-RINGS (3)

BRAKE
Parking Brake Pressure Supply Valve O-RING VALVE
BODY
WARNING
FILTER
power. Prior to servicing this system the depressurization SCREENS
procedures must be performed exactly as presented. Failure to (2)
depressurize the system may result in personal injury or PLASTIC COIL
death. NUT
4004852a
Figure 4.57
components, such as the air tank, in order to access the HPB 2. Use a clean rag to carefully clean the outside of the hydraulic
part. If this is necessary, refer to the vehicle manufacturer’s compact unit.
3. Use new, clean lubricant to lubricate the O-rings on the new
앫 Bleeding the SAHR circuit is required during installation of the parking brake valve. Use only DOT 3 or DOT 4 hydraulic brake
parking brake pressure supply valve. Bleed procedures appear in fluid. Refer to the vehicle specification sheet to determine
Section 5 of this manual. which fluid to use.
앫 After installing HPB components or making system repairs, use 4. Position the new pressure supply valve onto the hydraulic
TOOLBOX™ Software to remove the error code from the ECU compact unit. Use a socket, Snap-On Tools part number A121,
memory. Instructions for using TOOLBOX™ Software appear in to tighten the valve to 27-34 ft-lb (40-50 N폷m). Figure 4.58.
Section 3 of this manual. @
CAUTION Figure 4.58
When installing the new parking brake pressure supply valve ELECTRICAL
CONNECTOR
assembly, be careful not to damage the valve body O-rings
and filter screens.
NOTE: To help prevent leakage, the three O-rings and two

filter screens must be in place.
1. Remove the coil from the new pressure supply valve.

Figure 4.57.
PARKING
BRAKE
COIL VALVE
O-RING BODY
HCU
PLASTIC
NUT 4004855a
Figure 4.58

5. Place the coil, O-ring and plastic nut onto the pressure supply C. Use a wrench to open the bleeder fitting screw.
valve. Use a 12-point socket wrench to tighten the black plastic Figure 4.59.
nut to 26.5 in-lb (3 N폷m). @
Figure 4.59
6. Attach the electrical connector to the parking brake valve.

Figure 4.58.
8. Fill the master cylinder reservoir to the MAX mark with new
brake fluid from a sealed container. Use only DOT 3 or DOT 4
hydraulic brake fluid. Refer to the vehicle specification sheet to
10. Turn the ignition switch ON. The HCU pump motors will start up
and fill the accumulators. Approximate running time is 45
seconds.
11. Bleed the spring-applied/hydraulic release (SAHR) parking
brake circuit. Follow the instructions for bleeding the SAHR
circuit that appears in Section 5 of this manual.
4004437a
12. After bleeding the SAHR circuit, ensure that the brake fluid
level in the master cylinder reservoir is at the MAX mark. If the Figure 4.59
brake fluid in the reservoir is above or below the MAX mark,
remove or add brake fluid as necessary until the MAX mark D. Apply and hold the brake pedal down until no more brake
level is achieved. Never add fluid above the MAX mark. Refer to fluid runs out. Do not release the brake pedal.
Section 5 for detailed instructions on how to correctly fill the
master cylinder reservoir. E. With the brake pedal still applied, use a torque wrench to
13. Check the system for leaks. If there are no leaks, go to Step specified by the component manufacturer.
16.
앫 Repeat Steps A-E for the second axle.
necessary repairs. Use the following procedures to 14. After making the repairs, check the fluid level in the master
depressurize the system. cylinder reservoir to make sure it is at the MAX mark. Refill as
necessary with new clean brake fluid from a sealed container.
앫 Remove the two maxi-fuses for the pump motors or Use only the recommended DOT 3 or DOT 4 hydraulic brake
disconnect the battery. fluid. Refer to the vehicle specification sheet to determine
앫 Apply the brake pedal a minimum of 30 times to decrease which fluid to use.
pressure in the system. To ensure that the system is 15. Reinstall the two maxi-fuses for the pump motors or reconnect
depressurized, perform the following check on both the the battery.
16. Use TOOLBOX™ Software to cancel the diagnostic code for
A. Remove the protective cover from the end of the bleeder the pressure supply valve. Refer to Section 3 for TOOLBOX™
fitting on one brake caliper. Software instructions.
B. Attach a bleeder bottle hose to the bleeder fitting at the 17. Remove the wheel blocks.
into the bleeder bottle. Both the tubing and container 18. Test drive the vehicle. Refer to the test drive procedure in
must be able to withstand the effects of hydraulic brake Section 3 of this manual.
fluid.

Removal Figure 4.60
Low Pressure Hose

WARNING
death.
NOTE: WABCO does not manufacture low pressure hoses. Refer to

the vehicle manufacturer for specific installation and service
information. The following removal and installation procedures are
included to assist you in servicing WABCO’s HPB system.
4004437a
Figure 4.60
WARNING D. Apply and hold the brake pedal down until no more brake
WARNING: Block the front and rear tires to prevent the vehicle fluid runs out. Do not release the brake pedal.
from moving. Unwanted vehicle movement can result in
serious personal injury. E. With the brake pedal still applied, use a torque wrench to
2. Block the front and rear tires to prevent vehicle movement. specified by the component manufacturer.
3. Disconnect the battery. Repeat Steps A-E for the second axle.
4. Use a clean rag to carefully wipe the surface of the HCU and 6. Attach a pinch clamp to the low pressure hose near the outlet
the master cylinder reservoir. of the master cylinder reservoir. Do not damage the reservoir
outlet. Figure 4.61.
pressure in the system. To ensure the system is depressurized, NOTE: Be careful not to damage the HCU reservoir outlet when
perform the following check on both the front and rear axles. attaching the pinch clamp. If damaged, it will need to be
replaced.
fluid.
Figure 4.60.

Figure 4.61
Installation
MASTER
CYLINDER
RESERVOIR Low Pressure Hose
앫 When replacing the low pressure hose, bleeding the system is
LOW PRESSURE not necessary.
HOSE (TO HCU
RESERVOIR) 앫 To help prevent contamination of the system, keep the hose
ends sealed until you are ready to connect them.
1. Remove the plug from the HCU reservoir.
2. Remove the plugs from the ends of the new hose.
NOTE: When installing the hose clamps that hold the middle
portion of the low pressure hose to the vehicle, use the same
BRAKE TUBES location as was used for the original installation.
(TO HCU
ASSEMBLY)
3. Attach the new hose to the HCU reservoir and master cylinder
4004523a
reservoir. Reuse the “P” clamps to attach the middle portion of
Figure 4.61 the hose to the vehicle frame. Make sure the new hose does
not contact any sharp edges or hot components.
7. Remove the clamps that hold the middle section of the low 4. Fill the master cylinder reservoir with new brake fluid from a
pressure hose to the chassis. Note the position of the clamps sealed container. The fluid level must be at the MAX mark. Use
for installation of the new hose. DOT 3 or DOT 4 hydraulic brake fluid. Refer to the vehicle
8. To help prevent brake fluid from damaging the vehicle or floor specification sheet to determine which fluid to use.
paint, or from seeping into the ground, position a container 5. Connect the battery.
fluid. 6. Turn the ignition ON. The HCU pump motors will start up and
9. Remove the hose clamp and remove the hose from the master
cylinder reservoir. 7. Turn the ignition OFF and disconnect the battery.
NOTE: Some brake fluid may remain in protected areas of the pressure in the system. This will purge any trapped air from the
master cylinder reservoir. hose.
10. Remove the cap from the master cylinder reservoir to assist 9. After the fluid level is stabilized, ensure the fluid level in the
draining. When the reservoir is empty, replace the cap on the master cylinder reservoir is at the MAX mark. If the brake fluid
master cylinder reservoir and plug the reservoir outlet to in the reservoir is above or below the MAX mark, remove or
prevent any excess fluid from spilling during removal. add fluid as necessary until the MAX mark level is achieved.
Approximately one gallon (3.4 liters) should drain into the Never add fluid above the MAX mark. Refer to Section 5 for
container. detailed instructions on how to correctly fill the master cylinder
reservoir.
11. Remove the hose clamp and remove the hose from the HCU.
12. Remove the “P” clamps and remove the hose from the vehicle.
12. Pump the brakes rapidly four times to activate both HCU pump
motors. After the pumps stop, the brake fluid will be between
the MIN and MAX marks on the master cylinder reservoir.

13. Check the system for leaks. If there are no leaks, go to Step E. With the brake pedal still applied, use a torque wrench to
15. tighten the bleeder fitting screw to the torque value
necessary repairs. Use the following procedure to depressurize 앫 Repeat Steps A-E for the second axle.
the system.
14. After making the repairs check the fluid level in the master
앫 Remove the two maxi-fuses for the pump motors or cylinder reservoir to make sure it is at the MAX mark. Refill as
disconnect the battery. necessary, using only the recommended DOT 3 or DOT 4
hydraulic brake fluid, as described above. Never add fluid
above the MAX mark.
depressurized, perform the following check on both the 15. Reinstall the two maxi-fuses for the pump motors or reconnect
front and rear axles: the battery.
A. Remove the protective cover from the end of the bleeder 16. Remove the wheel blocks.
B. Attach a bleeder bottle hose to the bleeder fitting at the Section 3 of this manual.
into the bleeder bottle. Both the tubing and container Lubrication
fluid. Wheel Speed Sensor Specification
C. Use a wrench to open the bleeder fitting screw. WABCO specifications call for a sensor lubricant with the following
Figure 4.62. characteristics.
Figure 4.62
Lube must be mineral oil-based and contain molydisulfide. It should
have excellent anti-corrosion and adhesion characteristics and be
capable of continuous function in a temperature range of 40 to
300F (40 to 150C).
앫 Lubricants approved for use on WABCO sensors and spring clips
are:
— Mobilith SHC-220 (Mobil)
— TEK 662 (Roy Dean Products)
— Staburags NBU 30 PTM (Klüber Lubrication)
— Valvoline EP 633
— Klüberplex BE 31-512 (Klüber Lubrication)
— Urethyn-EZ (Fuchs Lubritech)
— Unirex N3 (ESSO)
4004437a — ECO-Li-Plus (BPW)
Figure 4.62 — Molykote P40 (Dow Corning)

— Moly-Fortified Multi-Purpose Grease (Ford) (Valvoline/USA)

Removal Figure 4.64
SENSOR
SPRING
Front Axle Wheel Speed Sensor CLIP
WARNING
prevent the vehicle from moving. Support the vehicle with
WHEEL SPEED
SENSOR
1. Park the vehicle on a level surface. Apply the parking brakes.
Block the rear tires to prevent the vehicle from moving. 4004479a
If necessary, raise the front tires off the ground. Place safety Figure 4.64
stands under the axle.
2. Disconnect the fasteners that hold the sensor cable to the Installation
other components.
Front Axle Wheel Speed Sensor
3. Disconnect the sensor cable from the chassis harness.
1. Connect the sensor cable to the chassis harness.
4. Remove the sensor from the sensor holder. Twist and pull the
sensor to remove it from the sensor bracket. Do not pull on 2. Install the fasteners used to hold the sensor cable in place.
the cable. Figure 4.63. 3. Apply a WABCO-recommended lubricant to the sensor spring
clip and sensor.
Figure 4.63
4. Install the sensor spring clip. Verify that the spring clip tabs are
KNUCKLE-MOUNTED on the inboard side of the vehicle.
SENSOR
5. With the tabs on the inboard side, push the sensor spring clip
into the bushing in the steering knuckle until the clip stops.
6. Push the sensor completely into the sensor spring clip until it
contacts the tooth wheel.
NOTE: After installation, there should be no gap between the

sensor and the tooth wheel. During normal operation, a gap of
up to 0.04-inch (1.016 mm) is allowable.
1004706a
CAUTION
Figure 4.63
Overtightening the tie wraps may damage the cables.
5. Remove the sensor spring clip. Figure 4.64. 7. Fasten the sensor cable with tie wraps every 12 inches. Do not
NOTE: When replacing the wheel speed sensor, the sensor overtighten the tie wraps. Correctly bundle and store any
spring clip must also be replaced. excess cable in the sub-frame. Figure 4.65.

Figure 4.65 NOTE: When replacing the wheel speed sensor, the sensor
spring clip must also be replaced.
Bundle Installation
excess
cable.
Rear Axle Wheel Speed Sensor
1. Connect the new sensor cable to the chassis harness.
2. Apply a WABCO-recommended lubricant to the spring clip.
3. Press the sensor spring clip into the sensor bracket, located on
the rear axle, until it stops. Verify that the tabs are on the
inboard side.
1004707a
4. Apply a WABCO-recommended lubricant to the sensor.
Figure 4.65
5. Push the sensor completely into the spring clip until it contacts
8. Remove the blocks and safety stands. the tooth wheel.
9. Test drive the vehicle. Refer to the test drive procedure in NOTE: After installation, there should be no gap between the
Section 3 of this manual. sensor and the tooth wheel. During normal operation, a gap of
up to 0.04-inch (1.016 mm) is allowable.
Removal
6. Reattach the sensor cable to the cable clamps or clips.
Rear Axle Wheel Speed Sensor
CAUTION
WARNING Overtightening the tie wraps may damage the cables.
prevent the vehicle from moving. Support the vehicle with 7. Fasten the sensor cable with tie wraps every 12 inches. Do not
safety stands. Do not work under a vehicle supported only by overtighten the tie wraps. Correctly bundle and store excess
jacks. Jacks can slip and fall over. Serious personal injury and cable in the sub-frame. Figure 4.65.
8. Use TOOLBOX™ Software to remove the error code from the
ECU memory.
1. Apply the parking brake. Block the front tires to prevent vehicle
movement. 9. Replace the tire and remove the safety stands. Lower the
vehicle and remove the blocks from the front tires.
2. Raise the rear tires off the ground. Place safety stands under
the axle. 10. Test drive the vehicle. Refer to the test drive procedure in
3. If the rear tire must be removed to gain access to the sensor,
release the parking brake to release the brake shoe.
Remove the wheel and tire assembly from the axle.
4. Remove the sensor from the mounting block in the axle
housing. Use a twisting motion if necessary. Do not pull on
the cable.
5. Disconnect the sensor cable from the chassis harness.
6. Remove the sensor cable from any cable clamps or clips.
7. Remove the sensor spring clip from the sensor bracket.

5 Brake Bleeding Procedures
Hazard Alert Messages Never add fluid above the MAX mark on the HPB master
cylinder reservoir regardless of the charging state of the

The following brake bleeding procedures explain how to bleed the accumulators. When the system is totally or partially
hydraulic power brake system during installation, or in the event of depressurized during service or overnight parking, fluid stored
air in the brake system. in the accumulators is returned to the master cylinder
When performing bleed procedures, read and observe all Warning reservoir. If the reservoir was previously filled above the MAX
and Caution hazard alert messages in this publication. They provide mark, a fluid spill could occur when these conditions exist.
information that can help prevent serious personal injury, damage to Overfilling the master cylinder reservoir may cause damage to
components, or both. the cap and other components, resulting in impaired braking
performance and could result in an accident and serious
WARNING personal injury.
when you perform vehicle maintenance or service. CAUTION
Hydraulic brake fluid is a caustic substance. Contact with
Park the vehicle on a level surface. Block the wheels to hydraulic brake fluid can cause skin irritation. Do not let
prevent the vehicle from moving. Support the vehicle with hydraulic brake fluid touch any painted surfaces, as it will
safety stands. Do not work under a vehicle supported only by remove the paint. Hydraulic brake fluid may also damage
jacks. Jacks can slip and fall over. Serious personal injury and certain non-metal surfaces. Do not let fluid get on brake pads,
damage to components can result. shoes, rotors or disks.
Failure to bleed the system whenever any hydraulic system Observe the following when working on the braking system.
fitting is loosened or disconnected will allow air to remain in
the system. This will prevent the hydraulic pressure in the WARNING
brake system from rising enough to apply the brakes correctly. Prior to working on the braking system, all bleeder screws and
This will cause the stopping distance to increase and can the master cylinder cap must be cleaned thoroughly;
result in serious personal injury. cleanliness of fluid and areas around the service points have
to be maintained. Do not use mineral oil-based fluid for this
Never reuse hydraulic brake fluid that has been removed from cleaning. Using mineral oil-based fluid can contaminate brake
a vehicle. Hydraulic brake fluid that has been removed can be fluid and could damage the interior of the components and
contaminated and can cause damage, loss of braking and cause a system malfunction. Cover all electrical connectors
serious personal injury. Always discard hydraulic brake fluid in near the bleeder screws carefully to make certain that no
accordance with applicable environmental requirements. brake fluid enters the terminals or plugs. Failure to do so may
cause loss of braking resulting in serious personal injury.
Use only the type of hydraulic brake fluid specified by the
equipment manufacturer. Do not use or mix different types of NOTE: After removing a component or disconnecting a brake tube
hydraulic brake fluid. The incorrect hydraulic brake fluid will connection, block off ports and brake tubes with appropriate plugs
damage the rubber parts of the brake caliper and can cause to prevent the ingress of dirt and unnecessary loss of fluid.
damage, loss of braking and serious personal injury.
Use only new specified brake fluid from a sealed container to refill
Do not let the brake master cylinder fluid get below the the system. Refer to the specification on the Master Cylinder (MC)
minimum level during the bleeding operation. Keep the master reservoir or in the vehicle service manual.
cylinder reservoir filled with new DOT-approved brake fluid, as
specified by the original equipment manufacturer. Failure to If a lubricant is required to aid assembly, use only the specified
keep the brake reservoir level above minimum could result in brake fluid from a sealed container. Do not use any other assembly
more air entering system, making it impossible to effectively lubricant.
bleed the system.

During bleeding procedures, brake fluid level must not be allowed to A. Fully depress the brake pedal a minimum of 30 times.
fall below the MIN mark on the master cylinder reservoir. The The pressure in each brake circuit can be monitored using
master cylinder reservoir should be regularly checked and filled to the TOOLBOX™ Software. Ensure that the pressure in
the MAX mark. each accumulator is at 0 psi.
B. While fully depressing the brake pedal, select the Deplete
Perform the bleeding procedure exactly as described in the
Accumulators function from the TOOLBOX™ Software
instructions. Perform the reservoir top-off procedure, when bleeding
EOL pull-down menu. The pedal must remain fully
is complete. Refer to technical publication TP-09121, Filling the
depressed during the entire process, until the
Hydraulic Power Brake (HPB) Master Cylinder Reservoir, for
TOOLBOX™ Software displays the completion message.
instructions on filling the master cylinder. To obtain this publication,
Ensure that the pressure in both accumulators is reading
refer to the Service Notes page on the front inside cover of this
zero on the diagnostic main screen then release the brake
manual.
pedal.
After completing all desired brake service operations, test the 5. Turn the ignition OFF.
braking system for function and check for leakage.
6. Verify that the brake fluid level in the master cylinder reservoir
is not below MIN level.
Use DOT 3 or DOT 4 hydraulic brake fluid. Refer to the vehicle
specification sheet to determine which fluid to use. NOTE: During bleeding procedures, brake fluid level must not
be allowed to fall below the MIN mark on the master cylinder
Brake Bleeding Procedures reservoir. The master cylinder reservoir should be regularly
checked and filled to the MAX mark with new specified brake
The pressure-assisted brake bleeding procedures described here
fluid from a sealed container. Do not add fluid above the MAX
may be used with any fill and bleed equipment capable of filling the mark.
system and creating pressure in the master cylinder reservoir.
7. Prepare the pressure bleeder device according to the
WARNING instructions provided with the equipment.
WABCO does not approve using manual bleeding procedures. NOTE: The pressurized fill and bleed equipment used can be
Manual bleeding procedures could result in loss of braking, either “air over fluid” or “fluid over air” type.
resulting in serious personal injury.
8. Install a suitable adapter from the fill and bleed equipment to
the master cylinder reservoir filler neck. Verify that the adapter
Pressure Bleed Procedures and bleed equipment are securely tightened onto the master
cylinder reservoir filler neck.
Master Cylinder Circuit
9. Remove the rubber caps from the two relay valve bleeder
1. Park the vehicle on a level surface. Apply the parking brake
screws located on the hydraulic control unit (HCU). Figure 5.1.
and block the wheels to prevent the vehicle from moving.
2. Turn the ignition OFF and remove the two 30-amp Maxi fuses
for the brake system motors. Refer to the vehicle
manufacturer’s specifications to determine where the fuses are
located.
3. Connect the diagnostic laptop to the diagnostic connector
located in the cab, under the instrument panel. Set the ignition
key to ON and open the TOOLBOX™ Software program.
4. Deplete pressure in the accumulators. There are two ways of
depressurizing the system as follows.

Figure 5.1 17. If brake caliper circuit bleeding is required, refer to the
procedure in this section.
18. If brake caliper circuit bleeding is NOT required, install the two
30-amp pump motor fuses and turn the ignition ON with 35 psi
(2.4 bar) pressure applied to the master cylinder reservoir. The
HCU pump motors will start up automatically and fill the
accumulators. Approximate running time is 45 seconds. The
brake light and buzzer will turn OFF.
19. Release the pressure from the master cylinder reservoir.
1 2 3 4
4008096a
20. Remove the bleed equipment.
1 BLEEDER PORT — PRIMARY MASTER CYLINDER CIRCUIT
2 MASTER CYLINDER INPUT PORT — PRIMARY CIRCUIT 21. Install the master cylinder reservoir cap.
3 MASTER CYLINDER INPUT PORT — SECONDARY CIRCUIT
4 BLEEDER PORT — SECONDARY MASTER CYLINDER CIRCUIT
22. Using the diagnostic laptop and the TOOLBOX™ Software
program, clear all the inactive fault codes.
Figure 5.1
NOTE: If faults remain, they should be diagnosed prior to

10. Fit the bleeder hose onto one relay valve bleeder screw located
releasing the vehicle to service.
on the hydraulic compact unit.
11. Submerge the free end of the bleeder hose into the partially 23. Turn the ignition OFF and disconnect the diagnostic laptop
filled bleed bottle. from the diagnostic connector.
12. Apply 35 psi (2.4 bar) of pressure from the fill and bleed 24. Check the system for external leaks.
equipment to the master cylinder reservoir. 25. Remove the wheel blocks.
13. Open one of the relay valve bleeder screws until the fluid
begins to flow (about 3/4 turn). Allow the fluid to run until 8.5 Brake Caliper Circuit
ounces (250 cc) has been collected. Take note of the fluid level
in the bottle before starting. NOTE: If the vehicle has “Quadraulic” calipers, refer to the
“Quadraulic Brake Caliper Bleeding Procedure” in this section.
14. When no further air bubbles enter the bleed bottle, close the
bleeder screw. Remove the bleeder hose and tighten the NOTE: If you are bleeding the front calipers, it is critical that you
bleeder screw to 35.4 to 39.8 lb-in (4 to 4.5 Nm). @ bleed the SAHR circuit also, if equipped.
NOTE: Verify the fluid level in the master cylinder reservoir.

During bleeding procedures, the brake fluid must not be WARNING
allowed to fall below the MIN mark on the master cylinder Park the vehicle on a level surface. Apply the parking brake
reservoir. The master cylinder reservoir should be regularly and block the wheels to prevent the vehicle from moving.
checked during the bleeding procedures and filled to the MAX Unwanted vehicle movement can result in serious personal
mark. injury.
15. Repeat Steps 13 and 14 with the second bleeder screw. 1. Park the vehicle on a level surface. Apply the parking brake
16. Ensure that the brake fluid level in the master cylinder reservoir
is at the MAX mark. If the brake fluid in the reservoir is above 2. Turn the ignition OFF and remove the two 30-amp Maxi fuses
or below the MAX mark, remove or add fluid as necessary until for the brake system motors. Refer to the vehicle
the MAX mark level is achieved. Never add fluid above the MAX manufacturer’s specifications to determine where the fuses are
mark. Refer to Section 5 for detailed instructions on how to located.
correctly fill the master cylinder reservoir.

3. Connect the diagnostic laptop to the diagnostic connector 12. Open one caliper bleeder screw until fluid begins to flow (3/4
located in the cab, under the instrument panel. Set the ignition turn). Allow the fluid to run until 8.5 ounces (250 cc) has been
key to ON and open the TOOLBOX™ Software program. collected. Take note of the fluid level in the bottle before
starting. Figure 5.2.
depressurizing the system as follows. Figure 5.2
A. Fully depress the brake pedal a minimum of 30 times.

The pressure in each brake circuit can be monitored using
the TOOLBOX™ Software. Ensure that the pressure in
each accumulator is at 0 psi.
pedal.
5. Turn the ignition OFF.
6. Verify that the brake fluid level in the master cylinder reservoir
is not below MAX level.
1004710a
NOTE: During bleeding procedures, brake fluid level must not
Figure 5.2
be allowed to fall below the MIN mark on the master cylinder
reservoir. The master cylinder reservoir should be regularly
checked and filled to the MAX mark with new specified brake 13. If no further air bubbles enter the bleed bottle, close the
fluid from a sealed container. bleeder screw. Remove the bleeder hose and tighten the
bleeder screw to the torque value specified by the component
7. Prepare the pressure bleeder device according to the manufacturer.
instructions provided with the equipment.
NOTE: Refer to the vehicle manufacturer’s specifications for
NOTE: The pressurized fill and bleed equipment used can be specific information about bleeding the calipers. Some calipers
either “air over fluid” or “fluid over air” type. have multiple bleeder screws and require removal of the
8. Install a suitable adapter from the fill and bleed equipment to wheels and tires to access the bleeder screws. Each bleeder
the master cylinder reservoir filler neck. Verify that the adapter screw must be bled.
and bleed equipment are securely tightened onto the master NOTE: Verify the fluid level in the master cylinder reservoir.
cylinder reservoir filler neck. During bleeding procedures, the brake fluid must not be
NOTE: If all wheel ends are to be bled, use the following allowed to fall below the MIN mark on the master cylinder
bleeding order: right rear, left rear, right front, left front. reservoir. The master cylinder reservoir should be regularly
checked during the bleeding procedures and filled to the MAX
9. Fit the bleeder hose onto the caliper bleeder screw at one mark.
wheel end.
14. Repeat Steps 9-13 with the other calipers in the specified
10. Submerge the free end of the bleeder hose into the bleed order.
bottle.
11. Apply 35 psi (2.4 bar) of pressure from the fill and bleed
equipment to the master cylinder reservoir.

15. If the vehicle is equipped with a power parking brake – SAHR Quadraulic Brake Caliper Bleeding Procedure
canister, then bleed the SAHR circuit now using Steps 9-13 of
This bleed sequence refers to bleeding the caliper and does not
the Spring-Applied/Hydraulic-Release (SAHR) Parking Brake
consider the hydraulic application system requirements. Identify
Circuit pressure bleed procedure in this section.
your vehicle hydraulic application system type and refer to that
16. Ensure that the brake fluid level in the master cylinder reservoir service manual before you perform any brake service. You must
is at the MAX mark. If the brake fluid in the reservoir is above adhere to the hydraulic application system bleeding procedures to
or below the MAX mark, remove or add fluid as necessary until prevent death, serious personal injury or damage to components.
the MAX mark level is achieved. Never add fluid above the MAX
mark. Refer to Section 5 for detailed instructions on how to NOTE: If you are bleeding the front calipers, it is critical that you
correctly fill the master cylinder reservoir. bleed the SAHR circuit also, if equipped.
17. Install the two 30-amp pump motor fuses and turn the ignition Refer to the manufacturer’s service information for ABS bleeding
ON with 35 psi (2.4 bar) of pressure applied to the master
instructions.
cylinder reservoir. The HCU pump motors will start up
automatically and fill the accumulators. Approximate running 1. Check the master cylinder reservoir and fill, if necessary, with
time is 45 seconds. The brake light and buzzer will turn OFF. DOT 3 or DOT 4 brake fluid.
18. Release the pressure from the master cylinder reservoir. 2. Bleed the brakes in the following order: right rear, left rear,
right front and left front.
19. Remove the bleed equipment.
20. Install the master cylinder reservoir cap. CAUTION
When you bleed a four-piston caliper, monitor the brake fluid
21. Using the diagnostic laptop and the TOOLBOX™ program,
level to ensure you do not drain the system. Add brake fluid to
while fully holding the brake pedal depressed, select the
the reservoir as needed to prevent damage to components
Deplete Accumulators function from the TOOLBOX™ Software
during operation. Always install new brake fluid into the
EOL pull-down menu. The pedal must remain fully depressed
caliper. Discard old brake fluid. Do not reuse it. Damage to
during the entire process, until the TOOLBOX™ Software
components can result.
displays the dialog box that will indicate the completion of the
function. Ensure that the pressure in both accumulators is
NOTE: Each four-piston caliper is equipped with two bleed
reading zero on the diagnostic main screen, then release the
screws. To ensure air is removed from a caliper, the bleed
brake pedal.
sequence is inboard, outboard, and repeat inboard.
NOTE: The DEPLETE ACCUMULATORS function performs a
cycle of releasing the pressure and charging the pressure back 3. Install a section of clear, flexible tubing with a 1/4-inch inner
up in each brake circuit. This cycle helps clear air from the HCU diameter over the inboard bleeder. Insert the other end of the
into the reservoir. tubing into a container to collect the purged brake fluid.
Discard the brake fluid. Do not reuse old brake fluid.
22. Repeat Step 21 two times.
4. If a pressurized bleeding system is not required by the vehicle
manufacturer’s service procedures, apply and hold the brakes
program, clear all the inactive fault codes.
to pressurize the system.
NOTE: If faults remain, they should be diagnosed prior to 5. Repeat the procedure for the outboard bleed screw.
releasing the vehicle to service.
6. Repeat the procedure for the inboard bleed screw.
24. Turn ignition OFF and disconnect the diagnostic laptop from 7. Tighten the bleed screws to specification. Refer to Section 8.
the diagnostic connector.
8. Test the brakes prior to returning the vehicle to service.
25. Check the system for external leaks.
26. Remove wheel blocks.

Spring-Applied/Hydraulic Release Parking 6. Verify that the brake fluid level in the master cylinder reservoir
Brake Circuit is not below MAX level.
NOTE: During bleeding procedures, brake fluid level must not
WARNING be allowed to fall below the MIN mark on the master cylinder
Before bleeding the circuit, you must disconnect the parking reservoir. The master cylinder reservoir should be regularly
brake cable from the spring-applied/hydraulic release (SAHR) checked during bleeding procedures and filled to the MAX
canister. This is to ensure that the SAHR piston achieves the mark with new specified brake fluid from a sealed container.
full stroke and forces most of the fluid volume out of the SAHR
canister, thus moving potential entrapped air into the bleeder
screw area. Refer to the vehicle manufacturer instructions for
how to disconnect the parking brake cable. NOTE: The pressurized fill and bleed equipment used can be
either “air over fluid” or “fluid over air” type.
The parking brake cable must be reconnected before
8. Install a suitable adapter from the fill and bleed equipment to
operating the vehicle. Never drive the vehicle if the parking
the master cylinder reservoir filler neck. Verify that the adapter
brake cable is disconnected or the parking brake system is not
and bleed equipment are securely tightened onto the master
operating correctly. Driving the vehicle without a correctly
functioning parking brake system can result in an accident
and serious personal injury. 9. Fit the bleeder hose onto the bleeder screw on the SAHR
chamber.
10. Submerge the free end of the bleeder hose into the bleed
bottle.
causing serious personal injury. 11. Apply 35 psi (2.4 bar) of pressure from the fill and bleed
equipment to the master cylinder.
for the brake system motors. Refer to the vehicle 12. Open the SAHR bleeder screw until fluid begins to flow (3/4
manufacturer’s specifications to determine where the fuses are turn). Allow the fluid to run until 8.5 ounces (250 cc) has been
located. collected. Take note of the fluid level in the bottle before
starting.
located in the cab, under the instrument panel. Set the ignition 13. If no further air bubbles enter the bleed bottle, close the
key to ON and open the TOOLBOX™ Software program. bleeder screw. Remove the bleeder hose and tighten the
bleeder screw to specified torque. Refer to the vehicle
manufacturer’s specifications for the correct torque value.
depressurizing the system as follows.
14. Ensure that the brake fluid level in the master cylinder reservoir
is at the MAX mark. If the brake fluid in the reservoir is above
or below the MAX mark, remove or add fluid as necessary until
the TOOLBOX™ Software. Ensure that the pressure in
the MAX mark level is achieved. Never add fluid above the MAX
each accumulator is at 0 psi.
mark. Refer to Section 5 for detailed instructions on how to
B. While fully depressing the brake pedal, select the Deplete correctly fill the master cylinder reservoir.
15. Install the two 30-amp pump motor fuses and turn the ignition
ON with 35 psi (2.4 bar) of pressure applied to the master
cylinder reservoir. The HCU pump motors will start up
automatically and fill the accumulators. Approximate running
time is 45 seconds. The brake light and buzzer will turn OFF.
pedal. 16. Release the pressure from the master cylinder reservoir.
5. Turn the ignition OFF. 17. Remove the bleed equipment.

18. Install the master cylinder reservoir cap. NOTE: The pressurized bleed equipment used for this drain
procedure must be the “air over hydraulic” type.
19. Connect the parking brake cable to the SAHR canister. Refer to
the vehicle manufacturer’s instructions for how to connect and 7. Install a suitable adapter from the fill and bleed equipment to
correctly adjust the parking brake cable. Verify correct the master cylinder reservoir filler neck. Verify that the adapter
application and release at the parking brake. and bleed equipment are securely tightened onto the master
program, clear all the inactive fault codes. 8. Apply 35 psi (2.4 bar) of pressure from the fill and bleed
equipment to the master cylinder.
21. Turn ignition OFF and disconnect the diagnostic laptop from
the diagnostic connector. 9. Fit the bleeder hose onto the caliper bleeder screw at one
wheel end.
22. Check the system for external leaks.
10. Submerge the free end of the bleeder hose into the bleed
23. Remove wheel blocks.
bottle.
Changing Hydraulic Brake Fluid 11. Open the bleeder screw until fluid begins to flow (3/4 turn).
Allow the fluid to run until the circuit is completely drained and
no more fluid comes out.
Failure to do so can result in unwanted vehicle movement 12. Close the bleeder screw.
13. Repeat Steps 8-12 for:
A. the remaining calipers,
for the brake system motors. Refer to the vehicle
manufacturer’s specifications to determine where the fuses are B. the two relay bleeder screws, and
located.
C. the SAHR bleeder screw, if equipped
14. Release the pressure from the master cylinder reservoir.
located in the cab, under the instrument panel. Set the ignition
key to ON and open the TOOLBOX™ Software program. 15. Remove the bleed equipment.
4. Deplete pressure in the accumulators. There are two ways of 16. Fill the master cylinder reservoir up to the MAX mark with new
depressurizing the system as follows. specified brake fluid from a sealed container. Use DOT 3 or
DOT 4 hydraulic brake fluid. Refer to the vehicle
manufacturer’s specifications to determine which fluid to use.
the TOOLBOX™ Software. Ensure that the pressure in NOTE: You can speed up the filling process by opening the
each accumulator is at 0 psi. bleeder screw of one of the rear calipers. This will allow better
brake fluid flow into the system by expelling the air through the
bleeder screw. Close the bleeder screw when no further air is
exiting the bleeder screw.
depressed during the entire process, until the 17. Bleed the master cylinder circuit using the master cylinder
TOOLBOX™ Software displays the completion message. bleeding procedure in this section.
Ensure that the pressure in both accumulators is reading 18. Bleed the rest of the brake system using the brake caliper
zero on the diagnostic main screen then release the brake circuit bleeding procedure and the SAHR circuit bleeding
pedal. procedure, if applicable, in this section.
5. Turn the ignition OFF.

Brake Fluid Replacement Requirement 1. Ensure vehicle is on a level surface and apply the parking
brake.
For the correct functioning of the ABS, seals and components,
WABCO recommends replacing brake fluid every two (2) years on all 2. Block the wheels to prevent the vehicle from moving.
vehicles equipped with WABCO HPB system. This is done to 3. Set the ignition key to OFF and remove the two 30-amp fuses
minimize exposure to contaminated brake fluid. To replace the that provide power to the brake system motors. The fuses are
brake fluid, please follow the instructions indicated under the in the fuse panel located on the engine side of the cowl.
“Changing Hydraulic Brake Fluid” section of this manual.
4. Remove master cylinder cap.
NOTE: While changing the brake fluid according to instructions
provided in this manual, please read and observe all Warning and 5. Connect a laptop computer containing TOOLBOX™ Software
Caution hazard alert messages published onwards from Page 52 to the diagnostic connector.
under Section 5, apart from those published below. 6. Turn the ignition key to ON and start the TOOLBOX™
Software.
Filling the Hydraulic Power Brake (HPB)
7. Depressurize the system as follows:
Master Cylinder Reservoir
A. Depress the brake pedal a minimum of 30 times.
WARNING B. Use the EZ-TECH and TOOLBOX™ Software to verify
Before you service the Hydraulic Power Brake (HPB) system, that pressure at both accumulators is at 0 psi.
you must perform the depressurization procedures exactly as
presented. The HPB system is a pressurized system that During this process, brake fluid will return to the master
reaches levels of up to 2,320 psi (160 bar). This pressure is not cylinder reservoir from the accumulators. Monitor the reservoir
reduced by switching the ignition off or removing battery fluid level to ensure it does not overflow.
power. If you do not depressurize the system, serious personal 8. Turn the ignition key to OFF.
injury or death can result.
9. With the accumulator pressure decreased, verify that the brake
Never add fluid above the MAX mark regardless of the fluid level is at the MAX mark on the master cylinder reservoir.
charging state of the accumulators. When the system is totally If brake fluid in the reservoir is above or below the MAX mark,
or partially depressurized during service or overnight parking, remove or add brake fluid as necessary until the MAX mark
fluid stored in the accumulators is returned to the master level is achieved. If brake fluid needs to be added, ensure that
cylinder reservoir. If the reservoir was previously filled above it is from a clean, sealed container. Never add fluid above the
the MAX mark, a fluid spill could occur when these conditions MAX mark.
exist. Overfilling the master cylinder reservoir may cause 10. Reinstall the 30-amp motor fuses and turn the ignition ON.
damage to the cap and other components, resulting in poor Both motors will start running until both circuits reach the
braking performance and serious personal injury. cut-off pressure at approximately 2000 psi (138 bar).
NOTE: The ability for the master cylinder to breath is critical to 11. Monitor the pressure in each circuit using the TOOLBOX™
correct brake system function. If the cap becomes Software.
contaminated, it will need to be replaced. 12. When both motors stop, ensure that the pressure level in each
circuit reached the cut-off level. This will decrease the brake
To prevent serious eye injury, always wear safe eye protection fluid level in the master cylinder reservoir.
13. With the system completely charged, the brake fluid level will
Park the vehicle on a level surface. Block the wheels to be between the MIN and MAX marks on the master cylinder
prevent the vehicle from moving. Support the vehicle with reservoir. Figure 5.3.

Figure 5.3
MAX
MIN
4007815a
Figure 5.3
WARNING
Never reuse hydraulic brake fluid that has been removed from
a vehicle. Hydraulic brake fluid that has been removed can be
contaminated and can cause damage, loss of braking and
serious personal injury. Always discard hydraulic brake fluid in
accordance with applicable environmental requirements. Use
DOT 3 or DOT 4 hydraulic brake fluid. Refer to the vehicle
specification sheet to determine which fluid to use. Do not use
or mix different types of hydraulic brake fluid. The incorrect
hydraulic brake fluid will damage the rubber parts of the brake
caliper and can cause damage, loss of braking and serious
personal injury.

6 Appendix
Leak Check Procedure for WABCO HPB 3. If the hydraulic system is compromised by exposure to air, it is
6 Appendix
necessary to bleed the affected circuit. Refer to the appropriate

System section in this manual.
Check the HPB System for Brake Fluid Leaks

System Test
With Pressure Removed: After all necessary repairs have been made and the system has
1. Park the vehicle on a level surface. For vehicles with manual been bled, verify the hydraulic circuits are connected correctly. Two
parking brakes, apply the parking brake. Block the wheels to people are required to perform this test.
keep the vehicle from moving. Failure to do so can result in
2. Block the front tires to keep the vehicle from moving. Failure to
2. Deplete system pressure. Refer to the appropriate section in
do so can result in unwanted vehicle movement causing
this manual for instructions.
3. Inspect the entire hydraulic brake system including brake lines
3. Raise the rear wheels. Place supports under the rear axle.
and line fitting connections for the presence of brake fluid
damage or other evidence of a leak. 4. Depress the brake pedal. Attempt to turn the rear wheels one
at a time. They should not move with the brakes applied.
앫 If a leak is identified, perform the following.
5. Connect the vehicle to a PC with TOOLBOX™ Software
A. Clean and dry the entire area.
installed. Use TOOLBOX™ Software to activate the solenoid
B. Determine the source of the leak. valves for the left rear wheel. You should be able to turn this
wheel by hand when the solenoids activate. Repeat this check
C. Make the necessary repairs.
for the right rear wheel. Go to Step 6.
4. If the hydraulic system is compromised by exposure to air, it is
6. Remove the axle stands from under the rear axle to lower the
necessary to bleed the affected circuit. Refer to the appropriate
vehicle.
section in this manual.
7. Remove the blocks from the front tires and place them in front
With Pressure Applied: of the rear tires.
If there was no evidence of a leak when the system was checked 8. Raise the front tires. Place supports under the front axle.
with the pressure removed, apply pressure to the system and
recheck for leaks. Two people are required to perform this check. 9. Repeat Steps 4 and 5.
1. With the vehicle parked on a level surface, depress the brake 10. Remove the axle stands from under the front axle to lower the
pedal and hold to deliver brake pressure to the calipers. vehicle.
2. Inspect the entire hydraulic brake system including brake lines 11. Make any necessary repairs. If any plumbing changes were
and line fitting connections for the presence of brake fluid made, bleed the system again.
damage or other evidence of a leak.
앫 If a leak is identified, perform the following.
A. Clean and dry the entire area.
B. Determine the source of the leak.
C. Deplete system pressure. Refer to the appropriate
section in this manual for instructions.
D. Make the necessary repairs.

(NYSE: WBC) is a connects trucks, trailers, cargo,
leading global supplier of technol- drivers, business partners and
ogies and services that improve fleet operators through advanced
the safety, efficiency and con- fleet management systems and
nectivity of commercial vehicles. mobile solutions. WABCO re-
Founded nearly 150 years ago, ported sales of $2.8 billion in
WABCO continues to pioneer 2016. Headquartered in Brussels,
breakthrough innovations for ad- Belgium, WABCO has 13,000 em-
vanced driver assistance, brak- ployees in 40 countries. For more
ing, stability control, suspension, information, visit:
transmission automation and
aerodynamics. Partnering with www.wabco-na.com
the transportation industry as it
maps a route toward autonomous
driving, WABCO also uniquely
© 2018 WABCO North America – All rights reserved – MM0401 / 08.2018

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WABCO HYDRAULIC

POWER BRAKE (HPB)

@ This symbol alerts you to tighten fasteners to a specified torque

How to Obtain Additional Maintenance,

WABCO Maintenance Manual MM-0401 (Revised 08-18)

pg. i Asbestos and Non-Asbestos Fibers pg. 68 Removal

pg. 94 Brake Caliper Circuit pg.

ASBESTOS FIBERS WARNING NON-ASBESTOS FIBERS WARNING

Regulatory Guidance Regulatory Guidance

WABCO Maintenance Manual MM-0401 (Revised 08-18) i

HCU WITH OPTIONAL POWER PARKING

system is also available with an optional parking brake pressure

HCU WITHOUT OPTIONAL POWER

앫 The HCU generates the service brake pressure.

WABCO Maintenance Manual MM-0401 (Revised 08-18) 1

HYDRAULIC COMPACT UNIT MASTER CYLINDER ASSEMBLY

2 WABCO Maintenance Manual MM-0401 (Revised 08-18)

Wheel-End Sensors Spring-Applied Hydraulic Release (SAHR) Parking

How the HPB System Works

WABCO Maintenance Manual MM-0401 (Revised 08-18) 3

HPB SYSTEM LAYOUT

MASTER ACCUMULATORS (2)

Functional Description For ABS, wheel pressure is individually modulated by eight

4 WABCO Maintenance Manual MM-0401 (Revised 08-18)

HPB Wiring Diagram for Multiplex Vehicles

BRAKE LIGHT SIGNAL

CAN HIGH ACC. SAE J1939

DIAGNOSE "A" ACC. SAE J1587

LOW BRAKE FLUID

PARKING BRAKE SWITCH

* SOLENOID VALVE GROUND

* SOLENOID VALVE SUPPLY

* PUMP MOTOR 2 GROUND

* PUMP MOTOR 2 SUPPLY

* PUMP MOTOR 1 GROUND

* PUMP MOTOR 1 SUPPLY

WABCO Maintenance Manual MM-0401 (Revised 08-18) 5

HPB Connector Diagram for Multiplex Vehicles

PIN IDENTIFICATION FOR WIRE HARNESS CONNECTORS TO THE ECU

SWITCH (OPTIONAL) NOT USED

FLUID NOT USED

BRAKE SWITCH 22 REAR RIGHT

PARKING BRAKE 27 WHEEL SPEED

DASH SWITCH 27 SENSOR

J1939 + HIGH 30 WHEEL SPEED

6 WABCO Maintenance Manual MM-0401 (Revised 08-18)

HPB Wiring Diagram for Non-Multiplexed Vehicles

WABCO Maintenance Manual MM-0401 (Revised 08-18) 7

HPB Connector Diagram for Non-Multiplexed Vehicles

PB-SUPPLY 4 15A UBAT

8 WABCO Maintenance Manual MM-0401 (Revised 08-18)

Testing the System Connecting TOOLBOX™ Software

parking brake and place the gear selector in NEUTRAL (manual

Never drive the vehicle if the parking brake cable is

Refer to, and follow, the vehicle manufacturer’s Warnings, Cautions

WABCO TOOLBOX™ Software 4011997a

WABCO Maintenance Manual MM-0401 (Revised 08-18) 9

앫 Verify the device software and firmware is up to date. Figure 3.3

Hydraulic Power Brake Menus and Toolbars