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Meritor WABCO Hydraulic Power Brake (HPB) System

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1. 929IAJ9S ON pe qesiq aga pue Oly sgy iva 01 19 UI 1 AJLA dwy weishs 14617 0 0111045 yno uedo uonduosoeg 40119338 Figure 3 27 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing pajre seu 123 pu sisisiod OLA JI 1981109 sjojeujeJed Ji JOQUINU yed 193 1292200 AWWA H Wed 1994109 JUS9A 359 pue 193 499u2 J6Ss999U JI 5 UOISOU09 JO eJnjsiouJ sewep ufs Aue 193 19edsui pue 19euuoosiq pejre seu eieoipur sjsisiod OLA 1991109 sjojeujeJed Ji Jequunu Wed 193 199409 A H lequunu yed 1994109 JU9A 359 pue 123 Ie Y29349 J6Ss999U JI 5 UBIO UOISOU09 JO eJnjsiouJ eDeuiep Aue s10128uuOO 193 198dsui pue 1 euuoosiq pejre seu eieoipur Aew sjsisiod OLA se1 pue 123 Y29349 5 JI 5 UOISOU09 JO eJnjs
2. 440 peidde NO duie1 Jojeoipu eyesg Buried 430 6261 due 99IAJeg 440 ejqipny NO dwe 440 dwe yeg NO duie1 sav uo YMS G 14677 uondio soeq 061 4011923 Figure 3 18 2 Meritor WABCO Maintenance Manual 0401 Revised 07 15 3 Troubleshooting and Testing 5 5 uana 1n990 ABW uonipuoo ul 4oeq Josues usnd pue deb 5 JOSUBS YO9UD JO S10128uuoo pue pue eouepeduul 10595 xo9u2 uoisou100 1 euo 2945 Sp4eAJ9ye Ul 4oeq Josues usnd pue def osneo INO euo pue Buueeq xy99u2 20 1 YOUI O70 O Ue eq 1ou pjnous deb au deb pue Duueeq 2949 uoisoJJ02 u199 Buissiu eDeuep euo 2949 Suluo 0002 006 ueewjeq einseeui pjnous eouejsiseJ JOSUBS punoJ6 oys JO uedo JO 105095 Jo pue sseuJeu 5 1921009 JO S1012euuoo pue Josues pue eouepeduul J0sues Y29049 SNIEIS HHVS Buip4oo
3. auc pue Buueeq 2 uuu 20 1 uour QpOo 0 uey Je e916 eq jou def au deb AjJeuuouqe ue JO sem sgy Udy OL uey speeds ye Aljeoipoued jno sdojp jeubis peeds 99uM 108095 peeds 5 MOA 9 p91o9jep seu oj uous JO uedo uy 00 si oDeyo Josues 00 s I0suag 5 YHVS 0 BuipJoooe 6261 due Jojeoipu Buried peseejau 440 peiqesiq NO 21 peiqesiq 430 6861 due JOSUM Sav N S 9 EJd 440 e qipny NO dwe 21V JJO dwe dwe Sav 5 YHVS 626 due Jojeoipu 440 41 NO due OI1V pajqesiq 440 6861 due SAV Hued 440 NO dwe 440 dwe7 sav Ssmejs HHVS Buipjoooe 6 6 due Jojeoipu 440 peiqesiq NO duie1 10jeoipu
4. G uid 1012euuoo UId eui 1v 0 amp z eq Pinoys uo p uid 1012euuoo urid e eui 1v 09 pinous Jo eui pL Suid ssojoe eouejsisaJ sseuJeu 6 5 JI SJOJOOBUUOD 00150100 JO eunjsiouJ Jo Aue UId y pue 1oeuuoosiq seu YOUMS OLY y peioelep INO JO p9AI929J 199110201 ney euJeju 511015 5 0 6261 due eyesg Hued 440 NO dure eyesg Hued 440 6261 due IIMS ued 440 eiqipny NO due 440 dwe 440 sav SNIEIS HHVS 01 Buipjoooe 6861 due Jojeoipu Bured 440 NO due Jojeoipu Bured 440 9519 20143 1e96 uoissiusueJ J 6861 99IAJOS 440 eiqipny 440 9519 ino euin 1299 NO duie1 440 dwg y
5. 6261 due Jojeoipu Bured peseejai JI 440 NO duie1 Jojeoipu 430 626 due 99IAJOS JJO Bulusen ZH 0 ONIHSV14 due1 440 dwg yeg 440 dure Sav SNIEIS HHVS 6261 due Jojeoipu exeag JI 440 NO Jojeoipu Burned 440 6861 due 99IAJOS 440 eiqipny 440 dwe 440 dwg BuiuJeA exeJg 440 dwe sav 1u6r1 snoad JOSUaS 1U9 4 OLV pei dde youms uomneoidde V N V N V N V N V N V N 4011952a Figure 3 46 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 Removal and Installation Hazard Alert Messages Read and observe all Warning and Caution hazard alert messages in this publication They provide information that can help prevent serious personal injury damage to components or both WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service
6. jo 1n2 eunsseJg 941 JI WIO 941 aedo pue sseuJeu pue eBeyo 0 1105 JJO IND eunssaJg oi Sgv 1In9JI9 JJO 1n2 eunssauJg s10j euuoo pue yOsUD 5 JI UBIO 0150109 JO eunjsiouJ sewep Aue 10 s1012euuoo pue 1oeuuoosiq seu 123 eieoipur sjsisiod OLA Ji pue sXoouo ssed jo 1n2 eunsseJg 941 JI WIO 941 pue solsoubeip ssausey pue Jjo 1n2 0 1105 JO jJO 1n2 eunssaJg oi Sgv 1In9JI9 AJLA JJO 1n2 eunssaJg 5 pue 429u2 5 JI 0150109 JO eunjsiouJ sewep Aue 10 s10128uuoo 1oedsur pue 1oeuuoosiq Seu 123 ereoipur sisisJed 91A Ji pue syoayo ssed pue Ajddns eunssaJg au I sonsouDeip Ajddns pere njen Ajddng eunssaJg eui se1eoipur oads 100 JJ Suluo Z eq pjnous eA eA Ajddns eunssaJg JO eoueljsisaJ 429u2 0 uous eA eA Ajddng eunssaJg 01 193 SV jddng eanssaJg JO sJoj euuoo
7. K ddns 123 Kyjeuonounj noga 5 Buunp sgy Snjeis HHVS 6261 due Jojeoipu Bured JI 440 NO dwe7 Jojeoipu Bured 6261 dweq 99IAJOS 440 eiqipny NO NO dwe dwe sav Snigls HHVS Buip4oooe 6261 due Jojeoipu peseejai JI 440 NO duie1 Jojeoipu Bured 440 626 due 99IAJOS 440 eiqipny NO 91V 440 dwg yeg dwe sav punog 0111045 Koneg A 0 01 gt M07 A 9 91 lt 6v0L 6v0L 2692 2692 2 uOnoeaH ulo1s S 1u6r1 uonduosoeg 40119418 Figure 3 35 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing SEY MOH y ayeoipul sisisJed 5180 03 Buroejdoi 194 seu sjsisiod OLA pue syoayo ssed Hum pue SJOJOBUUOD eunssaud j UOISOJJ02 JO eunj
8. 10014 psjgesiq Sav 9 97 51815 HHVS 01 6861 due Jojeoipu Bured peseejai 440 peidde NO dure Jojeoipu Bured 440 626 due 99IAJeS NO ButuieM eiqipny NO 91 NO dwg BuiuJeM exeJg NO dwe sav Snjeis HHVS 6261 due Jojeoipu Bured JI 440 NO dwe Jojeoipu Bured 430 6261 due 99IAJOS NO eiqipny NO due NO dwe NO dwe sav 1u044 eunsseJg 1 IN3O eda pue 5 mala sounos6 pue 123 Ie X99u2 5 JI 5 UOISOU09 JO eunjsiouJ sewep Aue 10 19edsui pue 1oeuuoosiq pue jojeuJaje YOOUD A ddns 123 IN3O eda pue 5 0 3591 peo sounos6 pue suamod 123 e Y22349 AJESSOOOU JI 5 0180109 JO INJSIOW sewep Aue 10 5 pue 1oeuuoosiq pue YOOUD
9. 440 dure sav 14617 yJed 01851 UO pejenjoe jou exeUq 1004 145 Aue ul ISd GZG MOJ9Q 9JnssaJg 0 0 enp p p f 5 wed ued Z JO Sd 429 eunsseJg e o pin 3 MO uonduosoeg V N V N V N 40119518 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing eJn rej Josues pue ui pepeeu se Jed eui JO eu Aew 123 Sgv pejoelep S di s YA e y JO YOUMS y UN peos JO OL ay HO 941 ui s 5 BU si j a9YyM YO IMS MOUS pue pni JO eui Aq SI di S SUOI IDUOD peojJ jjo JO UOI oeJ JepJo ui pepeeu se Jeo4 eui 10 y 123 Sgv 94
10. Jo YOOUD oeq 1osues usnd pue JO no euo pue Buueeq yosuD uey Je e916 eq jou def au deb 26 u00 JO pue Hum Josues pue eouepeduul sosu s x29u2 uoisoJJ09 uj99 104 euo 2945 Ul 4oeq Josues usnd pue def 1001 ejeuluu3 euo pue Buueeq yoouD 20 0 pjnous deb uoisoJ109 uj89 euo 2945 JUNOD 1294100 euo 2945 pJeM9ye Ul yoeq Josues usnd pue deb BuoJM pue peseo aJ uiu SI 9215 pue seam 499u2 eJn iej uiejs s 1n9290 uonipuoo sexyeJq uonepunoj 00 AIV s oDeyo 99uM Josues eBJe 00 Jeu1Qo si jeubis peedg Josueg peedsg JoeuM Jo 1 euin Ajjeusouge ue 21V JO payeanoe sem pejqesiq sgy J9e9euM sav
11. pejoelep 1ou eufiis 105095 peeds ud 01 uey 19uDiu speeds ye Ajjeoipoued sdoup peeds JeauM Josues peeds jeeuw pojoeuuoosip e SIo9jep N94 pejoejep u q seu punoJD 0 oys JO uedo uy Josues peeds y 1e 1u6r1 pejoeleq ON euo eouepeduuy uonduosoeg 64 64 64 64 4011924 Figure 3 19 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 2 3 Troubleshooting and Testing uoisouJ00 Y 99 euo YOOUD oeq Josues usnd pue uoisuejxe def 10 osneo jooJ euo pue Buueeq yOoyD uoui Qp0 Q uey eq jou pjnous deb au deb oou oeq Josues usnd pue oou Uonej ejsui JOSUBS Y29049 J26 u00 JO pue Josues pue eouepeduul Josuas x29u2 uoisouJ00 euo Y29049 ul 4oeq Josues usnd pue 1001 no euo pue Buueeq yooyuD zo uoui Qgo 0 eq deb deb
12. 440 eiqipny NO dwe 91V 440 dwg yeg NO dwe sav Snjeis HHVS o 6261 due Jojeoipu 440 perdde NO Jojeoipu ued 440 6261 due 99IAJOS 440 eiqipny NO 91V 440 dwg yeg NO dwe sav 11045 jeuBls 1961 pejoejep uedo jeuBls 1961 jeubis 14817 weishs 14617 ynon uedo 0111045 ynon uedo uonduosoeg 219 LES LvSe LYSE Figure 3 31 4011937 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing seu 123 sjsisiod OLA Ji pue sXoeuo ssed jo 1n2 eunsseJg 941 WIO 941 pue solsoubeip sseuJeu pue Jjo 1n2 eJnssaJgd eBeyo 1105 JO jJO 1n2 eunssaJg oi Sgv 1In9JI9 JJO 1n2 eunssaJg s10j9euuoo pue 5 JI UBIO uoisoJ109 JO eunjsiouJ sewep Aue 10 s10128uuoo 1oedsur pue 1oeuuoosiq seu 123 eieoipur sjsisiod OLA Ji pue sXoouo ssed
13. euo pue Buueeq uey jou pynous def au deb yoouy OL uey speeds je A jj eoipouued sdoJp jeubis peeds 99SuM ino unu euo pue Buueeq 29495 uoisoJ102 uj99 104 euo Y29490 Josues peeds pojoeuuoosip Sjoejep MOF pejoejep ueeq seu 0 yous JO uedo uy Suluo 0002 006 eunseeuu Pinoys eoueijsis8J Josueg 0 1000 20 S4012euuoo pue BuuiM 40sues pue Josues YOBUD uoisouJ00 euo Y92949 4oeq Josues usnd pue def jooJ euo pue Buueeq yOoyD 20 1 uoui Qpo 0 eq deb deb si Josues eBJe 00 s J0suag Josues 14614 OLV le9uM Sav OLV le9uM SEV leeuM Sav pe desi le9uM Sav ulojs S SNYEIS NHHVS 0 BuipJoooe 6261 due Jojeoipu exyeug JI 440 Idde NO dwe Joje
14. YOUMS JO eoue sisaJ YOOYD pue JO eouelsisaJ 499u2 punoJ6 10 eDejoA 0 oys uedo JO JO uid Y29949 5 JI SJ012euuo9 UBIO 0150109 JO eunjsiouJ eDeuuep 10 sJ012euuoo pue 1oeuuoosi NDF Jaye 5 nss 193 ul 1984100 A peziuDoooJ SUONISOd YOUMS Ji ees XOS 100 ul Y09490 pejoelep 201 uonisod YOUMS oxeJq ulo1s S uomeAnoe snjels YOUMS SAISSBOX wed pejoejep peurejureui 10119 eDueJ snjels YOUMS eweJq YOUMS Hulyied ulo1s S Snieis HHVS Buip4oooe 6261 due Jojeoipu Bured peseejeJ ONIHSV 13 peidde NO due e qisnejduul 101291 Hued 110 YOUMS NO 6861 NO 440 dwe 91V 440 dwg 440 dwe sav Snjeis HHVS 6261 due Jojeoipu ONIHSV 13 perdde NO Jojeoipu 430 6261 due 99IAJOS 440 eiqipny 440 dwe
15. 9JnssaJd 231u04129 3 ulo1s S 14617 269 269 4011947 Figure 3 41 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing seu 123 pu sjsisiod 91A pue syoayo ssed pue SJOJOBUUOD YMS 49 slue9 HHVS IN3O 24 1840 10 SHHYS 9euo poeuoo jou si Wed HHVS Jl enssi eA eA jddng eunssaJg ajeoipur osje Aew enssi oo ielul JO YOOUD ueuM s eJnsseJd ou j Jeam pejsenbai si ueuM 1e eJnssaJd 10 yoayy NAO 34 uim 5 pue senssi Aue 10 58 9 0 JI 5 2 UBIO 01501109 10 aunysiow Aue 19edsur pue 12euuoosiq NSO sonsouDeip pue JredaJ JAAP M XOS TOOL ul JOU seop snjejs Ing pue wed y Snjejs ENL asedwioo pue wi XOS TOOL SNIS YAMS exeJg 13 ssed
16. H lequunu 1994109 JUS9A 359 pue 193 Ie Y29349 5 JI 5 0102 JO eJnjsiouJ Aue 193 2905 pue 12 0251 seu eieoipur Aew sjsisiod OLA JI 294100 Ji Jequunu 123 109109 OLA H Jequunu yed 1994109 pue 123 yoeuyD AJesse29u JI 5 ue9j o uoisoJ109 JO eJnjsiouJ sewep Aue 1 193 198dsui pue 19euuoosiq peje seu eieoipur Aew sjsisiod OLA 1091109 sJojeuJeJed Ji Jequunu 193 199409 H Jequunu Wed 1994009 JUS9A se1 spuno4D pue 123 Ie 29490 AJESSODOU JI ue9j o uoisoJ109 JO eunjsiouJ eDeuiep Aue 1 193 198dsui pue 19euuoosiq 51815 HHVS 01 6861 due Jojeoipu peseeje JI 440 peiqesiq peidde NO dure pejoejep paiqesiq 440 6861 due SAV 440 Buturew eiqipny NO dure
17. peiqesiq 440 6861 duie1 Sav 99IAJeg 440 aiqipny NO due 440 dwe7 Bulwer exeJg NO duie sav Snjeis YHVS 0 BuipJoooe 6261 due Jojeoipu exyeug peseejei J 440 pajqesiq peidde NO dweq peigesiq 440 6261 due 99uM Sav Hued 440 dwe 440 dwe exyeJg NO duie1 sav Josues peedg 3u0J4J e uonoeoM 5 34617 uo U9yMS G e qisne d jou uonenjoe 19J U 5 4011921 Figure 3 16 Meritor WABCO Maintenance Manual 0401 Revised 07 15 3 Troubleshooting and Testing puno4B JO uedo J0J Josues Jo pue 2945 4oeq Josues pue deb 5 JOSUBS YOSUD J2e uoo JO pue Hum Josues pue Josues 2945 150 1090 euo 29495 jou euBis sosues SDJeMJ9 Je Ul 4oeq Josues usnd pue def peeds j yM no
18. y UO 5 eunsseJd eui seu ereoipur sisisiod 514 pue ssed IN3O pue sonsoubelp 0 31591 spunoJ6 pue suamod 123 Ie 2 Ji uonipuoo poo 5 YOO J49A uoisoJ409 JO eunijsiouJ ubis Aue JO SJOJOBUUOD uid pue uid z 193 eui 290 pue 25 1 seu MOH NOA sisisiod 91 pue ssed pue 5 J NAO pue sonsouBeip 31591 peo pue 123 Ie 2249 5 JI 5 uonipuoo 5 YOO uoisoJ109 JO eunjsiouJ ubis Aue JO 5 uld pue UId Z 193 JO9dSu pue pejoelep y eJnjreJ uoneJedo peioedxeun uoneJedo qaa 9 21 1002 5 Sav BuiuJeA 1949
19. JO S101289uuoo Josues pue eouepeduul Josues 29495 uoisoJ102 uj99 Buissiu eBeuuep JO euo Y29049 ul 4oeq Josues usnd pue def 1001 no euo pue Buueeq yoouD 20 1 uoui Qgo 0 eq deb 5 UO ISOJJO9 Y 99 euo Y29490 JUNOD Y OO 1294100 JO euo YOOUD Ul xoeq Josues usnd pue deb 5 oun BuoJM pue oDueJ SI 9218 pue seam Y99049 Snjejs YHVS 0 696 due Jojeoipu peseejei 440 NO Jojeoipu MO OLV s 99uM 16934 Josues eBJe 00 Jeu1Q 440 6261 due si u yeL jeubis 9olAJoS exejg peeds 440 aiqipny NO dwe 440 dwe7 yeg NO duie sav JOSUSS jJoauM 14618 Snjejs HHVS Buipjoooe 6261 due Jojeoipu exeug Buried peiqesiq 440 21 NO duie1 Jojeoipu eyesg Buried JayjO 4 440 6261 due uexye
20. uid e pue UId Z 123 198dsui pue seu MOH NOA ereoipur SjsisJed pue sXoeuo ssed pue 51 2 J IN3O pue sonsouBeip pasu 35291 peo Buipnjoui sounos6 pue suamod 123 Ie Y29349 5 JI uonipuoo poo 5 YOO J49A uoisoJ409 JO eunjsiouJ jo ubis Aue 10 5 uid g pue 2 123 198dsui pue 19euuoosiq 8Jd Suniel uoneJedo peioedxeun uoneJedo peioedxeun 1002 Sav BuiuJeA 1949 pslqesiq 10014 Sav 19497 10014 pslqesiq Sav 19497 Oly 10024 Sav 19497 Wa SAS Shjeis HHVS 6261 due Jojeoipu JI 440 NO dwe Jojeoipu 430 6261 due 99IAJOS Hued NO eiqipny NO due NO dure BuiuJeA oyeg NO dwe sav 51815 HHVS
21. 25 7 sey y Aew Ajpides seseaJoui ainssaid sonsouDeip asemyos yOauyD pejoejep 0 eubIS pei elep LIV 0 eUubIS 10014 Sav 1949 O1V 10014 Sav 19497 SNIEIS HHVS 01 6261 due Jojeoipu Bured 440 NO dwe Jojeoipu 440 6261 NO eiqipny NO due NO dure BuiuJeA yeg NO dwe sav Shjeis HHVS 6261 due Jojeoipu 440 peidde NO dwe 430 6261 due NO eiqipny NO due NO dure BuiuJeM NO dure sav Buisueg e1nssaJg y pejoejop indino e6e3oA eunssaJd juejsuo jueipe4D eunsseJd jeuuouqy pejqesiq 10044 Sav 1949 psjgesiq 10014 Sav 19497 Shjeis HHVS 01 B
22. 6261 due Jojeoipu peseeje 440 peidde NO dure Jo eoipu 440 6 61 due Hued NO ButuieM eiqipny NO NO dwg BuiuJeA yeg NO dwe sav SniEls HHVS 6261 due Bured 440 palidde NO dwe Jojeoipu 440 6261 due ued NO eiqipny NO NO dwe BuiuJeA yeg NO dwe sav SNIEIS HHVS 01 Buipjoooe 6261 due Jojeoipu Hued 440 NO dwe 430 6261 due NO eiqipny NO due NO dure BuiuJeM exeJg NO dwe sav O0J1uO2 eJnssaJg Aou nb UO 5 pue euin uns yous Aq 348 Josey 10 uauM SsojeJodo 0 sojeJodo uondiosog 40119468 Figure 3 40 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing
23. 123 yOeuD Jesso29u JI SJ012euuo2 ue9j o 0150109 JO eunjsiouJ sewep Aue s1012euuO0 193 198dsur pue 12euuoo siq seu MOF eieoipur sjsisiod OLA 359 pue 193 Ile Y29349 AJessooeu JI 001502100 JO eJnjsiouJ sewep Aue 10J 5 0129 2 193 198dsui pue 19euuoosiq seu 123 eieoipur sjsisiod OLA JI 359 Hulpnjoul pue 193 Ie Y29349 AJessooau JI ue9j o uoisoJ100 JO INJSIOW eDeuuep Aue 104 510 2 193 198dsui pue 19euuoosiq yed 19 od ON aga pue 21 Sav peioejep 1V9 10014 14619 AJLA 1no ps qesiq pejoejep punoJ6 0 Yous AI 1919 le9uM Sav peiqesiq 91 uedo AI 1 peiqesiq leeuM Sav 99IAJ9S ON pe qesiq aga pue 21 SAV LIVE 01 1941 JUOJ4 4437 AJLA dwy ulo1s S SNIEIS HHVS 6261 due Jojeoipu 440 NO dwe Jojeoipu 440
24. Bured 330 6861 due 99IAJOS 440 eiqipny NO dwe 440 dwg NO dwe sav Shjeis HHVS 01 6861 due Jojeoipu Burned 440 NO dwe Jojeoipu 440 6261 due 99IAJOS 440 eiqipny NO due 440 dure NO dure sav Snjeis HHVS 6861 due Jo eoipu Bured 440 NO Bured 430 6261 due 99IAJOS 430 ejqipny 440 dwg yeg NO dwe sav Snjeis HHVS 6861 due Jojeoipu JI 440 perdde NO Jojeoipu 430 6261 due 99IAJOS 440 eiqipny NO dwe 91V 440 dure yeg NO dwe sav Aejay Wa SAS 14617 punog 0111045 yunon uedo Koneg uonduosoeg 108 108 108 4011936 3 30 Meritor WABCO Maintenance Manual 0401 Revised 07 15 3 Trouble
25. UBIO UOISOU09 JO eunjsiouJ sewep Aue 193 1299 5 pue 19euuoosiq pejre seu eieoipui sjsisiod OLA 359 spuno pue 193 Ie 499u2 J6Ss929U JI SJOJOBUUOD UBIO 0180109 JO eunjsiouJ sewep Aue S10 O9UUOD 193 2905 pue pejre seu eieoipur sjsisiod OLA 359 spuno pue 123 499u2 AJESSOOOU JI 5 0150109 JO eunjsiouJ Aue s1012euuOO 193 198dsui pue 1 euuoosiq peje seu eieoipur sjsisiod OLA 4l se1 pue 123 Ie Y23949 AJess929u JI UBIO 0150109 JO eunjsiouJ ubis Aue 193 198dsui pue 19euuoosiq peiqesiq O1V uedo AI 1elUI peiqesiq leeuM Sav 19 od uonuSAJlul ON pejqesiq aga pue 21 SAV 1 01 OUS 1914 Je9H Yo AJLA duiy 19MOd 91V le9uM Sav punoJD 11045 1 peiqesiq peioejep oly u do AO RNO peiqesiq l99uM Sgv 10014 1uBiH AJLA INO dwy Wa SAS Snjeis HHVS
26. 4011940 Meritor WABCO Maintenance Manual 0401 Revised 07 15 Figure 3 34 3 Troubleshooting and Testing pelle SEU y sisisJed eui 09 Buroejdoi 194 seu MOF eieoipur sjsisiod OLA pue je ssed pue 05095 eunssaud j UOISOJJOO JO eJnjsiouJ sufis 10 pue sapis NOH pu 193 uloq 10sueg aJunssaJg pue 193 IN3O pue sonsouBeip pasu 3591 peo Buipnjoui sounos6 pue suamod 123 Ie 499u2 J6Ss929U JI 5 0150109 JO eJnjsiouJ eDeuiep ubis Aue 10 19edsur pue 1oeuuoosiq pejoejep punoJ6 01 1095 eubIS seu ereoipur Aew sjsisiod pue syoayp je ssed pue sJojoeuuoo eunssaud UOISOJJOO JO eJnjsiouJ sufis 10J pue sapis NOH pue 193 uloq 10sueg aJnssaJg pue 193 IN3O eda pue sonsouBeip m 0 pasu 359 peo Buipnjoui spunojJ6 suamod 123 Ie Y29349 J6Ss929U JI 5 UBIO UOISOU09 JO eunjsiouJ sewep 10 pue 1oeuuoosiq pei elep LIVE 01 1095 eubIS pslqesiq 10014 pejqesiq Sav BuiuJeA 1949 pejgesiq
27. 5 yoo uoisoJ109 JO ubis Aue JO uld pue 2 193 198dsur pue 4 NOH JO ees sjueuieoe daiJ NOH 10 dung seu JO e 9jeoipui ssed syoaup J 1esseoou JI 5 peej g uleis s y u ou si AJA JOU si 34 Apoo si deo 1epui Ao eui JuoA SEU NOH 10 sey 193 sjsisiod 518 pue ssed syoayo e jo yoeyyD 10J JOJOW pejoedxe 5591 JUNI OLV 1024 pejqesiq Sav 1949 pejqesiq OIV 10014 psjqesiq Sav BuiuJeM 1949 Snjeis HHVS 6261 due Jo0jeoipu peseelei JI 440 NO dwe7 Jojeoipu Hued 440 6861 99IAJOS ued NO uuem eiqipny NO dwe NO dwg exeJg NO dwe sav SniElsS HHVS 01 6261 due Jojeoipu ued 440
28. Maintenance Manual 38 Hydraulic ABS for Medium Duty Trucks Buses and Motor Home Chassis C Version Hydraulic ABS Maintenance Manual 39 Hydraulic ABS for Medium Duty Trucks Buses and Motor Home Chassis D Version Hydraulic ABS Maintenance Manual 0677 Hydraulic Anti Lock Braking systems HABS for Medium Duty Trucks Buses and Motor Home Chassis E Version Hydraulic ABS Visit Literature on Demand on meritor com to access and order additional information Contact the Meritor OnTrac Customer Call Center at 866 668 7332 United States and Canada 001 800 889 1834 Mexico or email OnTrac meritor com If Tools and Supplies are Specified in This Manual Call Meritor s Commercial Vehicle Aftermarket at 888 725 9355 to obtain Meritor tools and supplies 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 Meritor WABCO reserves the right to revise the information presented or to discontinue the production of parts described at any time pg i CON 10 14 15 16 17 18 90 53 54 09 56 60 62 63 Asbestos and Non Asbestos Fibers Section 1 Introduction Overview oystem Components How the HPB System Works Section 2 Wiring Diagram HPB Wiring Diagram for Multiplex Vehicles HPB Connector Diagram for Multiplex Vehicles HPB Wiring Diagram for Non Mult
29. pue seam 499u2 Ssmejs HHVS 0 BuipJoooe 6 6 due Jojeoipu Burned 440 peiqesiq NO dwe Jojeoipu AI 1919 __ 440 6261 duie1 Sav 440 ejgipny dwe JJO dwe DuiuJeAA dwe sgy snyeis HHVS 0 626 due Jojeoipu Buried peseejeJ 440 NO dwe Jojeoipu Buried 440 6261 dweq 440 NO 21 440 dwe7 NO dwe sav uonuaeAJ9jul ayes 99IAJOS ON pue 21 sgy 1178 01 1914 3437 eA eA Snjejs HHVS 0 626 due Jojeoipu Bupueg peiqesiq peseejei 440 21 peidde NO dwe Ajjewuouge ue 99uM 169 Buried 10 sem Jeujo WOJ 440 6261 due uy peads 440 aiqipny NO dwe 440 yeg NO sav Snjes HHVS Buipjoooe 6261 due Jo
30. uedo uy OLV psiqesiq le9uM Sav OO 5 si 21V Josues eBJe 00 p jqes q s def I0SsueS 99uM SEV JOSUSS p d U014 39 3091100 JOU SI 1 Bunse onsouBeip Buunp u q sey qaa pue SEV 19 ojuo 2 53015 HHVS 0 Buipsoooe 6261 due Jojeoipu Buried peseejeJ 440 NO duie1 Jojeoipu Buried 330 6861 due N S 440 ejqipny NO dwe 91V 440 dwe exeJg No Sav snjejs YHVS 0 BuipJoooe 6261 due Jojeoipu peseejaJ 440 NO dweq Jojeoipu Buried 330 6861 BdIAIBS 440 ejqipny NO dwe 91V 440 dwe eyeug NO dwe sav snjeis YHVS Buipjoooe 6261 due Jojeoipu 440 NO due Jojeoipu 440 6261 Hued 440 NO dwe 91V 440 dwe yeg NO Say S
31. 00150100 JO eunjsiouJ Jo Aue 104 1 y pue Buuiw suonoeuuoo snq 6661 JO 5 jean Y29949 pejre seu 123 eieoipui sisisied 01 pue syoayo ssed pue 4 51 HHVS WO 941 10 Hulysed uonounj S HHVS youd poeuoo jou si HHVS Jl enssi AJLA jddng eunssejg eoiueuoeui e ereoipul osje enssi oo iajul 10 YOOUO ueuM s eJnsseJd ou j Jeam pajsanba s eseo oJ ueuw HHVS W eJnssaJd 104 429u2 IN3O 991 uim sonsouBeip uoyws pue MOIY senssi Aue 104 X99u2 AYeSS9D9U JI 5 UBIO uoisoJ100 Jo aunysiow uis Aue 5 pue 1oeuuoosi WO sonsouDeip pue JredaJ wi XOS TOOL snjejs Ing eseoja pue seop wed y 511015 xeg jenjoe pue wi XOS TOOL SNES YMS exelg UA seu 123 ayeoipul sisisied 01 pue syoayo ssed pue 4 51
32. 6261 due Jojeoipu Bured JI 440 peidde NO dwe Jojeoipu 430 6261 due Hued 440 eiqipny due 440 dwg NO dwe sav 51815 HHVS 01 6261 due Jojeoipu Bured peseeje JI 440 peidde NO dure Jojeoipu 330 6861 due 440 Buturew eiqipny NO 440 dure yeg NO dwe sav 6 75 HHVS 6861 due Jojeoipu peseejai JI 440 peidde NO dure Jojeoipu 330 6861 due 99IAJOS 440 eiqipny NO due 91V 440 dure NO dure sav Snjeis HHVS 6261 due Jojeoipu peseejai 440 NO duie1 Jojeoipu 440 626 due 99IAJOS 440 eiqipny NO 440 dwg yeg NO dwe sav 1u6r1 Nd uedo 0 punog 0 HOUS uedo uonduoseg 40119318 Figure 3 25 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Test
33. 6261 due 99IAJOS 430 eiqipny NO 440 dwg yeg NO dwg Sav Snjeis HHVS Buip4oooe 6261 due Jojeoipu Burned JI 440 perdde NO dwe7 Jojeoipu Bured 440 6861 due 99IAJOS 440 eiqipny NO dwe 440 dwg yeg NO dwe sav Snjeis HHVS Buip oooe 6261 due Jojeoipu ued JI 440 NO dwe7 Jojeoipu ued 430 6261 due 99IAJOS ued 440 eiqipny NO dwe 440 dwg BuiuJeM exeJg NO dwe sav snjels HHVS 6261 due Jojeoipu Hued peseejai JI 440 peidde NO duie1 Jojeoipu Bured 440 6 61 dweq 99IAJOS 440 eiqipny NO 440 dwg exeJg NO dwe sav 14617 Kjeyeg 0 punog 0 HOUS uedo 0 5 uonduosoeg 40119298 Figure 3 24 2 Meritor WABCO Maintenance Manual 0401 Revised 07 15 3 Troubleshooting and Testing seu eieoipur sjsisiod OLA 359 pue 193 Y29349 JI 5
34. pejoolep 5 oxeJq peseojoJ 10 SNIEIS HHVS 01 6861 due ONIHSV TJ palidde NO dwe Bumed 440 6261 due BuImed 440 uuem eiqipny 440 dwe 91v 440 dwg yeg 440 sav l 5 HHYS 01 6261 due 10 201pu ONIHSV 13 NO dwe 430 6261 due Jou pino ued 440 uuem eiqipny 440 dwe 91v J4O dwg yeg 440 dure sav ulo1s S uoloeey 1u5r1 uonduosoeg 619 40119498 Figure 3 43 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing 3091100 sJejeujeJed 123 eui A IN3O pue YMS V pue Bum suonoeuuoo snq 6661 JO 5 Y29949 noa e ssed pue pue 6 61f II Senssi JO su euo pue pue jaaym josues xo9uo sjosues JO 2 JO
35. 440 eiqipny NO dwe 440 dwg yeg NO dwe sav Snjeis HHVS 6261 due Jojeoipu Bured JI 440 NO dwe7 pejoelep J0jeoipu exyeag L1Vvg 0 1045 430 6261 due 99IAJOS 440 eiqipny NO 440 dwg BuiujeM yeg NO dwe sav pejoejep uedo aunssauJg dwy uo SOA Z pue yo SHOA pjnous 0 0 5 104 usep 0 N93 Sgv Aejas peus 14677 JO s1012euuoo pue x29u2 5 JI uoisoJ109 JO eunjsiouJ sewep Aue 10 5 19edsur pue uo 5 Z pue yo SHOA pjnous 0 104 usep 123 Sgv Aejas euls 14677 JO s1012euuoo pue x29u2 Jess929u JI 0102 JO eJnjsiouJ Aue 10 1oedsur pue 1oeuuoosiq SNES HHVS o Bulpuoooe 6861 due Jojeoipu Bured JI 440 perdde NO Jojeoipu 440 6261 due 99IAJOS
36. 440 dwg 440 dure sav pojoejep youms Snjeis HHVS 6261 due Jojeoipu Bured JI ONIHSV 13 NO duie1 Jojeoipu 440 6 61 due 99IAJOS 440 eiqipny 440 440 dwg 440 dure Sav a6uel 1nO 14617 uonduosog 04 4011948 Figure 3 42 Meritor WABCO Maintenance Manual 0401 Revised 07 15 3 Troubleshooting and Testing Pere ereorpur ssed sxoeuo 6E6 Lf Ie Jreda4 pue 626 Lf G pue y suid jo y pue aui eq 5 1nq y uiui ejyenjonj G pue p suid 941 Ss9 JO 5 G z 5 uo G uid 1012euuoo sseuueu uid e eui Syo 0 amp z eq Pinoys uo p uid 1012euuoo sseuueu uid e eui 1v 09 eq pinoys yo eui Suid 55 BOULISISAJ sseuJteu 12 eui AJ6ss9298uU JI 5
37. 5 qaa 8 o1v 1024 5 Sav BuiuJeA 1849 pe desiq aaa 9 o1v 1024 psjqesiq Sav BuiuJeA 1949 pe desiq aaa 9 o1v 10014 pe desiq Sav BuiuJeA 18949 51015 HHVS Buip oooe 6261 due Jojeoipu peseejai JI 440 peidde NO dweq Jojeoipu Buried 440 626 due 99IAJOS ued NO eiqipny NO NO dwg yeg NO dwe Sgv SNIEIS HHVS Buip4oooe 6261 due Jojeoipu JI 440 NO dwe7 Jojeoipu Bured 440 6261 due 99IAJOS NO uuem NO dwe NO dwe NO dwe sav Snjeis HHVS 01 6261 due Jojeoipu JI 440 perdde NO dwe Jojeoipu 430 6261 due 99IAJOS NO eiqipny NO dwe 91V NO dwe NO dwe sav snjgls HHVS Buip4oooe 6261 due Jojeoipu Bured peseejaiJ JI 440 peidde NO duie1 Jojeoipu 440 6 61 due 99IAJOS NO eiqipny NO due 91V NO dwg exeJg NO dwe Sav 9 Xy 11044
38. 5 5 Jn220 sexeJq uonepunoj 499u5 ezis JOSIOOU le9uM Sav pe qesi 21 suoneigiA sJeyeuo pejqesiq Jo sheip eyeig SEV Josueg paads 11024 14614 Wa SAS Snjejs HHVS 0 Buipjoooe 6261 due exeJg peseejeJ 440 1 NO duie1 JOJCOIPU exeJg 440 6861 due N S 9 EJg Buried 440 e qipny NO dwe 440 NO duie1 sav Smejs HHVS 0 BuipJoooe 6261 due Jojeoipu 440 NO due Jojeoipu 440 6261 due eiqisnejd jou 99IAJeS Burned uonenjoe 440 ejgipny NO dwe 440 exyeJug NO dwe sav 5 YHVS 626 due Jojeoipu peseejeJ 440 NO JOJESIPU uoneuiquio2 330 6861 due 440 NO dwe 21V 440 dwe NO dwe sav Snjgs HHVS Buipjoooe 6 6 due Jojeoipu eyesg
39. NO Jojeoipu Buried 440 6861 99lAJOS ued NO uuem eiqipny NO dwe NO dwg yeg NO dwe sav 01 U0D 55 21u04129 3 Jojejnuunooe eDeyee jo yBly pe qesiq agg 8 1v 10014 pe qesiq Sav BuiuJeM 19497 5 aaa 9 21 10014 5 Sav BGuiuJeM 1949 Snjeis HHVS 01 6261 due Jojeoipu ued JI 440 NO Jojeoipu Buried 430 6261 due 99IAJOS ued NO uuem eiqipny NO dwe 91V NO dwe yeg NO dwe sav Snjeis HHVS 01 Buip oooe 6261 due Jojeoipu Hued peseejai JI 440 peidde NO dweq Jojeoipu Hued 330 6861 duie1 99IAJOS ued NO uuem eiqipny NO dwe 91V NO dwe yeg NO dwe sav 9 XV 1024 9JnssaJd 21u04129 3 ulo1s S 44917 Buuren JO oDexyeo L8Sc 890 0892 0892 Figure 3 39 4011945a Meritor WABCO
40. NOTE The Fault Information screen is also accessible from the HPB Main Menu pere 3 Lait Oper 4 Fight Fron erra 5 415928 Message merul 5 Brake Press Sense Rea siet ed t 127 aj Inxiructians Iren crcuk defected Check xenzar wing and corneciors lec contaci Fieplece tet 40044608 Figure 3 4 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 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 Wheel Speed select Wheel Speed to display the Wheel Speed screen Figure 3 5 hj Wheel Speed Graph 40044618 Figure 3 5 Use the Wheel
41. Wheel Sensor Left Front Right Front Left 2nd Right 2nd AX MO MO r Road Speed Retarder Relay mph Control Status Switches Voltages Battery DENE Ignition Foot Brake Df Centered _ Fei ATC Brake Brake Fluid fk or Wor or Bier 1222 _ 1438 ATCEnabed 4 10 2006 1024AM 7 4006207 Faults Learned Component NER Existing None Stored ABS Brake ot ABS Retarder NA ATC Brake ot ATC Engine ot PB Travel Switch ATC Releas ed 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 select Display from the HPB Main Screen pull down menu will appear Figure 3 3 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Meritor WABCO HPB Tractor ECU Display Component Tests Parameters EOL Wheel Speed Counters Infoi ECU Air Gap Size Pre Charge Pressure Part Number Manufacture Date 1 1 26 2003 p 4008958a Figure 3 3 Faults WARNING Do not drive the vehicle if active faults are present Driving the vehicle with active faults present can result in an accident and serious personal injury Select Faults to display the Fault Information screen Figure 3 4
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43. pejoelep SI di s e Duung 1591 105095 ssed speeds I99UuM JOSUBS JUSAS OLV DIV spjouseuui peseoJoul YOUMS 91 exeJq Buried enp uonuoeAJlul OxeJq BOIAIOS 51461 1 p10 euis ojenjoy suonipuo 5 ulo1s S HUN pejqesip snjels HHVS Buip4oooe 6261 due Jojeoipu paseajal 440 NO dwe 440 6861 99IAJOS 440 eiqipny sel Josues ssed speeds ie NO dwe 440 dure BuiuueM 1591 10sues ssed speeds 5 jun NO dwe sav Snjeis HHVS Buip4oooe 6261 due Jojeoipu Burned JI 440 NO Jojeoipu 430 6261 dure 99IAJOS 440 eiqipny NO dwe 440 dwg BuiujeM yeg 440 dwe sav snjgls HHVS
44. 440 eiqipny NO dwe 91V 440 dwg yeg NO dwe sav jddng dwy Wa SAS 14617 0 HOUS uedo 0111045 819 819 819 219 4011938 Figure 3 32 2 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing seu 1515 99 q pue ssed pue 5 J WO pue 2 peau OZ 1 SHOA ZL jo e eui NO pejoeuuoosip NOF 12 JO Og uid aui JO yayo seu 123 1515 99 q pue syoayo ssed pue 5 J NAO pue sonsouDeip peau punojJs 2 Je SHOA ZL eq jo e eui NO pejoeuuo9sip NOF J0 9euuoo 12 Jo 2 uid ejoJ sgy eui JO suonoeuuoo pue Hum x99u2 seu eieoipur SjsisJed 2 q pue syoayo ssed
45. NO Jojeoipu Bured 330 6861 due Ued 440 eiqipny NO due 91V 440 dwg NO dwe sav 19 wod UONUSAJS JU 99IAJ9S ON pejqesiq aga pue 21 SAV pajoejep 1Vq AO Jeay AJLA dwy Shjeis HHVS 6261 due Jojeoipu Bured JI 440 peiqesiq padde NO dure pejoejep Jojeoipu Bured 01 Hous 1914 peigesig 330 6861 due l99uM SAV eyelg 440 ejqipny NO 91V 440 dwg NO dwg BuiuueM Sgv SNYEIS HHVS 6861 due Jojeoipu Bured 440 peigesig NO duie1 pejoelep 21V Jo eoipu Burned uedo jelu palqesiq 440 6 61 due 99uM SEV 99IAJOS 440 eiqipny NO due 440 dwg yeg NO dwe sav Snjeis HHVS Bulpuoooe 6861 due Jojeoipu JI 440 perdde NO Jojeoipu Bured 430 6261 due 99IAJOS 440 eiqipny NO dwe 440 dure yeg NO due sav
46. ROLL PINS 40049788 Figure 4 47 Connect the low pressure hose to the reservoir Remove the pinch clamp from the low pressure hose Connect the fluid level switch on the master cylinder reservoir Figure 4 48 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 Removal and Installation NOTE Pressure should be left on the system during the first MASTER CYLINDER ASSEMBLY key on attempt to build pressure MASTER CYLINDER 10 Depress the brake pedal rapidly four times to activate both HCU VENTED a 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 12 Check the system for leaks If there are no leaks go to Step 15 SWITCH PRIMARY If there are leaks depressurize the system before making the FLUID LEVEL CIRCUIT necessary repairs Use the following procedure to depressurize SENSOR MF FRONT the system SWITCH SESECU AXLE AXLE 4004477 Remove the two maxi fuses for the pump motors disconnect the battery Figure 4 48 e Apply the brake pedal a minimum of 30 times to decrease 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 depres
47. euiDue sug 0 5 one 9608 0 Isd oinsseid jnun peuodisod 15 gd qaa 91 Sav suieis s uou uo pe qeu 4 due JO eolpu pin 4 exeJg 5 eioeds ulo1s S Shjeis HHVS 6861 due Jojeoipu Burned NO dwe Jojeoipu Bured 440 6261 due 99IAJeS SW 009 NO eiqipny 440 dwe 440 dwg yeg 440 dure sav NO dure Jojeoipu exeag Hued 440 6 61 duie1 eames SW 009 NO aiqipny 430 due 440 dwg 440 dwg Sav 51015 HHVS 01 6261 due Jojeoipu exeag Burned peseejaJ 440 peidde NO dure Jojeoipu exeag Bured 6861 due 99IAJOS NO eiqipny NO dwe NO dwg NO dwe sav SNIEIS HHVS 6261 due Jojeoipu 440 NO dwe7 Jojeoipu exeag Buried 440 6861 due 99IAJOS ued NO eiqipny 440 21V suiejs s 104 NO dwg
48. pejre seu 94 sejeolpul Vois U PUNO S enssi esnj 10 ayeoipul Aew 10 OU j JOJOBUUOD sseuJeu yms z uid je A CWO pue sonsouDeip enssi DuuiM ayedipul 1no sDuipeoJ j eunjrej yOUMs ayeoipul yno s uos J pesseudep 089 pue 1591 99 2 UOIIMS JO 5 pue JO 99UejsIS9J YOOUD punoJB 10 0 uedo 104 sseuieu uid JO 0 uid AJESSBOOU JI 5 001801109 10 aunysiow Aue 10 51 pue JOBULONSIG eje 50011500 YOUMS JI ees 0 XOS TOOL Ul 2949 pejre seu Jejseu Y S exeJa enssi asnj 10 ayeoipul Aew 10 OU j JOJOBUUOD yms z uid je A CWO pue sonsouDeip anssi ejeorpui j eunjrej ayeoipul eDuej yno s uos J pesseudep 089 pue
49. 2 amp 8 gt gt un t m 5 B a 3 aia c gl FS mii JE ls 2 5 5 ms a rm zU gt 2 gt gt 5 5 5 B 2 6 55 5 o a 2 gt P 15 1 mim E m o ER m 22 E E m m m gt a A gt um 5 ES lt A e Q 2 m s of gt 5 A 8 5 m x w fa lo lu 3 lo ia 5185 JE x m a gt J e e 2 m c rc 0 2 lt D lt T a oo c A OCO 970 OFF wl Fra AQ 1H9I9 v3 4 A 133 Hv33 ol at 1 14 1 083 ae 14 1331 LNOYS 10 3105 NOILYINGOW 34nss38d 133HM The Meritor WABCO HPB electronic control unit interface wiring diagram for non multiplexed vehicles is shown in Figure 2 YOLOANNOD NIid L LINN TOYLNOD 21INOM12313 aly Sal ON3108 201V 5 e JOION gOL23NNO02 NId 4011904a Figure 2 3 2 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 2 Wiring Diagram HPB Connector Diagram for Non Multiplexed Vehicles The Meritor WABCO electronic control unit interface connector diagram for multiplex vehicles is shown in Figure 2 4 SAE J1939 ATC L Q BUZZER RELAY IG SENSOR RR ABS WARNING 15
50. Check the vehicle dash lamps e Most of the dash lamps for HPB come on briefly approximately three seconds for a bulb check then go off This indicates the system is O K e f the ABS and ATC lamps do not go off within 3 seconds after turning the ignition ON the system is looking for a wheel speed test Drive the vehicle at speeds of 5 10 mph 8 16 km h The ABS and ATC lamps will then go off if the system is O K e f 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 there is a system fault Perform vehicle diagnostics and make all of the necessary repairs including appropriate bleed procedures before returning the vehicle to service WARNING Do not drive the vehicle if active faults are present Driving the vehicle with active faults present can result in an accident and serious personal injury 3 Drive the vehicle for a short distance Make gentle brake applications to verify brake performance Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 15 3 Troubleshooting and Testing Safety Features Limp Mode The HPB system has a feature known as Limp Mode In the event that power is lost at the 31 pin ECU connector or the 31 pin connector has become dislodged power for emergency foundation braking can still be provided through the 2 pin ECU connector Dynamic Park Brake Application If Equipped with the Hydraulic Park Brake System In the even
51. HHVS WO 104 1ueujjsn pe Hulysed uonounj S HHVS youd poaeuoo jou si HHVS Jl enssi AJLA jddng eunsseJg eorueuoeui e ereoipul osje enssi oo iajul JO YOU u ym s eJnsseJd ou j Jeam pajsenbai si eseo oJ UBUM YHYS W aunssaJd 104 0949 IN3O 991 uim sonsouBeip uoyws pue MOIY senssi Aue 104 x99u jesseoau JI 5 UBIO uoisoJ100 Jo aunysiow sewep uis Aue 5 pue 1oeuuoosiq WO sonsouDeip pue JredaJ MIIAD wi XOS TOOL snjejs Ing eseoja pue seop wed 511015 xeg jenjoe pue wi XOS TOOL SNIS YMS UA peuous 10 uedo Jo uBiu 661 Snjeis HHVS 01 6861 due Jojeoipu peseeje1 440 JI NO dure Buried NO 6261 due adas 440 e gipny NO 440 dure dwe sav no 6861 JO 5100 6 10443 sng eled 6261 6 61
52. JOSUAS omnee Aen WAO UUM Jredo4 pue 626 Lf MaA peau G jenbe pinoys pue y suid jo 210 pue y eq JeAeu 5 oDueij y Aew G pue p suid 941 Ss9 JO 2 eq 5 uo YUM G uid urid e eui SHOA 0 amp z eq Pinoys uo p uid 1012euuoo sseuueu uid y 09 pinoys Jo eui pL Suid 55 eouejsisaJ 55 0 6 JI SJOJOOUUOD 00150100 JO auNnjsiowW Jo Aue y p dsu pue suonoeuuoo snq 6661 Jo 5 peona Y20949 Pere ayeoipul ssed sxoeuo 661 IIE JI N3O pue 6661 peau e N G jenba pjnous pue y Suid jo 210 y pue aui eq JeAeu 5 y ayenjony Aew G pue p Suid 941 Ss9 JO G z eq pjnous uo YUM
53. MASTER CYLINDER VENTED Cue CAP n d FOOT BRAKE SWITCH MI PRIMARY CIRCUIT MF FRONT SECONDARY AXLE CIRCUIT MR REAR AXLE FLUID LEVEL SENSOR SWITCH 40044778 Figure 1 5 Wheel End Sensors A Meritor WABCO wheel speed sensor is installed at each wheel whose speed is to be monitored These sensors generate electronic signals which are sent to the ECU A sensor spring clip holds the wheel speed sensor in place Figure 1 6 The sensor and sensor clip must be lubricated before installation and whenever wheel end maintenance is performed SENSOR SPRING 4 E WHEEL SPEED S SENSOR 4004479a Figure 1 6 TOOLBOX Software TOOLBOX Software is a PC based diagnostics program required to diagnose HPB system faults For HPB version 9 0 or higher is recommended TOOLBOX Software is available at www meritorwabco com Figure 1 7 4011996a Figure 1 7 Low Pressure Hose The Removal and Installation section of this manual contains service information for a low pressure hose which is not produced by Meritor WABCO but is an integral part of the HPB system 1 Introduction Spring Applied Hydraulic Release Parking Brake Canister Optional NOTE The SAHR canister is not produced by Meritor WABCO and is an optional feature Please consult the OEM for maintenance and service information On vehicles equipped with hydraulic parking brakes the SAHR canister controls the force ap
54. NUT 4004852 Figure 4 57 2 Use clean rag to carefully clean the outside of the hydraulic compact unit 3 Use new clean lubricant to lubricate the O rings on the new parking brake valve Use only DOT 3 or DOT 4 hydraulic brake fluid Refer to the vehicle specification sheet to determine which fluid to use 4 Position the new pressure supply valve onto the hydraulic compact unit Use a socket Snap On Tools part number A121 to tighten the valve to 27 34 ft lb 40 50 Nem Figure 4 58 ELECTRICAL CONNECTOR COIL VALVE BODY PLASTIC NUT 4004855a Figure 4 58 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 10 11 12 13 Removal Installation Place the coil O ring and plastic nut onto the pressure supply valve Use a 12 point socket wrench to tighten the black plastic nut to 26 5 in Ib 3 Nem Attach the electrical connector to the parking brake valve Figure 4 58 Remove the pinch clamp from the low pressure hose 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 determine which fluid to use Connect the battery Turn the ignition switch ON The HCU pump motors will start up and fill the accumulators Approximate running time is 45 seconds Bleed the spring applied hydraulic release SAHR parking brake circuit Follow the
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60. 4 59 17 18 D Apply and hold the brake pedal down until no more brake fluid runs out Do not release the brake pedal E With the brake pedal still applied use a torque wrench to tighten the bleeder fitting screw to the torque value specified by the component manufacturer e Repeat Steps A E for the second axle After making the repairs check the fluid level in the master cylinder reservoir to make sure it is at the MAX mark Refill as necessary with new clean 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 Reinstall the two maxi fuses for the pump motors or reconnect the battery Use TOOLBOX M Software to cancel the diagnostic code for the pressure supply valve Refer to Section 3 for TOOLBOX software instructions Remove the wheel blocks Test drive the vehicle Refer to the test drive procedure in section 3 of this manual Removal Low Pressure Hose WARNING The full power brake system 15 a pressurized system that achieves pressures of up to 2320 psi This pressure is not reduced by switching the ignition off or removing battery power Prior to servicing this system the depressurization procedures must be performed exactly as presented Failure to depressurize the system may result in personal injury or death NOTE Meritor WABCO does not manufacture low pressure hoses Re
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62. Aue JO S10 19euuoo uid pue uid z 123 34 2945 pue 12euuoosiq seu ereompur SjsisJed q pue sXoeuo ssed pue 5 J NAO pue sonsouBeip peau 31591 sounos6 pue Ie 499u2 5 JI 5 uonipuoo Sqe 20 UOISOU09 JO eJunijsiouJ jo ubis Aue JO 5 uid pue uid z N93 2945 pue 12euuoosiq JI SJ0129UUO9 UOISOJJOO JO eunjsiouJ sewep 10J 10 2 pue 1oeuuoosiq sey y 9jeoipui Aew Ajpides seseaJoui ainssaid sonsouDeip yoouy JI SJOJOBUUOD UOISOU09 JO eunjsiouJ eDeuiep Aue 10 10 2 pue JOOUUODSIG Seu y Aew Ajpides seseaJoui ainssaid sonsouDeip yoouyD qaa 9 21 1001 Sav BuiuJeM 1949 pe desiq qaa 9 OLV pejoedxe e xy 1 0 4 559 juaJno pajqes
63. Fuchs Lubritech Unirex ESSO ECO Li Plus BPW Molykote P40 Dow Corning Moly Fortified Multi Purpose Grease Ford Valvoline USA ass gt 0 1 400443 7 Figure 4 62 D Apply and hold the brake pedal down until no more brake fluid runs out Do not release the brake pedal Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 Removal and Installation Removal SENSOR Front Axle Wheel Speed Sensor SPRING 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 SENSOR CE WHEEL SPEED 1 Parkthe vehicle on a level surface Apply the parking brakes Block the rear tires to prevent the vehicle from moving 40044798 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 1 Connect the sensor cable to the chassis harness 3 Disconnect the sensor cable from 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 Figu
64. JO41UO2 55 21u0J129 3 ulo1s S 1u6r1 UO YOUMS pue uni 00 348 INDIO JOU JOU sojeJodo uonduosoeg 0892 0892 0892 0892 4011944a Figure 3 38 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing seu MOH NOA Sisisiod 951 pue ssed pue 5 J NAO pue 0 35291 sounos6 pue suamod 123 Ie 2949 J6Ss929U JI 5 uonipuoo 5 yoo UOISOU09 JO eunjsiouJ jo ubis Aue JO 5 uld pue UId Z 193 198dsui pue seu MOH NOA sisisiod 951 pue ssed pue 5 NAO pue sonsouBeip pasu 4591 spuno46 pue N94 Ie 2940 JI SJOJOBUUOD uonipuoo
65. Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing seu Aeyy e amp ueuo eud yoauy Jepui Ao y enssi ue Seui y je JO 469 SI J y pue Jepul Ao y saui BU enssi ue 1 y je ng y 1e UBABUN JO SI J YIM enssi ue 9jeoipul Suoneoo ujoq 1e pue ue e SI J y JepuijAo BU YUM eui SMAJOS Jepee q 941 xoeJo y uo pejeisu eunsseJd eui seu MOH NOA SjsisJed pue Syoayo ssed 5 IN3O pue 0 peau 31591 sounos6 pue 123 Ie 99u2 JI SJOJOOUUOD uonipuoo 5 yoo JIJ9A uoisoJ409 JO eunjsiouJ jo ubis Aue 10 5
66. NO dwe 440 dwg yeg NO dwe Sav Snjeis HHVS Buip4oooe 6261 due Jojeoipu JI 440 peiqesiq NO dwe 21V Jojeoipu uedo AO peiqesiq 440 6261 due l99uM SEV 99IAJOS 440 eiqipny NO dwe 440 dwg yeg NO dwe sav 51815 HHVS 6261 due Jojeoipu Buried peseejai JI 440 peidde NO duie1 Jojeoipu Hued 440 6861 due 99IAJOS 440 eiqipny NO dwe 91V 440 dwg yeg NO dwe sav 1045 AO 1 yed ON aga pue 21 Sav yous AO Je9H Yd AJLA INO dwy Snjeis HHVS 01 6261 due Jojeoipu Hued 440 pe gesiq NO dwe pe1oejep Jojeoipu Buried 0 Hous AI 1919 peigesiq 440 6861 SEV S 440 eiqipny NO 440 dwg oyeg NO dwe Sgv 437 19MOd weishs 1u6r1 Buur
67. Speed screen to verify that sensors are connected at each wheel Speed at a sensed wheel FL FR RL RR indicates sensors are installed but does not verify correct sensor installation Wheel speed sensor installation information is available in the Removal and Installation section Counters select Counters to display the Counters screen Figure 3 6 3 Troubleshooting and Testing persi Tos Putt Motor Hoare Frond Hoge 1 Posts duas Ewent Cormier Deos 29 Des eg Oho Deos 20549 5 Ere Event DES Everts 4 85 Everts ATIC Evi Chea Everts Cycles 2 Chew prion Chas Pudong Broke Everts 4004462 Figure 3 6 The Counters screen provides an overview of HPB component performance pump hours brake events etc as well as general 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 E Lamps Relay ECU Information Engine Data Link ECU Type Disable ATC Number Enable Manufacture Date Miscellaneous Outputs Serial Number xi Rig Reset Memorized Left 40089598 Figure 3 7 Meritor WAB
68. Warnings Cautions and service procedures Meritor WABCO TOOLBOX Software NOTE The HPB system does not have blink code capability and Meritor WABCO TOOLBOX Software is needed to communicate with the system Use TOOLBOX Software to obtain DICs and verify the activation of various system components e urn valves pump and retarder relay if available on and off Valve Activation Menu e urn indicator lamps on and off Miscellaneous Output Activation Menu NOTE obtain TOOLBOX Software go to www meritorwabco com 3 Troubleshooting and Testing Connecting TOOLBOX Software To connect TOOLBOX Software to the vehicle a RP1210A compliant device will be needed Once TOOLBOX Software is connected and open verify the adapter settings are correct To access Adapter Selection for TOOLBOX Software 11 or newer click on Utilities from the main TOOLBOX page or under System Setup in J1707 TOOLBOX from the main TOOLBOX page To access Comport Settings for TOOLBOX Software versions prior to TOOLBOX Software 11 click on System Setup from the main TOOLBOX M page Make sure the Vendor and Adapter drop downs are set for the device being used and set the Protocol drop down to J1 08 and click OK Figure 3 1 Adapter Selection Adapter Settings Vendor Maregan Systems Inc OLA Adapter Protocol J1 708 Adapter ID
69. be equipped with a HEPA vacuum and worker arm sleeves With the enclosure in place use the HEPA vacuum to loosen and vacuum residue from the brake parts b Asan alternative procedure use a catch basin with water and a biodegradable non phosphate water based detergent to wash the brake drum or rotor and other brake parts The solution should be applied with low pressure to prevent dust from becoming airborne Allow the solution to flow between the brake drum and the brake support or the brake rotor and caliper The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed Wipe the brake parts clean with a cloth c Ifan enclosed vacuum system or brake washing equipment is not available carefully clean the brake parts in the open air Wet the parts with a solution applied with a pump spray bottle that creates a fine mist Use a solution containing water and if available a biodegradable non phosphate water based detergent The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed Wipe the brake parts clean with a cloth d Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when grinding or machining brake linings In addition do such work in an area with a local exhaust ventilation system equipped with a HEPA filter e NEVER use compressed air by itself dry brus
70. braking force Serious personal injury can result e Two people are needed to perform this procedure e n some vehicles it may be necessary to move non HPB system components such as the air tank in order to access the HPB part If this is necessary refer to the vehicle manufacturer s manual for information before moving the component e Dleeding the master oylinder circuit is required during installation of the master cylinder reservoir Bleed procedures appear in section 5 of this manual e After installing HPB components or making system repairs use TOOLBOX M Software to remove the error code from the ECU memory Instructions for using TOOLBOX Software appear in section 3 of this manual 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 determine which fluid to use 4 Removal and Installation Install the replacement reservoir by carefully pressing it fully into the grommets C Install the two new roll pins from the replacement kit Drive the pins through the holes in the master cylinder boss and the reservoir mounting tab holes Support the back of the tabs as you install each pin Figure 4 47 D Install the nut on the front bolt MASTER CYLINDER RESERVOIR
71. instructions for bleeding the SAHR circuit that appears in Section 5 of this manual After bleeding the SAHR circuit 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 brake fluid as necessary until the MAX mark level is achieved Never add fluid above the MAX mark Refer to section 5 for detailed instructions on how to correctly fill the master cylinder reservoir Check the system for leaks If there are no leaks go to Step 16 If there are leaks depressurize the system before making the necessary repairs Use the following procedures to depressurize the system Remove the two maxi fuses for the pump motors or disconnect the battery e Apply the brake pedal a minimum of 30 times to decrease pressure in the system To ensure that the system is depressurized perform the following check on both the front and rear axles A Remove the protective cover from the end of the bleeder fitting on one brake caliper B Attach a bleeder bottle hose to the bleeder fitting at the wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake fluid Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 C Use a wrench to open the bleeder fitting screw Figure 4 59 EI E gt TZ 400443 7 Figure
72. low pressure hose and the HCU reservoir inlet to prevent system contamination Before removing the HCU assembly from the vehicle drain the fluid from the HCU reservoir To do this A Reconnect the battery B Attach a bleeder bottle to one wheel end at the front axle C Connect the vehicle to a computer that has TOOLBOX software version 9 0 or higher installed Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 51 4 12 13 Disconnect the brake lines from the HCU There at least six 14 Removal and Installation 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 ad Meritor WABCO HPB Tractor ECU Display Component 400501 7a E Open the bleeder screw Apply and hold the brake pedal down until no more fluid runs out G Tighten the bleeder screw Attach a bleeder bottle to one wheel end at the rear axle Repeat Steps D G for the rear axle Disconnect the battery brake lines seven if the system is equipped with power parking brakes Plug the brake lines and ports on the HCU to prevent system contamination Mark the brake lines to ensure correct positioning during reassembly 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 con
73. mark on the master cylinder reservoir The master cylinder reservoir should be regularly checked during bleeding procedures and filled to the MAX mark with new specified brake fluid from a sealed container Prepare the pressure bleeder device according to the instructions provided with the equipment NOTE The pressurized fill and bleed equipment used can be either air over fluid or fluid over air type Install a suitable adapter from the fill and bleed equipment to the master cylinder reservoir filler neck Verify that the adapter and bleed equipment are securely tightened onto the master cylinder reservoir filler neck Fit the bleeder hose onto the bleeder screw on the SAHR chamber submerge the free end of the bleeder hose into the bleed bottle Apply 35 psi 2 4 bar of pressure from the fill and bleed equipment to the master cylinder Open the SAHR bleeder screw until fluid begins to flow 3 4 turn Allow the fluid to run until 8 5 ounces 250 cc has been collected Take note of the fluid level in the bottle before Starting If no further air bubbles enter the bleed bottle close the 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 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
74. 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 Park the vehicle on a level surface Apply the parking brake and block the wheels Disconnect the foot brake switch Remove the two machine screws securing the foot brake switch to the base of the master cylinder Remove the foot brake switch Remove and discard the paper gasket models built prior to 2006 from the master cylinder or O ring models built in 2006 and after from the foot brake switch Verify the warranty status If the switch is under warranty return it to Meritor WABCO 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 failed Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 Removal and Installation Installation Master Cylinder Foot Brake 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 entire master cylinder with the current design used in vehicles built after 01 01 2006 4008216 1 Clean the surface of the master cylinder base and install the Q ring seal on the foot brake switch 2 Install the foot brake switch to the base of the master cylinder Tighten the two screws to 26 5 35 4
75. on the relay valve Hand tighten all five screws Use a torque wrench to tighten all five screws to 71 in lb 8 Nem 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 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 Proceed with pressure filling and bleeding the master cylinder circuit Refer to Section 5 for procedures Proceed with pressure filling and bleeding the brake caliper circuits and the SAHR circuit if applicable Refer to Section 5 for procedures Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 Removal and Installation Removal Hydraulic Compact Unit HCU Pump Before removing the pump ensure the replacement pump Is readily accessible 1 2 Wear safe eye protection Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Failure to do so can result in unwanted vehicle movement causing serious pe
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77. 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 fluid Remove the hose clamp from the low pressure hose 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 reservoir to improve the draining process Plug the low pressure hose to prevent system contamination 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 out the two roll pins C Lift the reservoir off the master cylinder D Plugthe reservoir outlet ports to prevent contamination to the system E Pour any remaining fluid into a container that can withstand the effects of brake fluid Close the reservoir outlet ports to prevent spillage 11 Verify the warranty status If the master cylinder reservoir is under warranty return it to Meritor WABCO Installation Master Cylinder Reservoir WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Do not install a damaged reservoir A damaged reservoir will result in loss of hydraulic brake fluid which can lead to loss of
78. the TOOLBOX Software EOL pull down menu The pedal must remain fully depressed during the entire process until the TOOLBOX M Software displays the completion message Ensure that the pressure in both accumulators is reading zero on the diagnostic main screen then release the brake pedal Turn the ignition OFF Verify that the brake fluid level in the master cylinder reservoir is not below MIN level NOTE During bleeding procedures brake fluid level must not 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 fluid from a sealed container Do not add fluid above the MAX mark Prepare the pressure bleeder device according to the instructions provided with the equipment NOTE The pressurized fill and bleed equipment used can be either air over fluid or fluid over air type Install a suitable adapter from the fill and bleed equipment to the master cylinder reservoir filler neck Verify that the adapter and bleed equipment are securely tightened onto the master cylinder reservoir filler neck Remove the rubber caps from the two relay valve bleeder screws located on the hydraulic control unit HCU Figure 5 1 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 9 11 12 15 14 15 16 Brake Bleeding Procedures 4008096a BLEEDER PORT PRIMARY MASTER CYLINDER CIRCUI
79. the wheels to prevent the vehicle from moving Failure to do so can result in unwanted vehicle movement causing serious personal injury 3 Disconnect the battery 4 Apply the brake pedal a minimum of 30 times to decrease pressure in the system ensure the system 15 depressurized perform the following check on both the front and rear axles A Remove the protective cover from the end of the bleeder fitting on one brake caliper B Attach a bleeder bottle hose to the bleeder fitting at the wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake fluid C Use a wrench to open the bleeder fitting screw D Apply and hold the brake pedal down until no more brake fluid runs out Do not release the brake pedal E With the brake pedal still applied use a torque wrench to close the bleeder fitting screw 5 Useatorque wrench to tighten the bleeder fitting screw to the torque value specified by the component manufacturer 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 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4006216a Figure 4 26 NOTE Avoid bending or kinking the brake lines while di
80. to the vehicle specification sheet to determine which fluid to use NOTE Never add fluid above the MAX mark regardless of the State of the accumulator Connect the battery Turn the ignition to ON The HCU pump motors will start up and fill the accumulators Approximate running time is 45 seconds If the pump motors fail to deliver a sufficient amount of fluid the ECU module will control the pump motors in a self priming procedure The HCU pump motors should stop 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 NOTE Pressure should be left on the system during the first key on attempt to build pressure 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 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 Removal and Installation 9 Check the accumulator connections for leaks If there are no leaks go to Step 11 If there are leaks depressurize the system before making the necessary repairs Use the following procedure to depressurize the system e Apply the brake pedal a minimum of 30 times to decrease pressure in the system To ensure that the system i
81. 10014 pe qesiq Sav BuiuJeM 1949 pejoejep eDeyee jo Snjeis HHVS 6261 due Jojeoipu JI 440 NO 440 6261 due 99IAJOS ued 440 eiqipny 340 dwe NO dwg oyeg 440 dure sav SNIEIS HHVS 6261 due Jojeoipu ued JI 440 NO dwe7 Jojeoipu ued 440 6861 99IAJOS ued 440 eiqipny 440 dwe NO dwg yeg 440 dure sav a6uel 1nO Snjeis HHVS 6261 due Jojeoipu ued JI 440 NO Jojeoipu Hued 430 6261 due 99IAJOS uled NO eiqipny NO dwe NO dwg yeg NO dwe sav SniEls HHVS 01 6261 due Jojeoipu Buried peseelei JI 440 NO Jojeoipu Bured 440 6861 00 99lAJOS ued NO eiqipny NO dwe NO dwe oyeg NO dwe sav 9 XV 1014
82. 1591 SWYO 99 2 UOIIMS JO eoueisisaJ pue JO 99UejsIS9J YOOUD punoJB 10 0 uedo 104 uid JO 0 uid AJESSBOBU JI 5 ULAJI 001801109 10 aunysiow uis Aue 10 2 pue JOBUODSIG eje 50011500 YOUMS JI ees 0 XOS TOOL Ul 2949 NOH JO jueuieoe deu ees ed sjueuieoe daiJ NOH 10 dung seu JO e ssed syoaup J 5 peej g 5 5 y ui ou si JOU si Bu HSA si deo sapuljAd ay UA SEY JO palle sey 91e9ipui sisisiod 2 q pue ssed syoayo e uoneJedo jo Aouenbea yoouy abeyes euJe1xe JO 5 peiejlep daa 8 OLV pel gesip YOUMS esinJ2 pe qesip qaa 9 21 pe qesip 01 U09 esinJo pejoelep 5 U91IMS 1004 pe qesiq peioejep e xy 10014 Sgv BuiuJeM 1949 pe qesiq wily
83. 3 or DOT 4 hydraulic brake fluid Refer to the vehicle specification sheet to determine which fluid to use 10 Connect the battery 11 Turn the ignition ON The pump motors will start up and fill the accumulators Approximate running time is 45 seconds CLEVIS If the HCU pump motors fail to deliver a sufficient amount of fluid the ECU module will control the HCU pump motors in a self priming procedure The HCU pump motors should stop within three minutes with the brake warning light and the buzzer OFF If there are problems building pressure after 4004980a bleeding and powering up the system increase the pressure setting of the pressure bleeder equipment to 29 40 psi 2 2 5 bar and cycle the ignition off for 10 seconds then back on PUSHROD CLEVIS PIN Figure 4 42 4 Connect the brake tubes to the master cylinder Tighten the fittings to 10 8 14 4 ft lb 15 20 Nem 4 NOTE Pressure should be left on the system during the first Connect the low pressure hose to the master cylinder reservoir key on attempt to build pressure and secure the connection with a hose clamp 6 Remove the pinch clamp from the low pressure hose 12 Depress the brake pedal rapidly four times to activate both HCU pump motors 7 Connect the foot brake switch on the master cylinder and the fluid level sensor switch under the reservoir Figure 4 43 Tx MT BUMS SPANO charged the brake fluid level in the master cylinder re
84. 4 Removal and Installation 31 PIN HARNESS 2 PIN POWER Figure 4 19 Use a 4 mm Allen wrench to loosen and remove the four mounting screws that attach the ECU module to the HCU Remove the screws in the sequence shown Figure 4 20 S 0 ui CEA 92 Ly 4004452a 922 Figure 4 20 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 Meritor WABCO If it is not under warranty discard the used ECU Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 Removal and Installation CAUTION Do not touch the pressure sensor connectors The connectors are sensitive and can be damaged by static electrical shock 8 Use clean rag to carefully clean the area around the valves formerly covered by the ECU Do not touch the two pressure sensor connectors Figure 4 21 5 Do not touch pressure sensor connectors 4004453a Figure 4 21 9 Remove and discard the orange seals from the two pressure sensors Do not touch the two pressure sensor connectors Installation Electronic Control Unit ECU CAUTION Do not touch the pressure sensor connectors The connectors are sensitive and can be damaged by static electrical shock 1 Remove the replacement orange seals from the ECU replacement kit Install the seals onto the repla
85. 40 6861 99IAJOS ued 440 aiqipny NO 91V sesneo Spuooes 91 uey U9 IMS 9poo 440 dwg BuiuueM exeJg Y N dure sav 14617 Sav YOUMS EUJ9 U U91IMS 0 jqLun 5 Snjeis HHVS 01 6861 due Jojeoipu uonueAJelu peseojaJ 440 exyeJg peidde NO dwe 99IAJ9S ON exeag 440 6261 due agg pue S 21 SAV 440 eiqipny NO 440 dwg NO dwe sav Shjeis HHVS 01 Buipjoooe 6261 due Jojeoipu 440 NO dwe 34O 6261 due Ued 440 eiqipny NO due qaa pue 21 sgy 440 dwg NO dwe sav 041u09 55 sgy 104 Ajddns Aejay AJLA uOnoeaH waisks Jo uedo pepunoaut 10 uedo JOUUD Jo Bulssiw K ddns YOUMS
86. 61 due 99IAJOS ued NO eiqipny NO dwe NO dwe BuiujeA yeg NO dwe sav 1eoH DBuisueg e1nssaJg 44617 JO ou seop 10015000 Josueg 9JnsseJg yous eunssaJg uonduoseg 0892 0892 290 290 Figure 3 37 4011943a Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing pajre sey Jojejnuunooe Ipu NL XOS TOOL yoouyD Jepui Ao y YIM enssi ue 9jeoipur y UBASUN JO YeSM SI J y pue J9 SeuJ y enssi ue ajeoipul y je y 12 ueAeun JO SI J BU enssi ue 9jeaipul pue SI J pexoeJo y y Aejas y ye SMAIOS xoeJo
87. 69 LAMP RELAY N BRAKE WARNING 15 62 LAMP RELAY PARKING BRAKE SWITCH BRAKE ACUATION SWITHC FLUID LEVEL SWITHC PARKING BRAKE MONITOR SWITC REF GND PB CUTOFF PB SUPPLY BLR RELAY DBR RELAY A AA UIGN 4011905a Figure 2 4 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Testing the System This section contains information for testing the HPB system with TOOLBOX Software and for performing standard component and electrical tests WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Exhaust gas contains poison When testing a vehicle with the engine running test in a well ventilated area or route the exhaust hose outside To avoid serious personal injury keep away and keep test equipment away from all moving or hot engine parts To avoid unwanted vehicle movement when testing set the 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
88. BdIAIOS peeds 440 aiqipny NO dwe 21 440 dwe7 yeg NO dwe7 sgy Snjgejs YHVS Buipjoooe 6261 due Jojeoipu Buried 440 NO dweq Jojeoipu Buried jou 10595 peeds O1LV A jJeuuouqe ue 99uM Je93J 20 sem 440 6261 due sgy uy jeubis exyeJg peeds 440 ejgipny NO dwe 440 dwe exyeJug duie sav snjejs HHVS o BuipJoooe 6261 due Jojeoipu peiqesiq peseejei 440 olv NO duie1 99uM Jojeoipu exyeug Buried 1 4 O 4 940 6261 due BdIAIOS peedg 440 Buiuiew ejqipny NO dwe 440 dwe yeg NO dwe sav 5 5 4n290 sexyeJq uonepunoj 2949 9215 1291099 Josueg JoeuM Y T uojs g 14617 261 JebBu ON 162 ulum uo UO9yMS e qisnejd jou uonenjoe SAICA 19 U 6c9 uoneuiquio2 TS uondi soeg m 40119258 Figure 3 20 2 Meritor WABCO Maint
89. CO Maintenance Manual MM 0401 Revised 07 15 11 3 Troubleshooting and Testing Valves select Valves to display the Valve Activation test screen Figure 3 8 SS B a Valve Activation Valve Selection LellFrort C Fight Frort Lelt 2nd e Right 2nd ole vales 40044642 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 12 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 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 4 Parking Brake Parking Brake fe Release Apply 4004466a Figure 3 10 select Release or Apply then select Send to test the parking brake Select Close to exit this screen Relay Only on Non Mult
90. HPB master cylinder reservoir regardless of the charging state of the accumulators When the system is totally or partially depressurized during service or overnight parking fluid stored in the accumulators is returned to the master cylinder reservoir If the reservoir was previously filled above the MAX mark a fluid spill could occur when these conditions exist Overfilling the master cylinder reservoir may cause damage to the cap and other components resulting in impaired braking performance and could result in an accident and serious personal injury CAUTION Hydraulic brake fluid is a caustic substance Contact with hydraulic brake fluid can cause skin irritation Do not let 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 get on brake pads shoes rotors or disks Observe the following when working on the braking system WARNING Prior to working on the braking system all bleeder screws and the master cylinder cap must be cleaned thoroughly cleanliness of fluid and areas around the service points have to be maintained Do not use mineral oil based fluid for this cleaning Using mineral oil based fluid can contaminate brake fluid and could damage the interior of the components and cause a system malfunction Cover all electrical connectors near the bleeder screws carefully to make certain that no brake fluid ente
91. JOUURD uoldiusseg 4011939a Figure 3 33 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing Snjeis HHVS Buipjoooe 6861 due Jojeoipu 440 NAO pue sonsouBeip 0 peau NO due 1591 peo pue 123 Ie x99u2 Jojeoipu 5 JI 5 UBIO UOISOIJOD JO SJNISIOW 6261 due ON uoniub 193 jo ubis Aue 104 5 j2edsui pue 99IAJOS uled 440 430 duie1 91v 440 dure exeJg NO dwe sav SG 10 002 uey 5 peeds Jo Bulssiw Snjeis HHVS 6261 due Jojeoipu seu eieoipur 440 SjsisJed pue sXoeuo ssed 5 J pejdnuuoajul snes NO due NAO pue sonsouBeip mala pasu JO 551 gt Jojeoipu 35281 peo spuno pue 123 e Y29349
92. LA USB 4011997 Figure 3 1 NOTE When switching between J1939 and J1708 communications vehicle ignition must be cycled between sessions to correctly communicate with ECU NOTE TOOLBOX Software must be connected to the vehicle and the vehicle ignition must be ON in order to display information If unable to communicate with the ECU e Verify device and data link connections are secure e Verify the device is RP1210A compliant and that the comport settings Vendor Protocol Adapter in TOOLBOX Software are correct Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing e Verify the device software and firmware is up to date Check all the powers and grounds coming to the ECU including load testing 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 Main HPB Screen This screen provides icons and pull down menu task selections It also provides information about the current status of Meritor WABCO Figure 3 2 Meritor WABCO HPB Tractor ECU Display Component Tests Parameters EOL Help Lal Information ECU Type Part Number Manufacture Date Serial Number Software Rey 129 4360460012 05 03 2008 0003020
93. MERITOR WABCO Maintenance Manual MM 0401 Meritor WABCO Hydraulic Power Brake HPB System Revised 07 15 service Notes About This Manual This manual contains maintenance procedures for Meritor WABCO s Hydraulic Power Brake HPB system for trucks tractors and buses Before You Begin 1 Read and understand all instructions and procedures before you begin to service components 2 Read and observe all Warning and Caution hazard alert messages in this publication They provide information that can help prevent serious personal injury damage to components or both 3 Follow your company s maintenance and service installation and diagnostics guidelines 4 Use special tools when required to help avoid serious personal injury and damage to components 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 Meritor WABCO s Hydraulic Power Brake HPB systems Meritor WABCO Maintenance Manual MM 0401 Revised 07 15
94. NCE GROUND PUMP MOTOR 2 19 8 SOLENOID VALVE GROUND SOLENOID VALVE SUPPLY E WIRING DIAGRAM FOR MULTIPLEX MUX VEHICLES WITH POWER BRAKE OPTION PUMP MOTOR 2 GROUND T lt 1 c a0 25 as H PUMP MOTOR 2 SUPPLY Zr EE be m ra a AH i aE rt e PUMP MOTOR 1 SUPPLY Z tc amp TRAVEL SWITCH 40044814 Figure 2 1 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 5 2 Wiring Diagram HPB Connector Diagram for Multiplex Vehicles The Meritor WABCO electronic control unit interface connector diagram for multiplex vehicles is shown in Figure 2 2 PIN IDENTIFICATION FOR WIRE HARNESS CONNECTORS TO THE ECU co PUMP MOTOR 2 SUPPLY 12 IGNITION 12V BRAKE SIGNAL PRESSURE SUPPLY VALVE OPTIONAL CUT OFF SOLENOID OPTIONAL REFERENCE GROUND SAHR TRAVEL SWITCH OPTIONAL NOT USED SOLENOID VALVE SUPPLY 12V PUMP MOTOR 2 GROUND wraps ps pa Pr EN 0c isl bl 19 _ ___ SOLENOID VALVE GROUND ABSOFFROAp O NOTUSED SWITCH OPTIONAL Ow BRAKE FLUID E S NOT USED MASTER CYLINDER gt RIGHT BRAKE SWITCH zU PARKING BRAKE E erm WHEEL SPEED DASH SWITCH NOT USED is 27 SENSOR NOT USED mE B E 23 REAR LEFT J1939 HIGH 7 m 11939 LO
95. Park the vehicle on a level surface For vehicle equipped with manual parking brakes apply the parking brakes Ensure that the ignition is turned off 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 Release all air from the air systems before you remove any components Pressurized air can cause serious personal injury The full power brake system is a pressurized system that achieves pressures of up to 2320 psi This pressure is not reduced by switching the ignition off or removing battery power Prior to servicing this system the depressurization procedures must be performed exactly as presented Failure to depressurize the system may result in personal injury or 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 CAUTION The HPB hydraulic power brake system is a complex device that provides optimum efficiency and operation If the system sustains damage or a component malfunctions and requires replacement the replacement procedures provided by Meritor WABCO must be followed exactly with the associated steps performed in the order presented Hydraulic brake fluid is a causti
96. Pressure Supply Valve WARNING The full power brake system 15 a pressurized system that achieves pressures of up to 2320 psi This pressure is not reduced by switching the ignition off or removing battery power Prior to servicing this system the depressurization procedures must be performed exactly as presented Failure to depressurize the system may result in personal injury or death e Two people are needed to perform this procedure e n some vehicles it may be necessary to move non HPB system components such as the air tank in order to access the HPB part If this is necessary refer to the vehicle manufacturer s manual for information before moving the component e Bleeding the SAHR circuit is required during installation of the parking brake pressure supply valve Bleed procedures appear in section 5 of this manual e After installing HPB components or making system repairs use TOOLBOX M Software to remove the error code from the ECU memory Instructions for using TOOLBOX Software appear in section 3 of this manual CAUTION When installing the new parking brake pressure supply valve 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 4 Removal and Installation O RINGS 3 PARKING FILTER SCREENS 2 PLASTIC
97. T MASTER CYLINDER INPUT PORT PRIMARY CIRCUIT MASTER CYLINDER INPUT PORT SECONDARY CIRCUIT BLEEDER PORT SECONDARY MASTER CYLINDER CIRCUIT Fit the bleeder hose onto one relay valve bleeder screw located on the hydraulic compact unit oubmerge the free end of the bleeder hose into the partially filled bleed bottle Apply 35 psi 2 4 bar of pressure from the fill and bleed equipment to the master cylinder reservoir 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 ounces 250 has been collected Take note of the fluid level in the bottle before starting When no further air bubbles enter the bleed bottle close the bleeder screw Remove the bleeder hose and tighten the bleeder screw to 35 4 to 39 8 Ib in 4 to 4 5 NOTE Verify the fluid level in the master cylinder reservoir During bleeding procedures the brake fluid must not be allowed to fall below the MIN mark on the master cylinder reservoir The master cylinder reservoir should be regularly checked during the bleeding procedures and filled to the MAX mark Repeat Steps 13 and 14 with the second bleeder screw 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 MAX mark level is achieved Never add fluid above the MAX mark Refe
98. The advantages provided by ABS may not be fully available No ABS related faults detected Fe 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 BEES UO ATC is operating correctly the Mud and Snow mode has not been selected and the vehicle is not experiencing an ATC event ELI BRAKE X ON Park Brake is applied Im Park Brake not applied o PARK im position Apply Parking Brake Do not drive until the failure has been repaired A Park Brake related fault has been detected Immediately find a location to safely park the vehicle 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 BRAKE STEADY ON position Apply Parking Brake Do not drive until the failure has been repaired or SSS NOTE If the ABS and or lamps are flashing after the parameters have been downloaded verify the System Check Status has been set see System Check Sta
99. W m y a WHEEL SPEED 2 25 FRONT RIGHT WHEEL SPEED 30 SENSOR X2 26 J1587 DIAG B 30A LOW J1587 DIAG A 31 HIGH 4008946b URAT1 Figure 2 2 6 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 2 Wiring Diagram HPB Wiring Diagram for Non Multiplexed Vehicles 3 05435 1337 Ev3u 905 35 HOSN35 LHJIY LINHA 1431 1 083 MOSN3S Hi 03151 WSs OXZ Oxe Q31S1MI 2 Wags OXE LE 66 Sc ec S f Q31S IMI z 0 54313 OL dO LIHON3 11V33AO NY OL SONOdSAYHOD SWHO 90 0 g c6 9 051 31932 5 1 293151539 79101 gz WS SZ A13A1123dS33 318Y9 1X9 dAl 8411 JYS ZL OMV 3215 SHIM N3dO 1VAHON ON 035019 TVWNHON 3A1VA 131100 AO LAINI Al SNOILVIA3U88V JYS OL S9NIOSJODOV INOHIIM 53503 3441 30v18 71 66 9 051 UML AT73A1123dS34 318VO T1XLl dAL 8211 AVS BL OMV S318vV9 21312313 a 5310 lt gt EX T TE Tm xo xul gt lt ho m or o_o s gt o_o M322n8 G9 NOLL INI i Ex 0334 8 4 0A8351H 035 8303 19 01180 r 8BBLT JYS OS 7 vs 7 vsi vazi E o e 0 e J gt T zanis LANs EN D a NO ONS
100. aintenance Manual MM 0401 Revised 07 15 3 While using the 15 mm wrench to hold the canister shaft unscrew the threaded rod using an 8 mm wrench The rod must be unscrewed approximately 2 5 inches before the cable disconnects The cable will exhibit some resistance while being unscrewed because it is under tension Towing Vehicle with Front Wheels Suspended When it is necessary to tow a vehicle with the front wheels suspended extra precautions must be taken to avoid transmission or differential damage Disconnect the axle shafts at the rear axle to prevent the wheels from driving the differential and the transmission If axle shaft is not disconnected remove the rear axle shafts from the axle assembly Cover the wheel hub ends to prevent loss of axle lubricant and entrance of contaminants Towing Vehicles with Rear Wheels Suspended Whenever possible it is preferable to tow a disabled vehicle from the rear by raising the rear of the chassis When towing a vehicle with the rear of the chassis suspended the front wheels must be locked in the straight ahead position 3 Troubleshooting and Testing 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 igniti
101. al a minimum of 30 times B Use the EZ TECH and TOOLBOX Software to verify that pressure at both accumulators is at 0 psi During this process brake fluid will return to the master reservoir from the accumulators Monitor the reservoir fluid level to ensure it does not overflow Turn the ignition key to OFF With the accumulator pressure decreased verify that the brake fluid level is at the MAX mark on the master cylinder reservoir If brake fluid in the reservoir is above or below the MAX mark remove or add brake fluid as necessary until the MAX mark level is achieved If brake fluid needs to be added ensure that it is from a clean sealed container Never add fluid above the MAX mark Reinstall the 30 amp motor fuses and turn the ignition ON Both motors will start running until both circuits reach the cut off pressure at approximately 2000 psi 138 bar Monitor the pressure in each circuit using the TOOLBOX Software When both motors stop ensure that the pressure level in each circuit reached the cut off level This will decrease the brake fluid level in the master cylinder reservoir With the system completely charged the brake fluid level will be between the MIN and MAX marks on the master cylinder reservoir Figure 5 3 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 5 Brake Bleeding Procedures 4007815 Figure 5 3 WARNING Never reuse hydraulic brake fluid that has b
102. aled Beam headlight for approximately 10 seconds The headlamp should be bright if the lamp does not light is dim or flickers it would indicate an issue with the wiring may need to review wiring diagnostics and repair with the OEM Standard Component Testing Indicator Lamps If the indicator lamps do not come on after the ignition is turned on or it comes on but does not go out after three seconds check all ABS fuses or circuit breakers and replace if necessary After checking the indicator lamps make repairs as necessary Sensor Adjustment On steering axles the sensor is typically accessible on the in board side of the steering knuckle 3 Troubleshooting and Testing On drive axles the sensor is typically accessible on the in board side of the rear axle spindle To adjust the sensor push the sensor in until it contacts the tooth wheel e o not pry or push sensors with sharp objects e Sensors will self adjust during wheel rotation NOTE No gap is allowed at installation During normal operation the gap should not be greater than 0 04 inch 1 02 mm Vehicle Test Drive After replacing an HPB component use TOOLBOX M Software to ensure there are not active faults then test drive the vehicle as follows 1 Turn ignition ON NOTE Depending on the vehicle the ATC lamp may be labeled differently and some vehicles may not have an ATC lamp Refer to the vehicle specification sheet for label designation 2
103. aled container to lubricate the reservoir grommets Use DOT 3 or DOT 4 hydraulic brake fluid Refer to the vehicle specification sheet to determine 4004448 which fluid to use Figure 4 10 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 55 4 Removal and Installation 5 Position the reservoir on the HCU and verify orientation The mounting screw holes must line up and the inlet port for the low pressure hose must face the front of the HCU Figure 4 12 40044498 Figure 4 12 6 Install the new reservoir by pressing it carefully and completely into the grommets in the ports Figure 4 13 40044508 Figure 4 13 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 7 Use the four new mounting screws to attach the reservoir to the HCU Using a number 4 Phillips head screwdriver tighten the screws to 43 60 in Ib 5 7 Nem 8 Reinstall the HCU assembly on the vehicle Refer to the hydraulic compact unit installation procedure in this section Removal HCU Accumulators WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Park the vehicle on a level surface For vehicle equipped with 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 Release all air from the air systems bef
104. aster Cylinder Foot Brake Switch Removal Master Cylinder Fluid Level Sensor Switch Installation Master Cylinder Fluid Level Sensor Removal Parking Brake Pressure Supply Valve Installation Parking Brake Pressure Supply Valve Removal Low Pressure Hose Installation Low Pressure Hose Lubrication Wheel Speed Sensor Specification Removal Front Axle Wheel Speed Sensor Installation Front Axle Wheel Speed Sensor Removal Rear Axle Wheel Speed Sensor Installation Rear Axle Wheel Speed Sensor section 5 Brake Bleeding Procedures Brake Bleeding Procedures Pressure Bleed Procedures Master Cylinder Circuit Contents 92 95 96 97 99 Brake Caliper Circuit opring Applied Hydraulic Release Parking Brake Circuit Changing Hydraulic Brake Fluid Brake Fluid Replacement Requirement Filling the Hydraulic Power Brake HPB Master Cylinder Reservoir Section 6 Appendix Leak Check Procedure for Meritor WABCO HPB System Check the HPB System for Brake Fluid Leaks oystem Test ASBESTOS FIBERS WARNING 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 available from Meritor Hazard Summary Because some brake linings contain asbestos workers who service brakes must understand the potential hazards of asbestos and precautions for reducing risks Exposure to airborne asbestos dust can cause ser
105. atory 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 with the removal of the wheels 3 Procedures for Servicing Brakes a Enclose the brake assembly within a negative pressure enclosure The enclosure should be equipped with a HEPA vacuum and worker arm sleeves With the enclosure in place use the HEPA vacuum to loosen and vacuum residue from the brake parts b Asan alternative procedure use a catch basin with water and a biodegradable non phosphate water based detergent to wash the brake drum or rotor and other brake parts The solution should be applied with low pressure to prevent dust from becoming airborne Allow the solution to flow between the brake drum and the brake support or the brake rotor and caliper The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed Wipe the brake parts clean with a cloth c Ifan enclosed vacuum system or brake washing equipment is not available employers may adopt their own written procedures for servicing brakes provided that the exposure levels associated with the employer s procedures do not exceed the levels associated with the enclosed vacuum system or brake washing equipment Consult OSHA regulations for more details d Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA
106. c brake fluid is a caustic substance Contact with hydraulic brake fluid can cause skin irritation Do not let 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 get on brake pads shoes rotors or disks NOTE Use DOT 3 or DOT 4 hydraulic brake fluid Refer to the vehicle specification sheet to determine which fluid to use 1 Remove the plug from the accumulator counterbore on the HCU Clean the counterbore and the surrounding area The old accumulator O rings should have been removed from the counterbore during removal of the accumulators Verify that the O ring was removed 2 Use clean brake fluid from a sealed container to lubricate the O ring on the new accumulator Use DOT 3 or DOT 4 hydraulic brake fluid Refer to the vehicle specification sheet to determine which fluid to use 3 Place the new accumulator and O ring into the counterbore After positioning use a torque wrench with a strap wrench attachment to tighten to 43 4 50 ft lb 60 70 Nem Do not overtighten Figure 4 17 4 4 Removal and Installation 4004445 Figure 4 17 Repeat Steps 1 3 to replace the second accumulator Check the fluid level in the master cylinder reservoir Fluid level should be at the MAX mark If not fill the reservoir to the MAX mark with new brake fluid from a sealed container Use only DOT 3 or DOT 4 brake fluid Refer
107. c substance Contact with the hydraulic brake fluid can cause skin irritation Do not let 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 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Before disposing of used components verify the warranty status Contact the Meritor OnTrac Customer Call Center at 866 OnTrac1 668 7221 for instructions Removal Hydraulic Compact Unit WARNING The full power brake system is a pressurized system that achieves pressures of up to 2320 psi This pressure is not reduced by switching the ignition off or removing battery power Prior to servicing this system the depressurization procedures must be performed exactly as presented Failure to depressurize the system may result in serious personal injury NOTE The following general guidelines are provided to facilitate the safe removal of the HCU from the vehicle e Two people are needed to perform this procedure e Forthe HCU drain procedure in Step 11 TOOLBOX M Software version 9 0 or higher is required If you do not have this version of TOOLBOX Software go to meritorwabco com e n some vehicles it may be necessary to move non HPB system components such as the air tank in order to access the HPB part If this is necessary refer to the vehicle manufacturer s manual for inf
108. can result NOTE Before installation the replacement HCU must be fitted with the HCU reservoir Refer to the HCU reservoir installation information in this section NOTE Meritor WABCO recommends that you install the replacement HCU in the same location as the old one 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 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 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 32 34 ft lb 43 46 3 Attach the two mounting brackets to the frame rail of the vehicle Tighten the nuts to 79 7 99 6 ft Ib 108 135 Nem 4 Removal and Installation 4 Connect the brake lines Remove the protective cover before attaching the line Check the line markers to ensure correct installation on the HCU Figure 4 6 and Figure 4 7 e Four lines leading to the wheel ends e wo lines leading to the master cylinder e One line leading to the parking brake if equipp
109. cement ECU CAUTION Excessive force in positioning the ECU onto the HCU will damage the ECU housing Do not force the ECU into position Use a gentle even pressure when positioning the ECU Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Position the ECU onto the HCU valves Apply gentle pressure to seat the ECU Motor connectors must achieve full depth into the housing The gap between the HCU and ECU must not exceed 0 08 inch 2 mm Figure 4 22 4004455a Figure 4 22 Use a 4 mm Allen wrench to tighten the four mounting screws that attach the ECU to the HCU Tighten to 14 in Ib 1 5 Nem Do not exceed this torque The metal sleeves on the ECU housing must rest flat on the body of the HCU Tighten the screws using the correct sequence Figure 4 23 4 E gt ONG N ZING KR e 4004452 4 When the ECU is correctly installed with the metal sleeves on the HCU tighten the bolts to 21 30 in Ib 2 5 3 5 WARNING Electrical connectors must be correctly installed with the latch pushed in to lock the connection to prevent them from coming loose or disconnecting Failure to securely connect and correctly latch the connectors could result in loss of braking functions during vehicle operation Serious personal injury can result 5 Attach the 31 pin harness and then the two pin power connector to the ECU Pu
110. cuit 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 The HCU generates the service brake pressure Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 1 Introduction Two pump motors drive the piston pumps to build hydraulic pressure The pressure 15 stored in accumulators The motors are not serviceable The motors cannot be replaced without replacing the entire HCU The accumulators are two gas filled hydraulic accumulators The accumulators store energy supplied by the pumps Accumulators are sealed at the factory and are non refillable Accumulators may be replaced as a set without replacing the entire HCU The ECU processes sensor signals and generates solenoid valve commands to reduce maintain or increase brake pressure for control function The ECU constantly monitors the pressure in the accumulators using one pressure sensor per brake circuit The ECU may be replaced without replacing the complete HCU The optional pressure supply valve controls the Spring Applied Hydraulic Released SAHR parking brake The pressure supply valve is mounted on the HCU The pressure supply valve may be replaced without replacing the entire HCU The dual circuit HCU reservoir holds the hydraulic brake fluid The reservoir ma
111. d by exposure to air it is necessary to bleed the affected circuit Refer to the appropriate section in this manual With Pressure Applied If there was no evidence of a leak when the system was checked with the pressure removed apply pressure to the system and recheck for leaks Two people are required to perform this check 1 With the vehicle parked level surface depress the brake pedal and hold to deliver brake pressure to the calipers Inspect the entire hydraulic brake system including brake lines and line fitting connections for the presence of brake fluid damage or other evidence of a leak e 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 6 Appendix 3 If the hydraulic system is compromised by exposure to air it is necessary to bleed the affected circuit Refer to the appropriate section in this manual System Test After all necessary repairs have been made and the system has been bled verify the hydraulic circuits are connected correctly Two people are required to perform this test 1 2 Park the vehicle on a level surface Block the front tires to keep the vehicle from moving Failure to do so can result in unwanted vehicle movement causing serious personal injury Raise the rear wheels Place s
112. e Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 Removal and Installation Attach a pinch clamp to the low pressure hose at the HCU reservoir Figure 4 54 NOTE Be careful not to damage the HCU reservoir inlet when attaching the pinch clamp If damaged it will need to be replaced 40051 43a Figure 4 54 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 fluid Unscrew the black plastic nut by hand from the pressure supply valve Remove the coil and O ring Figure 4 55 ELECTRICAL CONNECTOR COIL VALVE O RING BODY PLASTIC NUT 4004854a Figure 4 55 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 PARKING BRAKE VALVE BODY NOTE Do not use a 17 mm wrench to remove the pressure supply valve The Snap On Tool specified in Step 10 must be used Use a socket Snap On Tools part number A121 to remove the pressure supply valve from the hydraulic compact unit Figure 4 56 TO REAR BRAKE CIRCUIT TO PARKING BRAKE SAHR CIRCUIT i J TO REAR BRAKE CIRCUIT BLEEDERS 4004853a FROM MASTER CYLINDER Figure 4 56 Plug the open port to prevent contaminants from entering the System Verify the warranty status If the pressure supply valve is under warranty return it to Meritor WABCO Installation Parking Brake
113. e 3 7 NOTE The status bar on the HPB Main Menu reflects the current AIC status enabled disabled or not available Miscellaneous Outputs select Miscellaneous Outputs to display the Activate Miscellaneous Outputs test screen Figure 3 13 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 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 13 3 Troubleshooting and Testing Actuate Miscellaneous Output Output Selection ABS Lamp Buzzer ATC Lamp Supply Valve Brake Warning Lamp C Valve Pump Frant Parking Brake Failure Lamp Pump Rear Brake Light Relay 40051428 Figure 3 13 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 Highlight the component you wish to test then select the Send button to actuate the component Component activation status appears in the Status Box field Select Close to exit this screen Reset Memorized select Reset Memorized to display the Learned Component screen Figure 3 14 Component W Relay 4004471 Figure 3 14 Relay is an automatic default and cannot be de selected It indicates the ECU has memorized the installed retarder relay Once the ECU has seen r
114. e HCU also supplies the energy to release and control the service and park brakes The Meritor WABCO HPB system for trucks is illustrated in Figure 1 8 A complete HPB system layout with hydraulic brake lines appears in the Appendix Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 1 Introduction HPB SYSTEM LAYOUT HCU RESERVOIR MASTER CYLINDER RESERVOIR HCU ASSEMBLY m PRESSURE SUPPLY VALVE E ud E LN eer Ly MASTER ACCUMULATORS 2 CYLINDER ASSEMBLY Figure 1 8 Functional Description Hydraulic energy is stored in the gas filled hydraulic accumulators one for each circuit When the vehicle s ignition is turned on internal pumps are activated and fill both accumulators with pressurized hydraulic brake fluid Two internal sensors one for each accumulator measure pressure and the ECU continuously monitors and controls pressure During normal operation the ECU actuates two separate power drivers for the electric motors keeping the pressure level within the system at desired limits Two pressure relief valves provide safety against overpressurization 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 4 Meri
115. e caliper circuit bleeding procedure and the SAHR circuit bleeding procedure if applicable in this section Brake Fluid Replacement Requirement For the correct functioning of the ABS seals and components Meritor WABCO recommends replacing brake fluid every two 2 years on all vehicles equipped with Meritor WABCO HPB system This is done to minimize exposure to contaminated brake fluid To replace the brake fluid please follow the instructions indicated under the Changing Hydraulic Brake Fluid section of this manual NOTE While changing the brake fluid according to instructions provided in this manual please read and observe all Warning and Caution hazard alert messages published onwards from Page 52 under Section 5 apart from those published below Filling the Hydraulic Power Brake HPB Master Cylinder Reservoir WARNING Before you service the Hydraulic Power Brake HPB system you must perform the depressurization procedures exactly as presented The HPB system is a pressurized system that reaches levels of up to 2 320 psi 160 bar This pressure is not reduced by switching the ignition off or removing battery power If you do not depressurize the system serious personal injury or death can result Never add fluid above the MAX mark regardless of the charging state of the accumulators When the system is totally or partially depressurized during service or overnight parking fluid stored in the accumulators 15 re
116. e master cylinder and master cylinder reservoir Apply the brake pedal a minimum of 30 times to decrease pressure in the system ensure the system 15 depressurized perform the following check on both the front and rear axles A Remove the protective cover from the end of the bleeder fitting on one brake caliper B Attach a bleeder bottle hose to the bleeder fitting at the wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake fluid C Use a wrench to open the bleeder fitting screw to the torque value specified by the component manufacturer Figure 4 45 ass E 0 TZ 4004437 Figure 4 45 D Apply and hold the brake pedal down until no more brake fluid runs out Do not release the brake pedal Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 E With the brake pedal still applied use a torque wrench to tighten the bleeder fitting screw Repeat Steps A E for the second axle Attach a pinch clamp to the low pressure hose near the outlet to the master cylinder reservoir Do not damage the reservoir outlet Figure 4 46 NOTE Be careful not to damage the HCU reservoir outlet when attaching the pinch clamp If damaged it will need to be replaced MASTER CYLINDER RESERVOIR LOW PRESSURE HOSE TO HCU RESERVOIR BRAKE TUBES TO HCU ASSEMBLY 40049758 Figure 4 46 10 To help
117. ed TO REAR BRAKE CIRCUIT PARKING BRAKE SAHR CIRCUIT D PARKING BRAKE PRESSURE SUPPLY VALVE BLEEDERS FROM MASTER CYLINDER 4004441a Figure 4 6 TO FRONT 40044428 Figure 4 7 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 53 4 Removal and Installation 5 Connect the low pressure hose from the master cylinder 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 WARNING Electrical connectors must be correctly installed with the latch pushed in to lock the connection to prevent them from coming loose or disconnecting Failure to securely connect and correctly latch the connectors could result in loss of braking functions during vehicle operation Seriou
118. eels to prevent the vehicle from moving Failure to do so can result in unwanted vehicle movement Causing serious personal injury 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 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 Deplete pressure in the accumulators There are two ways of depressurizing the system as follows A Fully depress the brake pedal a minimum of 30 times The pressure in each brake circuit can be monitored using the TOOLBOX M Software Ensure that the pressure in each accumulator is at O psi B While fully depressing the brake pedal select the Deplete Accumulators function from the TOOLBOX Software EOL pull down menu The pedal must remain fully depressed during the entire process until the TOOLBOX Software displays the completion message Ensure that the pressure in both accumulators is reading zero on the diagnostic main screen then release the brake pedal Turn the ignition OFF 10 11 12 13 14 15 16 17 5 Brake Bleeding Procedures Verify that the brake fluid level in the master cylinder reservoir is not below MAX level NOTE During bleeding procedures brake fluid level must not be allowed to fall below the MIN
119. een 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 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Leak Check Procedure Meritor WABCO HPB System Check the HPB System for Brake Fluid Leaks With Pressure Removed 1 Park the vehicle a level surface For vehicles with manual parking brakes apply the parking brake Block the wheels to keep the vehicle from moving Failure to do so can result in unwanted vehicle movement causing serious personal injury Deplete system pressure Refer to the appropriate section in this manual for instructions Inspect the entire hydraulic brake system including brake lines and line fitting connections for the presence of brake fluid damage or other evidence of a leak e lf leak is identified perform the following A Clean and dry the entire area B Determine the source of the leak C Make the necessary repairs If the hydraulic system is compromise
120. effects of hydraulic brake fluid C Use a wrench to open the bleeder fitting screw Figure 4 1 SZ 0 TZ 400443 7 Figure 4 1 D Apply and hold the brake pedal down until no more brake fluid runs out Do not release the brake pedal E With the brake pedal still applied use a torque wrench to tighten the bleeder fitting screw to the torque value specified by the component manufacturer Repeat Steps A E for the second axle NOTE Be careful not to damage the HCU reservoir inlet when attaching the pinch clamp If damaged it will need to be replaced 5 4 Removal and Installation Attach hose clamp pliers to the low pressure hose at the HCU reservoir inlet Clamp the rubber hose at least 3 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 2 Do not damage the reservoir inlet LOW PRESSURE HCU RESERVOIR 4004438a Figure 4 2 10 11 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 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 fluid Disconnect the low pressure hose from the HCU reservoir Plug both the
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122. en 0 HOUS ynon uedo punog 0111045 uonduosoeg 40119328 Figure 3 26 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing seu eieoipur Aew sjsisiod OLA JI 359 peo spuno pue 193 Ie Y29349 5 JI 5 0150109 JO enjsiouJ sewep Aue 193 P dsu pue peje seu ereoipur sjsisiod OLA 359 spuno pue 123 Ie Y29349 5 JI 5 0180109 JO eJnjsiouJ sewep us Aue s1012euuO0 193 129 5 pue peje seu ereoipur sjsisiod OLA se1 spuno4D pue 123 Ie Y29349 Jess929u JI 5 uoisoJ109 JO eJnjsiouJ eDeuiep Aue s10128uuO9 193 198dsur pue 1 euuoosiq seu eieoipur sjsisiod OLA 4l se1 pue 123 Ie yOeuD 5 JI ue9j o uoisoJ109 JO eunjsiouJ eDeuiep Aue 10 193 198dsui pue 19euuoosiq snjels HHVS 6261 due Jojeoipu peseejaJ 440
123. enance Manual 0401 Revised 07 15 3 Troubleshooting and Testing 5 5 uaaa 1n990 ABW uonipuoo ui Josues usnd pue deb yOouyD 5 105095 99 1021000 JO S10128uuoo pue Josues pue eouepeduul 10595 x99u2 uoisou100 euo 2945 6 Ul 4oeq Josues usnd pue def osneo INO euo pue Buueeq xy99u2 20 1 uoui 0p0 0 uey eq 1ou pjnous deb au deb euoj pue Buueeq 2949 UoisoJJ02 u199 Buissiu eDeuep euo 2949 Suluo 0002 006 ueewjeq einseeui pjnous eouejsiseJ JOSUBS punoJ6 Oys JO uedo JO 105095 Jo pue sseuJeu 5 1921009 JO pue Josues pue eouepeduul J0sues Y29049 pejoelep Jeuuouqy sJeneuo Jo pejoelep 1ou eufiis 105095 peeds JeauM ud 01 uey speeds ye Ajjeoipoued sdoup peeds Josues peeds pojoeuuoosip e SIo9jep N94 9 ueeq seu puno4D 11045 JO uedo uy 51815 HHVS Buip4oooe 6261 due Jojeoipu Bured peigesiq pe
124. er cylinder assembly when replacing the reservoir e Two people are needed to perform this procedure e n some vehicles it may be necessary to move non HPB system components such as the air tank in order to access the HPB part If this is necessary refer to the vehicle manufacturer s manual for information before moving the component e Bleeding the master cylinder circuit is required during installation of the master cylinder reservoir Bleed procedures appear in section 5 of this manual e After installing HPB components or making system repairs use TOOLBOX M Software to remove the error code from the ECU memory Instructions for using TOOLBOX Software appear in section 3 of this manual WARNING Park the vehicle on a level surface For vehicles with manual parking brakes apply the parking brakes Block the front and rear tires to prevent vehicle movement Failure to do so can result in unwanted vehicle movement causing serious personal injury 1 Parkthe vehicle on a level surface For vehicles with manual parking brakes apply the parking brakes Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 75 4 Removal and Installation Block the front and rear tires to prevent vehicle movement Failure to do so can result in unwanted vehicle movement Causing serious personal injury Remove the two maxi fuses for the pump motors or disconnect the battery Use clean rag to carefully clean the outside of th
125. er screw to the torque value specified by the component manufacturer NOTE Refer to the vehicle manufacturer s specifications for specific information about bleeding the calipers Some calipers have multiple bleeder screws and require removal of the wheels and tires to access the bleeder screws Each bleeder screw must be bled NOTE Verify the fluid level in the master cylinder reservoir During bleeding procedures the brake fluid must not be allowed to fall below the MIN mark on the master cylinder reservoir The master cylinder reservoir should be regularly checked during the bleeding procedures and filled to the MAX mark Repeat Steps 9 13 with the other calipers in the specified order Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 5 Brake Bleeding Procedures 15 If the vehicle is equipped with a power parking brake canister then bleed the SAHR circuit now using Steps 9 13 of the Spring Applied Hydraulic Release SAHR Parking Brake Circuit pressure bleed procedure in this section 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 or below the MAX mark remove or add fluid as necessary until the MAX mark level is achieved Never add fluid above the MAX mark Refer to Section 5 for detailed instructions on how to correctly fill the master cylinder reservoir 17 Install the two 30 amp pump motor fuses and turn the ignit
126. er the inboard bleeder Insert the other end of the tubing into a container to collect the purged brake fluid Discard the brake fluid Do not reuse old brake fluid 4 pressurized bleeding system is not required by the vehicle manufacturer s service procedures apply and hold the brakes to pressurize the system Repeat the procedure for the outboard bleed screw Repeat the procedure for the inboard bleed screw Tighten the bleed screws to specification Refer to Section 8 peo Ww dO OM Test the brakes prior to returning the vehicle to service Spring Applied Hydraulic Release Parking Brake Circuit WARNING Before bleeding the circuit you must disconnect the parking brake cable from the spring applied hydraulic release SAHR canister This is to ensure that the SAHR piston achieves the 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 The parking brake cable must be reconnected before operating the vehicle Never drive the vehicle if the parking brake cable is disconnected or 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 1 Park the vehicle on level surface Apply the parking brake and block the wh
127. eritor WABCO Maintenance Manual MM 0401 Revised 07 15 Quadraulic Brake Caliper Bleeding Procedure This bleed sequence refers to bleeding the caliper and does not consider the hydraulic application system requirements Identify your vehicle hydraulic application system type and refer to that service manual before you perform any brake service You must adhere to the hydraulic application system bleeding procedures to prevent death serious personal injury or damage to components NOTE If you are bleeding the front calipers it is critical that you bleed the SAHR circuit also if equipped Refer to the manufacturer s service information for ABS bleeding instructions 1 Checkthe master oylinder reservoir and fill if necessary with DOT 3 or DOT 4 brake fluid 2 Bleed the brakes in the following order right rear left rear right front and left front 4 amp CAUTION When you bleed a four piston caliper monitor the brake fluid level to ensure you do not drain the system Add brake fluid to the reservoir as needed to prevent damage to components during operation Always install new brake fluid into the caliper Discard old brake fluid Do not reuse it Damage to components can result NOTE Each four piston caliper is equipped with two bleed screws To ensure air is removed from a caliper the bleed sequence is inboard outboard and repeat inboard 3 Install a section of clear flexible tubing with a 1 4 inch inner diameter ov
128. etarder it expects to see it every time the vehicle is powered up Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 standard Testing Test Equipment Volt Ohm Meter VOM Use of a VOM with automatic polarity sensing 15 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 that exceeds 16 Failure to do so may cause reduced braking force and result in serious personal injury Calculate the tire size with the following equation RPM Steer RPM Drive RPM tire revolutions per mile Difference 1 x 100 Checking Power Ground and Load Test CAUTION When troubleshooting or testing the ABS be careful not to 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 ECU circuits 1 15 recommended to check all the power and ground circuits as there are redundant powers and grounds Disconnect the 2 pin and 31 pin connectors and verify all the lock tabs are there and good check for any signs of damage moisture or corrosion Ground Checks Check all the ground wire circuits with the key off discon
129. fer to the vehicle manufacturer for specific installation and service information The following removal and installation procedures are included to assist you in servicing Meritor WABCO s HPB system 1 Park the vehicle on a level surface WARNING WARNING Block the front and rear tires to prevent the vehicle from moving Unwanted vehicle movement can result in serious personal injury 2 Block the front and rear tires to prevent vehicle movement 3 Disconnect the battery 4 Use a clean rag to carefully wipe the surface of the and the master cylinder reservoir 5 Apply the brake pedal a minimum of 30 times to decrease pressure in the system To ensure the system is depressurized perform the following check on both the front and rear axles A Remove the protective cover from the end of the bleeder fitting on one brake caliper B Attach a bleeder bottle hose to the bleeder fitting at the wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake fluid C Use a wrench to open the bleeder fitting screw Figure 4 60 4 Removal and Installation EI TZ 40044378 Figure 4 60 D Apply and hold the brake pedal down until no more brake fluid runs out Do not release the brake pedal E With the brake pedal still applied use a torque wrench to tighten the bleeder fitting screw to the tor
130. for use with asbestos when grinding or machining brake linings In addition do such work in an area with 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 filter when cleaning brake parts or assemblies NEVER use carcinogenic solvents flammable 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 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 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 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 vacuum work clothes after they are worn Launder them separately Do not shake or use compressed air to remove dust from work clothes 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 disposal Regulatory Guidance References to OSHA NIOSH MSHA and EPA which are regulatory agencies in the Un
131. h drill bit to slowly and carefully drill approximately 1 2 inch 12 7 mm into the accumulator Figure 4 16 Center punch prior to drilling WELDED Lee SEAM THREADED PORT 4004451a Figure 4 16 D After releasing the internal pressure correctly dispose of the accumulator Repeat Steps A D to depressurize the second accumulator Installation HCU Accumulators WARNING Failure to bleed the system whenever any hydraulic system fitting is loosened or disconnected will allow air to remain in the system This will prevent the hydraulic pressure in the brake system from rising enough to apply the brakes correctly This will cause the stopping distance to increase and can result in serious personal injury Correctly discard hydraulic brake fluid that is removed from 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 CAUTION Hydrauli
132. he associated steps performed in the order presented Hydraulic brake fluid is a caustic substance Contact with the hydraulic brake fluid can cause skin irritation Do not let 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 NOTE The following general guidelines are provided to facilitate the Safe removal of the accumulators from the HPB Accumulators are precharged with gas pressure to 1087 psi and have a limited shelf life When replacing an accumulator note and record the expiration date of the replacement accumulator Used accumulators must be depressurized before disposal Follow Steps 10A 10D to perform this procedure Meritor WABCO recommends replacing both accumulators at the same time It is not necessary to remove the entire HCU to replace the accumulators Replacing the accumulators does not require any brake bleed procedures Accumulators still under warranty must be returned without depressurizing Drilling accumulators will void the warranty Two people are needed to perform this procedure After installing HBP components or making system repairs use TOOLBOX M Software to remove the error code from the ECU memory Instructions for using TOOLBOX Software appear in section 3 of this manual Park the vehicle on a level surface For vehicle
133. hing or a vacuum not equipped with a HEPA filter when cleaning brake parts or assemblies NEVER use carcinogenic solvents flammable solvents or solvents that can damage brake components as wetting agents 4 leaning 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 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 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 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 compressed air to remove dust from work clothes 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 disposal Regulatory Guidance 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 Employers and workers employed outside of the United States should consult the regulations that apply to the
134. id to use Brake Bleeding Procedures The pressure assisted brake bleeding procedures described here may be used with any fill and bleed equipment capable of filling the system and creating pressure in the master cylinder reservoir WARNING Meritor WABCO does not approve using manual bleeding procedures Manual bleeding procedures could result in loss of braking resulting in serious personal injury Pressure Bleed Procedures Master Cylinder Circuit 1 Parkthe vehicle on a level surface Apply the parking brake and block the wheels to prevent the vehicle from moving Failure to do so can result in unwanted vehicle movement causing serious personal injury 2 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 5 Brake Bleeding Procedures A Fully depress the brake pedal a minimum of 30 times The pressure in each brake circuit can be monitored using the TOOLBOX M Software Ensure that the pressure in each accumulator is at O psi B While fully depressing the brake pedal select the Deplete Accumulators function from
135. in into the container Remove the cap from the master cylinder reservoir to improve the draining process Plug the low pressure hose to prevent system contamination Figure 4 38 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 m 4 Removal and Installation MASTER CYLINDER RESERVOIR BRAKE TUBES TO HCU LOW PRESSURE ASSEMBLY HOSE TO HCU RESERVOIR 4004976 Figure 4 38 NOTE Some brake fluid may remain in protected areas of the master cylinder reservoir 11 When the reservoir is empty replace the cap on the master cylinder reservoir and plug the reservoir outlet to prevent any excess fluid from spilling during removal 12 Disconnect the two brake tubes from the master cylinder Plug the brake tubes and the master cylinder ports to protect them from contamination Figure 4 39 72 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 PORT PLUGS MASTER CYLINDER RESERVOIR BRAKE TUBES TO HCU ASSEMBLY 40049778 Figure 4 39 13 Disconnect the master cylinder pushrod clevis pin from the brake pedal Figure 4 40 COTTER PIN PUSHROD CLEVIS PIN CLEVIS 40049798 Figure 4 40 14 15 16 Loosen and remove the two bolts that hold the master cylinder assembly to the bracket on the fire wall Remove the master cylinder and master cylinder reservoir assembly from the vehicle If the master cylinder reservoir is undamaged and is going to be reused follow these steps
136. in Ib 3 4 Nem Figure 4 51 MASTER 17 CYLINDER F r MOUNTING FOOT BRAKE p SCREWS SWITCH 4008215b Figure 4 51 3 Connect the foot brake switch 4 Remove the safety stands and wheel blocks 5 lest drive the vehicle Refer to the test drive procedure in oection 3 of this manual Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Removal Master Cylinder Fluid Level Sensor 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 Apply the parking brake and block the wheels 2 3 Remove the electrical connector from the fluid level sensor 4 oqueeze the tabs together to remove the fluid level sensor from its mounting location on the master cylinder reservoir 5 Verify the warranty status If the switch is under warranty return it to Meritor WABCO Installation Master Cylinder Fluid Level Sensor 1 Install the fluid level sensor in the same direction as the switch you removed Figure 4 52 FILL CAP FLUID LEVEL SENSOR CONNECTOR RESERVOIR RESERVOIR MASTER MOUNTING CYLINDER NUT BODY 40051458 Figure 4 52 2 Connect the fluid level sensor connector 3 Remove the safety stands and wheel bloc
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138. ing at the wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake fluid C Use a wrench to open the bleeder fitting screw Figure 4 36 EI E eg gt T 40044378 Figure 4 36 D Apply and hold the brake pedal down until no more brake fluid runs out Do not release the brake pedal E With the brake pedal still applied use a torque wrench to tighten the bleeder fitting screw to the torque value specified by the component manufacturer Repeat Steps A E for the second axle Attach a pinch clamp to the low pressure hose near the outlet of the master cylinder reservoir Do not damage the reservoir outlet Figure 4 37 NOTE Be careful not to damage the HCU reservoir outlet when attaching the pinch clamp If damaged it will need to be replaced 4 Removal and Installation MASTER CYLINDER RESERVOIR LOW PRESSURE HOSE TO HCU RESERVOIR BRAKE TUBES TO HCU ASSEMBLY 4004975 Figure 4 37 10 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 fluid Remove the hose clamp 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 dra
139. ion 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 18 Release the pressure from the master cylinder reservoir 19 Remove the bleed equipment 20 Install the master cylinder reservoir cap 21 Using the diagnostic laptop and the TOOLBOX program while fully holding the brake pedal depressed select the Deplete Accumulators function from the TOOLBOX M Software EOL pull down menu The pedal must remain fully depressed during the entire process until the TOOLBOX Software displays the dialog box that will indicate the completion of the function Ensure that the pressure in both accumulators is reading zero on the diagnostic main screen then release the brake pedal NOTE Ihe DEPLETE ACCUMULATORS function performs a cycle of releasing the pressure and charging the pressure back up in each brake circuit This cycle helps clear air from the HCU into the reservoir 22 Repeat Step 21 two times 23 Using the diagnostic laptop and the TOOLBOX M Software program clear all the inactive fault codes NOTE If faults remain they should be diagnosed prior to releasing the vehicle to service 24 urn ignition OFF and disconnect the diagnostic laptop from the diagnostic connector 25 Check the system for external leaks 26 Remove wheel blocks M
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141. ious and possibly fatal diseases including asbestosis a chronic lung disease and cancer principally lung cancer and mesothelioma a cancer of the lining of the chest or abdominal cavities Some studies show that the risk of lung cancer among persons who smoke and who are exposed to asbestos is much greater than the risk for non smokers Symptoms of these diseases may not become apparent for 15 20 or more years after the first exposure to asbestos 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 employer for more details 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 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 allowable exposure levels will eliminate the risk of disease that can result from inhaling asbestos dust OSHA requires that the following sign be posted at the entrance to areas where exposures exceed either of the maximum allowable levels DANGER ASBESTOS CANCER AND LUNG DISEASE HAZARD AUTHORIZED PERSONNEL ONLY RESPIRATORS AND PROTECTIVE CLOTHING ARE REQUIRED IN THIS AREA 2 Respir
142. iplex Vehicles Select Relay to display the Activate Relay test screen Figure 3 11 a Activate Relay Turn Hetarder Relay On E E E E E T T E E a E E 4004467 Figure 3 11 This screen allows you to turn the retarder relay on or off This 15 helpful in verifying correct operation installation and wiring of the unit under test Select Close to exit this screen Engine Data Link select Engine Data Link to display the Data Link test screen Figure 3 12 3 Troubleshooting and Testing Data Link S elect Destination Enape Retarder 40044688 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 automatic traction control This is the normal state of the ECU Figur
143. iplexed Vehicles HPB Connector Diagram for Non Multiplexed Vehicles Section 3 Troubleshooting and Testing Testing the System Meritor WABCO TOOLBOX Software Connecting TOOLBOX M Software Hydraulic Power Brake Menus and Toolbars otandard Testing Test Equipment Volt Ohm Meter VOM oystem Requirements and Component Tests Tire Size Range Checking Power Ground and Load Test otandard Component Testing Indicator Lamps oensor Adjustment Vehicle Test Drive oafety Features Towing Procedure for Navistar CE Buses Warning Lamps SPN SID FMI Diagnostic Trouble Code List Section 4 Removal and Installation Removal Hydraulic Compact Unit Installation Hydraulic Compact Unit Removal HCU Reservoir Installation HCU Reservoir Removal HCU Accumulators Installation HCU Accumulators Removal Electronic Control Unit ECU Installation Electronic Control Unit ECU Parameter Downloading pg 66 67 68 69 70 13 19 11 79 80 81 83 85 86 87 88 89 90 91 Contents Removal Hydraulic Compact Unit HCU Relay Valve Installation Hydraulic Compact Unit HCU Relay Valve Removal Hydraulic Compact Unit HCU Pump Installation Hydraulic Compact Unit HCU Pump Removal Master Cylinder Replacement Information Master Cylinder Installation Master Cylinder Removal Master Cylinder Reservoir Installation Master Cylinder Reservoir Removal Master Cylinder Foot Brake Switch Installation M
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145. ir only reusing master cylinder Replacement kits specific to each of these three replacements are available from Meritor WABCO Make sure the replacement kit 15 available before you begin the removal If the current reservoir is to be reused you will need to be careful when removing the master cylinder and reservoir assembly from the vehicle and when you separate the components If the reservoir is damaged in any way it is not reusable e The master cylinder replacement kit contains a master cylinder travel switch grommets and roll pins It does not include the master cylinder reservoir e The master cylinder reservoir replacement kit contains a master cylinder reservoir with a fluid level switch and four rubber grommets Master Cylinder 4 amp CAUTION To avoid damage to the system while working on the brake system do not apply the foot pedal unless instructed to do so e Two people are needed to perform this procedure e n some vehicles it may be necessary to move non HPB system components such as the air tank in order to access the HPB part If this is necessary refer to the vehicle manufacturer s manual for information before moving the component e Dleeding the master oylinder circuit is required during installation of the master cylinder Bleed procedures appear in Section 5 of this manual e After installing HPB components or making system repairs use TOOLBOX M Software to remove the error code from the ECU me
146. ited 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 apply to them for further guidance Asbestos and Non Asbestos Fibers NON ASBESTOS FIBERS WARNING The following procedures for servicing brakes are recommended to reduce exposure to non asbestos fiber dust a cancer and lung disease hazard Material Safety Data Sheets are available from Meritor Hazard Summary Most recently manufactured brake linings do not contain asbestos fibers These brake linings may contain one or more of a variety of ingredients including glass fibers mineral wool aramid fibers 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 silicosis a non cancerous lung disease Silicosis gradually reduces lung capacity and efficiency and can result in serious breathing difficulty Some scientists believe other types of non asbestos fibers when inhaled can cause similar diseases of the lung In addition silica dust and ceramic fiber dust are known to the State of California to cause lung cancer U S and international agencies have also determined that dust from mineral wool ceramic fibers and silica are potential causes of cancer Accordingly workers
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148. ks 4 Removal and Installation 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 Apply the brake pedal a minimum of 30 times to decrease pressure in the system To ensure that the system 15 depressurized perform the following check on both the front and rear axles WARNING The full power brake system is a pressurized system that achieves pressures of up to 2320 psi This pressure is not reduced by switching the ignition off or removing battery power Prior to servicing this system the depressurization procedures must be performed exactly as presented Failure to depressurize the system may result in personal injury or death Parking Brake Pressure Supply Valve Remove the protective cover from the end of the bleeder fitting on one brake caliper B Attach a bleeder bottle hose to the bleeder fitting at the wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake fluid C Useawrench to open the bleeder fitting screw to the torque value specified by the component manufacturer Figure 4 53 NOTE It is not necessary to remove the entire HCU assembly from the vehicle when replacing the parking brake valve e Two people are needed to perform this procedure e n some vehicles it may be necessary to m
149. l injury and damage to components can result Failure to bleed the system whenever any hydraulic system fitting is loosened or disconnected will allow air to remain in the system This will prevent the hydraulic pressure in the brake system from rising enough to apply the brakes correctly This will cause the stopping distance to increase and can result in serious personal injury 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 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 Do not let the brake master cylinder fluid get below the minimum level during the bleeding operation Keep the master cylinder reservoir filled with new DOT approved brake fluid as specified by the original equipment manufacturer Failure to keep the brake reservoir level above minimum could result in more air entering system making it impossible to effectively bleed the system Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Never add fluid above the MAX mark on the
150. m for further guidance Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 1 Overview Meritor WABCO s Hydraulic Power Brake HPB is a braking and vehicle control system for Business Class trucks Classes 4 through 7 and buses that are equipped with hydraulic brakes The HPB system provides the following functions Full power brake performance Brake control functions including Anti Lock Braking System ABS Automatic Traction Control ATC and Electronic Brake force Distribution EBD e Optional parking brake control System Components The HPB system consists of two main components the Hydraulic Compact Unit and a dual circuit master cylinder The HPB system is also available with an optional parking brake pressure supply valve Figure 1 1 and Figure 1 2 illustrate the HPB system with and without the park brake supply valve Figure 1 3 illustrates the master cylinder assembly HCU WITHOUT OPTIONAL POWER PARKING BRAKE SUPPLY VALVE Figure 1 1 1 Introduction HCU WITH OPTIONAL POWER PARKING BRAKE PRESSURE SUPPLY VALVE PRESSURE SUPPLY 4004474 Figure 1 2 MASTER CYLINDER ASSEMBLY 4004475 Figure 1 3 Hydraulic Compact Unit The HCU consists of an electronic control unit two independent electric motors driving two piston pumps two accumulators a dual circuit fluid reservoir with integrated filters pressure relief valves solenoid valves and a dual cir
151. mory Instructions for using TOOLBOX Software appear in section 3 of this manual Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 NOTE Removing the master cylinder involves removing the master cylinder reservoir If the old reservoir is going to be installed onto the new master cylinder care must be taken during the removal process not to damage the reservoir Do not install a damaged reservoir 1 Parkthe vehicle on a level surface For vehicles with manual parking brakes apply the parking brakes 2 Block the front and rear tires to prevent vehicle movement Failure to do so can result in unwanted vehicle movement causing serious personal injury 3 Disconnect the battery Use a clean rag to carefully clean the outside of the master cylinder and master cylinder reservoir NOTE Both the foot brake switch and the fluid level sensor switch can be replaced without draining the brake fluid If you are replacing either of these switches follow the procedures given in this manual 5 Disconnect the foot brake switch on the master cylinder and the fluid level switch on the master cylinder reservoir 6 Apply the brake pedal a minimum of 30 times to decrease pressure in the system To ensure the system is depressurized perform the following check on both the front and rear axles A Remove the protective cover from the end of the bleeder fitting on one brake caliper B Attach a bleeder bottle hose to the bleeder fitt
152. 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 your employer for more details 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 2 Respiratory Protection OSHA has set a maximum allowable level of exposure for silica of 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 kept below 1 0 f cc as an 8 hour time weighted average Scientists disagree however to what extent adherence to these maximum allowable exposure levels will eliminate the risk of disease that can result from inhaling non asbestos dust Therefore wear respiratory protection at all times during brake servicing beginning with the removal of the wheels Wear a respirator equipped with a high efficiency HEPA filter approved by NIOSH or MSHA if the exposure levels may exceed OSHA or manufacturers recommended 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 3 Procedures for Servicing Brakes a Enclose the brake assembly within a negative pressure enclosure The enclosure should
153. nd remove the hose from the HCU Remove the P clamps and remove the hose from the vehicle Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Installation Low Pressure Hose e When replacing the low pressure hose bleeding the system is not necessary e helo prevent contamination of the system keep the hose ends sealed until you are ready to connect them Remove the plug from the HCU reservoir 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 location as was used for the original installation Attach the new hose to the HCU reservoir and master cylinder reservoir Reuse the P clamps to attach the middle portion of the hose to the vehicle frame Make sure the new hose does not contact any sharp edges or hot components Fill the master cylinder reservoir with new brake fluid from a sealed container The fluid level must be at the MAX mark Use DOT 3 or DOT 4 hydraulic brake fluid Refer to the vehicle specification sheet to determine which fluid to use Connect the battery Turn the ignition ON The HCU pump motors will start up and fill the accumulators Approximate running time is 45 seconds Turn the ignition OFF and disconnect the battery Apply the brake pedal a minimum of 30 times to decrease pressure in the system This will purge any trapped air from the hose After
154. nder a vehicle supported only by jacks Jacks can slip and fall over Serious personal injury and damage to components can result Apply the parking brake Block the front tires to prevent vehicle movement Raise the rear tires off the ground Place safety stands under the axle 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 Remove the sensor from the mounting block in the axle housing Use a twisting motion if necessary Do not pull on the cable Disconnect the sensor cable from the chassis harness Remove the sensor cable from any cable clamps or clips Remove the sensor spring clip from the sensor bracket 4 Removal and Installation NOTE When replacing the wheel speed sensor the sensor spring clip must also be replaced Installation Rear Axle Wheel Speed Sensor Connect the new sensor cable to the chassis harness 2 Apply a Meritor 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 4 Apply a Meritor WABCO recommended lubricant to the sensor 5 Push the sensor completely into the 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
155. nect the 2 pin and 31 pin connectors and in the 2 pin harness connector check resistance to ground pin 1 and in the 31 pin harness connector check resistance to ground pins 6 18 19 All readings should be less than 1 ohm if the readings are not in spec may need to review wiring diagnostics and repair with the OEM Voltage Checks Check all the power wire circuits with the key off disconnect the 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 voltage to ground pins 1 16 17 All readings should be approximately 12 volts except pin 17 There should be no voltage key off With the key on recheck voltage at pin 2 of the 2 pin 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 may need to review wiring diagnostics and repair with the OEM Load Test compromised wire or circuit may still be able to provide resistance and voltage readings that would be within specification for a Digital Volt Ohm Meter or test light but might not be capable of handling enough current to allow the system to function correctly make sure of the integrity of the wire or circuit a load test is necessary With the key on load test across pins 1 2 of the 2 pin harness connector and pins 1 6 16 18 17 19 of the 31 pin harness connector with a device that will draw about 5 amps such as a se
156. nectors 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 52 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 31 PIN HARNESS 2 PIN POWER Figure 4 4 NOTE space does not permit removing the HCU with the mounting brackets attached skip Step 15 and proceed to Step 16 While supporting the HCU loosen and remove the four nuts 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 FRAME RAIL MOUNTING BRACKETS 40044408 Figure 4 5 16 Loosen and remove the two bolts that hold the HCU to the front mounting bracket Then loosen and remove the two bolts that hold the HCU to the rear mounting bracket 17 Remove the mounting brackets from the HCU 18 Examine the four bushings inside the brackets for potential deformations Replace if necessary 19 Verify the warranty status If the HCU is under warranty return it to Meritor WABCO Installation Hydraulic Compact Unit CAUTION The replacement HCU is pre charged with brake fluid to ensure successful bleeding To prevent fluid loss do not remove the protective caps until you are ready to connect the brake lines Damage to components
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158. not allow any contaminants to enter the HCU ports 4 Removal and Installation 3 Use anumber 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 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 to ensure it is clean and free from debris or other contaminants 4004447 2 Remove the plugs from the reservoir ports on the 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 Meritor WABCO 5 Remove the old rubber grommets from the four ports Do not 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 4004448a Figure 4 11 4 Use new clean brake fluid from a se
159. ock the wheels to prevent the vehicle from moving Unwanted vehicle movement can result in serious personal injury 1 Park the vehicle level surface Apply the parking brake and block the wheels to prevent the vehicle from moving 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 10 11 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 Deplete pressure in the accumulators There are two ways of depressurizing the system as follows 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 B While fully depressing the brake pedal select the Deplete Accumulators function from the TOOLBOX Software EOL pull down menu The pedal must remain fully depressed during the entire process until the TOOLBOX Software displays the completion message Ensure that the pressure in both accumulators is reading zero on the diagnostic main screen then release the brake pedal Turn the ignition OFF Verify that the brake fluid level in the master cylinder reservoir is not below MAX level NOTE During bleeding procedures brake fluid le
160. oe 6261 due Jojeoipu peseejaiJ 440 peidde NO duie1 Jojeoipu 430 6 61 due 99IAJOS BuImsed 440 eiqipny NO 440 dwg yeg NO dwg Sav Snjeis HHVS Buip oooe 6261 due Jojeoipu Hued peiqesiq peseejaJ 440 oly NO dure 99uM Jo0jeoipu Buried 190 330 6861 due JeuBis 99lAJOS peeds 440 eiqipny NO dwe 91V 440 dwg BuiuJeA yeg NO dwe sav Snjiels HHVS Buip oooe 6261 due Jojeoipu exeag pe gesiq JI 440 21 NO dwe7 99uM J0jeoipu 49u1O W014 440 6861 due jeubis 99IAJOS uled peeds 440 eiqipny NO dwe 440 dwg BuiuJeA exeJg NO dwe sav SniEls HHVS 6261 due Jojeoipu exeag peiqesiq peseelei JI 440 21 NO dwe7 99uM Je9H J0jeoipu exeag Bured Jeu1O WO 440 6861 due uexye jeubis 99IAJOS peeds 440 eiqipny NO dwe 440 dwg BuiuJeM exeJg NO dwe sav pe qesiq peioelep suoneJqi Ayesoduay Jeuuouqy sJeneuo peiqesiq Jo 99uM Sav
161. oipu 440 6861 99IAJOS Burned 440 e qipny NO dwe JJO NO dwe BuiuueM exeJg dwe Sav Snjes HHVS 696 due Jojeoipu exeJug p se 440 NO dweq Jojeoipu 6261 440 eigipny NO 21v sso NO dwe eyesg sgy 513035 0 Buipsoooe 6261 due Jojeoipu JI 440 peidde NO duie1 Jojeoipu 440 6861 duie1 BdIAIOS 440 aiqipny NO 91V JJO NO dwe sgy YHVS pJoooe 6661 dwe Jojeoipu 440 peidde NO dweq Jojeoipu 440 6261 due 440 ejgipny NO dwe JJO NO dwe BuiuJeM exeJg dwe Sav 3u5r1 BuruueM ON Dury eouepeduu uondio soeg 062 064 40119228 Figure 3 17 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing uoisoJ100
162. ommet seals into the 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 determine which fluid to use B Install the original or replacement reservoir by carefully pressing it fully into the grommets C Install two new roll pins from the replacement kit Drive the pins through the holes in the master cylinder boss and the reservoir mounting tab holes Support the back of the tabs as you install each pin Figure 4 41 D Install the nut on the front bolt MASTER CYLINDER RESERVOIR ROLL PINS 40049788 Figure 4 41 2 Usethe two mounting nuts included in the replacement kit to attach the master cylinder assembly to the bracket on the fire wall Tighten the bolts to 50 ft lb 70 Nem 4 WARNING Failure to correctly install the clevis pin as described may result in damage to the pushrod abnormal brake pedal feel and or loss of brakes during vehicle operation 3 Connect the master cylinder pushrod clevis pin to the pedal 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 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 73 4 Removal and Installation 9 Fill the master cylinder reservoir to the MAX mark with new brake fluid from a sealed container Use DOT
163. on Note Indicator not generating pressure at the proper 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 oystem pressures are in normal operating range BRAKE FLUID STEADY ON Low brake fluid level in the Master Cylinder Reservoir Braking force from the Hydraulic Power Brake may be reduced or impaired Immediately find a location to safely park the vehicle When safely off the road and stopped turn off ignition and ensure the vehicle transmission is in the park Use parking brake if necessary OFF Brake fluid level detected in the Master Oylinder 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
164. or add fluid as necessary until the MAX mark level is achieved Never add fluid above the MAX mark Refer to Section 5 for detailed instructions on how to correctly fill the master cylinder reservoir 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 Release the pressure from the master cylinder reservoir Remove the bleed equipment Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 18 19 20 2 22 29 Brake Bleeding Procedures Install the master cylinder reservoir cap Connect the parking brake cable to the SAHR canister Refer to the vehicle manufacturer s instructions for how to connect and correctly adjust the parking brake cable Verify correct application and release at the parking brake Using the diagnostic laptop and the TOOLBOX M Software program clear all the inactive fault codes Turn ignition OFF and disconnect the diagnostic laptop from the diagnostic connector Check the system for external leaks Remove wheel blocks Changing Hydraulic Brake Fluid 1 Park the vehicle level surface Apply the parking brake and block the wheels to prevent the vehicle from moving Failure to do so can result in unwanted vehicle movement Causing se
165. ore brake fluid runs out Do not release the brake pedal E With the brake pedal still applied use a torque wrench to tighten the bleeder fitting screw to the torque value specified by the component manufacturer Repeat Steps A E for the second axle 15 After making the repairs check the fluid level in the master cylinder reservoir to make sure it is at the MAX mark Refill as necessary using only the recommended DOT 3 or DOT 4 hydraulic brake fluid as described above 16 Reinstall the two maxi fuses for the pump motors or reconnect the battery 17 Use TOOLBOX Software to clear the diagnostic code for the master cylinder Refer to Section 3 for TOOLBOX Software instructions 18 Remove the wheel blocks 4 Removal and Installation 19 Test drive the vehicle Refer to the test drive procedure in section 3 of this manual Removal Master Cylinder Reservoir WARNING The full power brake system is a pressurized system that achieves pressures of up to 2320 psi This pressure is not reduced by switching the ignition off or removing battery power Prior to servicing this system the depressurization procedures must be performed exactly as presented Failure to depressurize the system may result in personal injury or 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 mast
166. ore you remove any components Pressurized air can cause serious personal injury It is possible for the removed accumulator to retain an internal pressure of up to 1087 psi To eliminate any removed accumulator from posing a safety hazard depressurize the accumulator and disable its pressure chamber The full power brake system is a pressurized system that achieves pressures of up to 2320 psi This pressure is not reduced by switching the ignition off or removing battery power Prior to servicing this system the depressurization procedures must be performed exactly as presented Failure to depressurize the system may result in personal injury or 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 CAUTION The HPB hydraulic power brake system is a complex device that provides optimum efficiency and operation If the system sustains damage or a component malfunctions and requires replacement the vehicle owner 15 strongly advised to contact the nearest dealer for professional assistance and repair If location and circumstances prevent consulting the dealer and components must be replaced the replacement procedures provided by Meritor WABCO must be followed exactly with t
167. ormation before moving the component e HPB systems may include automatic parking brakes If your vehicle is equipped with manual parking brakes refer to the manual parking brake procedures To determine the type of parking brake on the vehicle refer to the vehicle specification sheet e Bleed the brake and master cylinder circuits Bleed procedures appear in Section 5 of this manual e After installing HPB components or making system repairs use TOOLBOX M Software to remove the error code from the ECU memory Instructions for using TOOLBOX Software appear in section 3 of this manual 1 Parkthe vehicle on a level surface Apply the parking brake Ensure that the ignition is turned OFF 2 Block the front and rear tires to prevent the vehicle from moving Failure to do so can result in unwanted vehicle movement causing serious personal injury 3 Disconnect the battery 4 Use clean rag to carefully clean the surface of the HCU and the surrounding area Apply the brake pedal a minimum of 30 times to decrease pressure in the system ensure the system 15 depressurized perform the following check on both the front and rear axles A Remove the protective cover from the end of the bleeder fitting on one brake caliper B Attach a bleeder bottle hose to the bleeder fitting at the wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the
168. otors or disconnect the battery e Apply the brake pedal a minimum of 30 times to decrease pressure in the system To ensure that the system is depressurized perform the following check on both the 15 front and rear axles Reinstall the two maxi fuses for the pump motors or reconnect the battery A Remove the protective cover from the end of the bleeder 16 Remove the wheel blocks VUN ONONE prake CADEI 17 Test drive the vehicle Refer to the test drive procedure in B Attach a bleeder bottle hose to the bleeder fitting at the Section 3 of this manual wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake fluid Lubrication Wheel Speed Sensor Specification Meritor WABCO specifications call for a sensor lubricant with the following characteristics C Use a wrench to open the bleeder fitting screw 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 Lubricants approved for use on Meritor WABCO sensors and spring clips are Mobilith SHC 220 Mobil TEK 662 Roy Dean Products Staburags NBU 30 PTM Kl ber Lubrication Valvoline EP 633 Kl berplex BE 31 512 Kluber Lubrication Urethyn EZ
169. ove non HPB system components such as the air tank in order to access the HPB part If this is necessary refer to the vehicle manufacturer s manual for information before moving the component e Bleeding the SAHR circuit is required during installation of the parking brake pressure supply valve Bleed procedures appear in section 5 of this manual e After installing HPB components or making system repairs use TOOLBOX M Software to remove the error code from the ECU memory Instructions for using TOOLBOX Software appear in section 3 of this manual 4 amp WARNING Park the vehicle on a level surface Block the front and rear tires to prevent vehicle movement Failure to do so can result in unwanted vehicle movement causing serious personal injury Figure 4 53 EI z D TZ 400443 7 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 causing serious personal injury With the brake pedal still applied use a torque wrench to tighten the bleeder fitting screw Disconnect the battery Repeat Steps A E for the second axle 4 Use a clear rag to carefully wipe the surface of the and the 6 surrounding area Disconnect the electrical connection from the parking brake pressure supply valv
170. ownload 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 ECUSs 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 To create a parameter file you must obtain the correct VIN specific parameter data set numbers using the following procedure If you are able to communicate with the original ECU try to obtain the parameter data set numbers as follows 1 Open TOOLBOX Software and go to the HPB main page and click on Parameters in the toolbar 2 Select read parameters from the drop down menu and write down the 10 settings i e Data 1 1 Data 2 15 If you are unable to communicate with the original ECU it will be necessary to contact the OEM or Meritor WABCO to obtain the parameter data set numbers Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 Removal and Installation Create a New File to Calibrate ECU Parameters Once the parameter data set numbers have been obtained you must create a new file to calibrate the ECU parameters using the following procedure 1 O
171. pen Notepad as follows A Click the computer Start icon and type run into the search window Click run and enter Notepad into the search window and click OK This will bring up a blank Notepad page 2 Once the Notepad page has been brought up type the VIN on the first line and press enter to move down to the next line 3 the 10 data set numbers on each line below example 1 lt enter gt 15 lt enter gt do not hit enter after the 10th last entry Use the data sets that were saved from the original ECU If the 10 data set numbers could not be obtained from the original ECU it will be necessary to contact the OEM or Meritor WABCO to obtain the correct parameter data set numbers NOTE If the parameter file was obtained from the OEM it may be necessary to remove the underscores from the file name for TOOLBOX M Software to recognize it 4 Once the VIN and data set numbers have been entered click File and Save as In the File Save window save the file as follows oave in For TOOLBOX Software 10 or lower Windows XP or Vista C Program Files WABCO WINNT HPB Windows 7 C Program Files x86 WABCO WINNT HPB For TOOLBOX Software 11 Windows XP or Vista C Program Files Meritor WABCO TOOLBOX HPB Windows 7 C Program Files x86 Meritor WABCO TOOLBOX HPB File name MW ABS Param dat save As Type All files Encoding ANSI This is
172. plied to the parking brake cable Internal springs are used to apply tension to the parking brake cable which applies the parking brake When pressurized brake fluid is 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 information WARNING 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 Parking Brake Switch The parking brake switch optional is a three position electrical switch apply neutral and release It controls the driver requested operation of the parking brake How the HPB System Works Meritor 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 th
173. pment to the master cylinder reservoir filler neck Verify that the adapter and bleed equipment are securely tightened onto the master cylinder reservoir filler neck Apply 35 psi 2 4 bar of pressure from the fill and bleed equipment to the master cylinder Fit the bleeder hose onto the caliper bleeder screw at one wheel end submerge the free end of the bleeder hose into the bleed bottle 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 Close the bleeder screw Repeat Steps 8 12 for A theremaining calipers thetwo relay bleeder screws and C the SAHR bleeder screw if equipped Release the pressure from the master cylinder reservoir Remove the bleed equipment Fill the master cylinder reservoir up to the MAX mark with new 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 NOTE You can speed up the filling process by opening the 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 Bleed the master cylinder circuit using the master cylinder bleeding procedure in this section Bleed the rest of the brake system using the brak
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175. que value specified by the component manufacturer Repeat Steps A E for the second axle Attach a pinch clamp to the low pressure hose near the outlet of the master cylinder reservoir Do not damage the reservoir outlet Figure 4 61 NOTE Be careful not to damage the HCU reservoir outlet when attaching the pinch clamp If damaged it will need to be replaced Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Removal and Installation MASTER CYLINDER RESERVOIR LOW PRESSURE HOSE TO HCU RESERVOIR ET BRAKE TUBES TO HCU ASSEMBLY 40045238 Figure 4 61 10 11 12 Remove the clamps that hold the middle section of the low pressure hose to the chassis Note the position of the clamps for installation of the new hose 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 fluid Remove the hose clamp and remove the hose from the master cylinder reservoir NOTE Some brake fluid may remain in protected areas of the master cylinder reservoir Remove the cap from the master cylinder reservoir to assist draining When the reservoir is empty replace the cap on the master cylinder reservoir and plug the reservoir outlet to prevent any excess fluid from spilling during removal Approximately one gallon 3 4 liters should drain into the container Remove the hose clamp a
176. r to Section 5 for detailed instructions on how to correctly fill the master cylinder reservoir Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 19 20 21 22 2 24 29 If brake caliper circuit bleeding is required refer to the procedure in this section 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 Release the pressure from the master cylinder reservoir Remove the bleed equipment Install the master cylinder reservoir cap Using the diagnostic laptop and the TOOLBOX Software program clear all the inactive fault codes NOTE If faults remain they should be diagnosed prior to releasing the vehicle to service Turn the ignition OFF and disconnect the diagnostic laptop from the diagnostic connector Check the system for external leaks Remove the wheel blocks Brake Caliper Circuit NOTE If the vehicle has Quadraulic calipers refer to the Quadraulic Brake Caliper Bleeding Procedure in this section NOTE If you are bleeding the front calipers it is critical that you bleed the SAHR circuit also if equipped WARNING Park the vehicle on a level surface Apply the parking brake and bl
177. re 4 63 3 Apply a Meritor WABCO recommended lubricant to the sensor spring clip and sensor 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 Overtightening the tie wraps may damage the cables Figure 4 63 9x eNO VE NE eNO DRG E 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 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Bundle excess cable 1004707 Figure 4 65 8 Remove the blocks and safety stands 9 est drive the vehicle Refer to the test drive procedure in section 3 of this manual Removal Rear Axle Wheel Speed Sensor 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 u
178. rformed in the order presented Hydraulic brake fluid is a caustic substance Contact with the hydraulic brake fluid can cause skin irritation Do not let 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 NOTE Do not open the ECU Opening the ECU to gain access to the internal components will void the warranty NOTE The following general guidelines are provided to facilitate the Safe removal of the ECU module from the HCU assembly e t is not necessary to remove the entire HCU to replace the Electronic Control Unit ECU e After replacing the ECU new system parameters must be entered Refer to Section 3 of this manual for parameter entry procedures When only the ECU 15 replaced bleeding the system 15 not necessary 1 Park the vehicle on a level surface For vehicles with manual parking brakes apply the parking brakes 2 Block the front and rear tires to prevent vehicle movement Failure to do so can result in unwanted vehicle movement Causing serious personal injury 3 Disconnect the battery 4 Use a clean rag to carefully wipe the surface of the and the surrounding area 5 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 19
179. rious personal injury 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 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 Deplete pressure in the accumulators There are two ways of depressurizing the system as follows A Fully depress the brake pedal a minimum of 30 times The pressure in each brake circuit can be monitored using the TOOLBOX M Software Ensure that the pressure in each accumulator is at O psi B While fully depressing the brake pedal select the Deplete Accumulators function from the TOOLBOX Software EOL pull down menu The pedal must remain fully depressed during the entire process until the TOOLBOX Software displays the completion message Ensure that the pressure in both accumulators is reading zero on the diagnostic main screen then release the brake pedal Turn the ignition OFF Prepare the pressure bleeder device according to the instructions provided with the equipment Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 10 11 12 13 14 15 16 17 18 NOTE The pressurized bleed equipment used for this drain procedure must be the air over hydraulic type Install a suitable adapter from the fill and bleed equi
180. rs the terminals or plugs Failure to do so may cause loss of braking resulting in serious personal injury NOTE After removing a component or disconnecting a brake tube connection block off ports and brake tubes with appropriate plugs to prevent the ingress of dirt and unnecessary loss of fluid Use only new specified brake fluid from a sealed container to refill the system Refer to the specification on the Master Cylinder MC reservoir or in the vehicle service manual If a lubricant is required to aid assembly use only the specified brake fluid from a sealed container Do not use any other assembly lubricant During bleeding procedures brake fluid level must not 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 Perform the bleeding procedure exactly as described in the instructions Perform the reservoir top off procedure when bleeding is complete Refer to technical publication TP 09121 Filling the Hydraulic Power Brake Master Cylinder Reservoir for instructions on filling the master cylinder To obtain this publication refer to the Service Notes page on the front inside cover of this manual After completing all desired brake service operations test the braking system for function and check for leakage Use DOT 3 or DOT 4 hydraulic brake fluid Refer to the vehicle specification sheet to determine which flu
181. rsonal injury Disconnect the battery Apply the brake pedal a minimum of 30 times to decrease pressure in the system ensure the system 15 depressurized perform the following check on both the front and rear axles A Remove the protective cover from the end of the bleeder fitting on one brake caliper B Attach a bleeder bottle hose to the bleeder fitting at the wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake fluid C Use a wrench to open the bleeder fitting screw D Apply and hold the brake pedal down until no more brake fluid runs out Do not release the brake pedal E With the brake pedal still applied use a torque wrench to close the bleeder fitting screw Use a torque wrench to tighten the bleeder fitting screw to the torque value specified by the component manufacturer Repeat Step 4 and Step 5 for the other axle Use hose clamp pliers to clamp the rubber hose at least three inches 6 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 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4006216a Figure 4 31 NOTE Avoid bending or kinking the brake lines while disconnecting and handling other components For a rear axle pump proceed to Step 9 For a front axle pump carefully remove the rela
182. s depressurized perform the following check on both the front and rear axles A Remove the protective cover from the end of the bleeder fitting on one brake caliper Attach a bleeder bottle hose to the bleeder fitting at the wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake fluid C Use wrench to open the bleeder fitting screw Figure 4 18 ass E 72 4004437 Figure 4 18 D Apply and hold the brake pedal down until no more brake fluid runs out Do not release the brake pedal E With the brake pedal still applied use a torque wrench to tighten the bleeder fitting screw to the torque value specified by the component manufacturer Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 e Repeat Steps A E for the second axle 10 After making the repairs check the fluid level in the master cylinder reservoir to make sure it is at the MAX mark when both accumulators are fully depleted Refill as necessary using only the recommended DOT 3 or DOT 4 hydraulic brake fluid as described above Refer to Section 5 for detailed instructions on how to correctly fill the master cylinder reservoir NOTE Never add fluid above the MAX mark regardless of the State of the accumulator 11 Use TOOLBOX Software to cancel the diagnostic code for the accumulator Refer to Section 3 for TOOLBOX Software in
183. s personal injury can result 8 Attach the 31 pin harness and then the two pin power connector to the ECU Push the latch into position to lock the connection Figure 4 8 If the vehicle is equipped with a hydraulic parking brake attach the pressure supply valve connector Refer to the Parking Brake Pressure Supply Valve removal and installation procedures in this section Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4004443a Figure 4 8 9 Proceed with pressure filling and bleeding the brake caliper circuits and the SAHR circuit if applicable Refer to Section 5 for procedures 10 new complete ECU HCU assembly was installed it will be necessary to download the parameters into the ECU NOTE Io make sure of correct ABS performance the correct parameters must be downloaded into the ECU Parameters are OEM and VIN number specific and should not be swapped vehicle to vehicle Refer to the Parameter Downloading section in this manual 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 of the HCU and the HCU reservoir to ensure the area is free from any dirt or other contaminants Clean if necessary Do
184. s with manual parking brakes apply the parking brakes 4 Removal and Installation Block the front and rear tires to prevent vehicle movement Failure to do so can result in unwanted vehicle movement causing serious personal injury Disconnect the battery Use clean rag to carefully wipe the surface of the HCU and the surrounding area Apply the brake pedal a minimum of 30 times to decrease pressure in the system To ensure the system 15 depressurized perform the following check on both the front and rear axles A Remove the protective cover from the end of the bleeder fitting on one brake caliper B Attach a bleeder bottle hose to the bleeder fitting at the wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake fluid C Use a wrench to open the bleeder fitting screw Figure 4 14 ass s TZ 4004437a Figure 4 14 D Apply and hold the brake pedal down until no more brake fluid runs out Do not release the brake pedal E With the brake pedal still applied use a torque wrench to tighten the bleeder fitting screw to the torque value specified by the component manufacturer Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 57 4 Removal and Installation 6 Repeat Steps A E for the second axle 7 help prevent brake fluid from damaging the vehicle or floor paint or from seeping into
185. sconnecting and handling other components Disconnect the two master cylinder brake lines from the relay valve Plug the two lines to prevent contamination Use a 4 mm socket wrench to loosen and remove the five Allen head screws that secure the relay valve to the hydraulic compact unit HCU Figure 4 27 400621 a Figure 4 27 Carefully lower and remove the relay valve Remove and discard the rubber coated seal plate Do not reuse this plate During installation use the new seal plate included with the relay valve replacement kit Figure 4 28 4006218 4 28 12 Use denatured alcohol and lint free rags to clean the valve mounting surface Ensure there is no rubber sticking to the HCU Do not allow rubber or other debris to fall into the HPB bore holes Figure 4 29 9 SFIN 4 DN 40062198 Figure 4 29 Installation Hydraulic Compact Unit HCU Relay Valve 1 Place a screw into the center mounting hole of relay valve Use a hex head socket tool for positioning Place the new relay valve seal onto the relay valve using the screw to align the seal The orientation should match Figure 4 30 Position the relay valve against the HCU Thread the screw into the HCU 6 4 Removal and Installation 100 SEAL PLATE IDENTIFICATION Tightening sequence Tighten each bolt twice 4006221 Figure 4 30 Place the remaining four screws into the mounting holes
186. seejaiJ JI 440 71 NO Jojeoipu 440 6861 due SAV BdIAIBS exejg Ayesodua 440 siqipny NO dwe 440 dwg yeg NO dwe sav Snjeis HHVS Buip oooe 6261 due Jojeoipu Buried 440 NO dwe7 99uM IH 10je2ipu Burned J8u1O WO 440 6861 due JeuBis 99IAJOS BuImsed peeds 440 eiqipny NO dwe 440 dwg BuiuJeM exeJg NO dwe sav Snjeis HHVS 6261 due Jojeoipu exeag pe gesiq JI 440 21 NO dwe7 99uM IH J0jeoipu exeag Bured Jeu1O WO 440 6861 due jeubIS 99IAJOS ued peeds 44O DuiueM NO dwe7 91V 440 duie1 NO Sav SNIEIS HHVS Bulpsoooe 6261 dwe Buried peiqesiq peseelei JI 440 21 NO dwe gt 99uM J0jeoipu exeag gt 430 6261 dure uexye jeubis 99IAJOS uled peeds 440 eiqipny NO dwe 440 dwg exeJg NO dwe sav Jeneuo peioejeq
187. servoir should be between the MIN and MAX marks Adjust if necessary Refer to Section 5 for detailed instructions on how to correctly fill the master cylinder reservoir MASTER CYLINDER ASSEMBLY 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 e Remove the two maxi fuses for the pump motors or disconnect the battery e Apply the brake pedal a minimum of 30 times to decrease pressure in the system To ensure that the system is PRIMARY depressurized perform the following check on both the FLUID LEVEL CIRCUIT SENSOR SECONDARY MF FRONT front and rear axles pre CIRCUIT AAEE A Remove the protective cover from the end of the bleeder MR REAR AXLE 4004477a fitting on one brake caliper SWITCH Figure 4 43 8 Bleed the master cylinder circuit Refer to Section 5 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 B Attach a bleeder bottle hose to the bleeder fitting at the wheel end Submerge the open end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake fluid C Use a wrench to open the bleeder fitting screw Figure 4 44 EI D TZ 4004437 Figure 4 44 D Apply and hold the brake pedal down until no m
188. sh the latch into position to lock the connection Figure 4 24 4004443a Figure 4 24 6 Connect the battery 7 Ifthe original ECU was just reinstalled test drive the vehicle Refer to the Test Drive Procedure in this manual 8 Ifa new ECU was installed it will be necessary to download the parameters into the ECU NOTE make sure of correct ABS performance the correct parameters must be downloaded into the ECU Parameters are OEM and VIN number specific and should not be swapped vehicle to vehicle Refer to the Parameter Downloading section 4 Removal and Installation Parameter Downloading After Installing a new ECU or a new ECU HCU assembly it will be necessary to download the parameters into the ECU NOTE make sure of correct ABS performance the correct parameters must be downloaded into the ECU Parameters are OEM and VIN number specific and should not be swapped vehicle to vehicle NOTE TOOLBOX Software will be needed to enter the HPB system parameters into the ABS ECU For Navistar vehicles it is recommended to go to the Navistar ISIS website to download the parameters per VIN using the TOOLBOX software Contact Navistar for assistance 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 d
189. shooting and Testing Seu 123 ereoipur sjsissod Ji pue syoayo ssed pue Ajddns eunssaJg 941 I y sonsouDeip ALA Ajddns aJunssaJg pere njen A ddns eunssaJg eui se1eoipur oads 100 JJ Suluo z eq 5 eA eA Ajddns eunssaJg JO eoueljsisaJ 0949 eDejoA 0 uous JO Ajddng eunssaJg 01 193 jddng eanssaJg JO 510 2 pue 499u25 AJesso29u JI ue9j o 001501109 JO eunjsiouJ sewep ubis Aue 10 s10128uuoo 1oedsur pue 1oeuuoosiq seu 123 eieoipur sjsisiod OLA Jl pue syoayo ssed pue eA eA Ajddns eunssaJg eui y ALA Ajddns aJunssaJg pere njen Ajddng eunssaJg eui se1eoipur oads 100 Suluo Z eq eA eA Ajddns eunssaJg JO eoueljsisaJ 429u2 eDejoA 0 uous JO Ajddng eunssaJg 01 193 SV 8A eA jddng eanssaJg JO sJoj euuoo pue 499u25 Jesso29u JI SJ012euuo2 ue9j o uoisoJ109 JO eunjsiouJ sewep Aue 10 s10128uuoo 19edsur pue 1oeuuoosiq 51015 HHVS Buip4oooe 6261 due Jojeoipu Bured 440 peidde NO Jojeoipu Bured 330 6861 due 99IAJOS
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191. structions 12 Perform the Deplete Accumulators function two times Refer to the procedure in this section 13 Remove the wheel blocks 14 Test drive the vehicle Refer to the test drive procedure in section 3 of this manual Removal Electronic Control Unit ECU 4 amp WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Park the vehicle on a level surface For vehicle equipped with 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 serious personal injury Release all air from the air systems before you remove any components Pressurized air can cause serious personal injury The full power brake system 15 a pressurized system that achieves pressures of up to 2320 psi This pressure is not reduced by switching the ignition off or removing battery power Prior to servicing this system the depressurization procedures must be performed exactly as presented Failure to depressurize the system may result in personal injury or death CAUTION The HPB hydraulic power brake system is complex device that provides optimum efficiency and operation If the system sustains damage or a component malfunctions and requires replacement the replacement procedures provided by Meritor WABCO must be followed exactly with the associated steps pe
192. surized 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 bleeding the master cylinder circuit that appear in Section 5 of B Attach a bleeder bottle hose to the bleeder fitting at the this manua wheel end Submerge the free end of the bleeder hose into the bleeder bottle Both the tubing and container must be able to withstand the effects of hydraulic brake 7 After bleeding ensure that the fluid level in the master cylinder is at the MAX mark If brake fluid in the reservoir is above or 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 MAK mark torque value specified by the component manufacturer 8 Install the two maxi fuses or connect the battery Figure 4 49 9 the ignition ON The HCU pump motors will start up and fill the accumulators Approximate running time is 45 seconds If the HCU pump motors fail to deliver a sufficient amount of fluid the ECU module will control the HCU pump motors in a self priming procedure The HCU pump motors should stop within three minutes with the brake warning light and the buzzer OFF If
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194. t that the HPB system should lose all power and pressure the park brake will automatically apply while moving or at rest Interlocks If Equipped with the Hydraulic Park Brake System The HPB system with the hydraulic park brake feature may not allow the park brake to be release unless certain interlock messages are received such as a door being left open or a wheel chair lift that is not seated correctly in the stored position Review interlock operation and diagnostics with the OEM 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 4 amp 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 Meritor WABCO M
195. the fluid level is stabilized ensure the 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 MAX mark level is achieved Never add fluid above the MAX mark Refer to Section 5 for detailed instructions on how to correctly fill the master cylinder reservoir Connect the battery Turn the ignition ON The pump motors will start up and fill the accumulators Approximate running time is 45 seconds 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 15 If there are leaks depressurize the system before making the necessary repairs Use the following procedure to depressurize 4 Removal and Installation E With the brake pedal still applied use a torque wrench to tighten the bleeder fitting screw to the torque value specified by the component manufacturer e Repeat Steps A E for the second axle the system 14 After making the repairs check the fluid level in the master cylinder reservoir to make sure it is at the MAX mark Refill as necessary using only the recommended DOT 3 or DOT 4 hydraulic brake fluid as described above Never add fluid above the MAX mark e Remove the two maxi fuses for the pump m
196. the ground position a container beneath the work area to collect any drained or spilled brake fluid 8 Use a strap wrench to remove the accumulator The accumulator has a right hand thread Figure 4 15 4004444a Figure 4 15 9 Useaclean rag to clean the counterbore on the HCU Inspect the counterbore to ensure that the O ring seal was removed Plug the counterbore to prevent contamination from entering the HCU 10 Determine the warranty status of the accumulators If the accumulators are under warranty do not perform Step 11 depressurizing the accumulators Return the accumulators to Meritor WABCO If the accumulators are not under warranty the accumulators MUST be depressurized before disposal Step 11 WARNING A slight hissing sound may be heard when the wall of the accumulator is pierced Metal shavings may be blown away from the hole during this procedure Wear protective goggles not glasses to protect the eyes 11 Use the following steps to depressurize the accumulator and disable the internal pressure chamber before disposing of the accumulators Figure 4 16 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 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 B Center punch the accumulator C Usea3mm or 1 8 inc
197. 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 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 2 E V A 40044378 Figure 4 49 13 14 15 16 17 D Apply and hold the brake pedal down until no more brake fluid runs out Do not release the brake pedal E With the brake pedal still applied use a torque wrench to tighten the bleeder fitting screw Repeat Steps A E for the second axle After making the repairs check the fluid level in the master cylinder reservoir to make sure it is at the MAX mark Refill as 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 Reinstall the two maxi fuses for the pump motors or reconnect the battery Use TOOLBOX Software to cancel the diagnostic code for the master cylinder reservoir Refer to Section 3 for TOOLBOX Software instructions Remove the wheel blocks Test drive the vehicle Refer to the test drive procedure in section 3 of this manual 4 Removal and Installation Removal Master Cylinder Foot Brake Switch WARNING Park the vehicle on a level surface Block the wheels to prevent the vehicle from
198. tions Adapter is selected Click the Start Download button Follow the screen prompts to reflash the ECU During the reflash the ignition should be off and the brake pedal must be depressed through the entire process which may take several minutes When the process is complete a message will appear stating Flashing Complete Release the brake pedal and wait three seconds Re apply the brake pedal and verify that the ECU and software ID is correct message stating the Flashing is complete and Software ID verified will appear when flashing is complete 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 M Software is unable to communicate with the ECU repeat the download procedure Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 Removal and Installation 12 Connect TOOLBOX Software note and clear any DTCs 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 Meritor WABCO 16 Test drive the vehicle Refer to the Test Drive procedure in section 3 of this manual Removal Hydraulic Compact Unit HCU Relay Valve 1 Wear safe eye protection 2 Park the vehicle on a level surface Block
199. to remove the undamaged reservoir from the old master cylinder A Remove the nut from the front bolt Use a punch to drive out the two roll pins Use care and support the tabs while you drive out the pins Lift the reservoir off the master cylinder C Pour any fluid remaining in the reservoir into a suitable container D Plug the reservoir outlet ports to prevent contamination to the system Verify the warranty status If the master cylinder is under warranty return it to Meritor WABCO Installation Master Cylinder WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Two people are needed to perform this procedure In some vehicles it may be necessary to move non HPB system components such as the air tank in order to access the HPB part If this is necessary refer to the vehicle manufacturer s manual for information before moving the component Bleeding the master cylinder circuit is required during installation of the master cylinder Bleed procedures appear in Section 5 of this manual After installing HPB components or making system repairs use TOOLBOX Software to remove the error code from the ECU memory Instructions for using TOOLBOX Software appear in section 3 of this manual Attach the original or replacement reservoir to the new master cylinder as follows 4 Removal and Installation A Install two new rubber gr
200. tor WABCO Maintenance Manual MM 0401 Revised 07 15 PARKING BRAKE ECU VALVES C gt WHEEL END A SENSORS 4 REAR AXLE FRONT AXLE 4004478a For ABS wheel pressure 15 individually modulated by eight integrated ABS solenoid valves in the ECU HCU For ATC the normally closed ATC solenoid valve in the ECU is actuated and hydraulic energy is supplied to the sensed wheel At the same time the normally open ATC valve is actuated to prevent fluid flow back into the reservoir The brake pressure is then modulated by the corresponding ABS solenoid valves WARNING Do not install any add on hydraulic devices to the HPB system A loss of braking ability may occur resulting in an accident and serious personal injury 2 Wiring Diagram HPB Wiring Diagram for Multiplex Vehicles The Meritor WABCO HPB electronic control unit interface wiring diagram for multiplex vehicles is shown in Figure 2 1 2 0 75 mm4 TWISTED V E REAR RIGHT ores VIELE ro ces fl SENSOR SENSOR FRONT REAR RIGHT LEFT REAR LEFT SENSOR FRONT LEFT BRAKE LIGHT SIGNAL CAN LOW CAN HIGH ACC SAE J1939 FRONT RIGHT DIAGNOSE B WHEEL PRESSURE MODULATION SOLENOIDS DIAGNOSE A ACC SAE J1587 31 PIN CONNECTOR FRONT LEFT LOW BRAKE FLUID eS uj BRAKE SWITCH woes a ATC ELECTRONIC CONTROL UNIT ATC SOLEN E NC _ REFERE
201. turned to the master cylinder reservoir If the reservoir was previously filled above the MAX mark a fluid spill could occur when these conditions exist Overfilling the master cylinder reservoir may cause damage to the cap and other components resulting in poor braking performance and serious personal injury NOTE The ability for the master cylinder to breath 15 critical to correct brake system function If the cap becomes contaminated it will need to be replaced To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service 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 10 11 12 13 5 Brake Bleeding Procedures Ensure vehicle is on a level surface and apply the parking brake Block the wheels to prevent the vehicle from moving the ignition key to OFF and remove the two 30 amp fuses that provide power to the brake system motors The fuses are in the fuse panel located on the engine side of the cowl Remove master cylinder cap Connect a laptop computer containing TOOLBOX Software to the diagnostic connector Turn the ignition key to ON and start the TOOLBOX Software Depressurize the system as follows A Depress the brake ped
202. tus in Parameter Downloading section of this manual Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 17 3 Troubleshooting and Testing SPN SID FMI Diagnostic Trouble Code List unu euo pue Buueeq 2945 1502109 99 104 euo YOSYUD SWUO 0002 006 eunseeui eoueijsisaJ Josuag uoys Jo uedo JO JOSUaS Jo pue ss usey J2e uoo 20 pue Josues pue eouepeduii Josues Y92949 uoisou100 euo yOouyD oeq Josues usnd pue uoisuejxe def ejeuiul3 no unu euo pue Buueeq xo9u5 201 uey Je e916 eq JOU deb eu deb oou seu ejeoipui Aew sjsisued IIRS ssed sxXoeuo Bus peo pue spunojJ6 389 peo pue N93 SgY Y42949 sisisued J wu XO8 10O0O L ui uondo y Buisn Ag 10 uoniuBi Aq 103 19594 Udy OL uey JeuBiu speeds je Ajjeoipoued sdouJp jeubis peeds j yM pe qesiQ OlV SEV Josues peeds pajoeuuoosip e Sjoejep N94 p9joejep ueeq seu 0 uous JO
203. uipjoooe 6861 due Jojeoipu Bured peseejai 440 padde NO dure Jojeoipu Bured 440 6 61 due NO ButuieM eiqipny NO NO dure BuiuJeM NO dwe sav 6 75 HHVS 01 6861 due Jojeoipu peseejai 440 peidde NO dure Jojeoipu 440 626 due 99IAJOS NO ButuieM eiqipny NO NO dure BuiuJeM exeJg NO dwe sav 1u044 eunsseJg 1 Wa SAS 14617 0 HOUS 0 10 5000 indino oDeyoA 105095 1 5 5 yous eunsseJg uonduosoeg 290 290 6v0L 6v0l 40119428 Figure 3 36 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 3 Troubleshooting and Testing seu MOH NOA sisisiod q pue syoayo ssed pue 5 J NAO pue sonsouBeip Mmaa pasu 3521 peo Buipnjoui sounos6 pue 123 Y29349 AJESSODOU JI SJOJOOBUUOD uonipuoo Sqe yoo JIJ9A uoisoJ109 JO eJunijsiouJ jo ufs
204. ump before installing the first replacement pump Installation Hydraulic Compact Unit HCU Pump CAUTION Use care when installing the pump to prevent damage to the O rings 1 Uselight hand pressure to slowly seat the pump into the bore Use care not to damage the O rings Figure 4 34 4 Removal and Installation 4006205a Figure 4 34 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 Ib 22 2 Nem Figure 4 35 4 4006206a Figure 4 35 Repeat the procedure for removing and installing the second pump if replacing both pumps If the front axle pump was replaced install the relay valve Refer to 0672 Hydraulic Compact Unit Pump Relay Valve Replacement for the correct procedures Remove the hose clamp from the rubber hose Proceed with pressure filling and bleeding the master cylinder circuit Refer to Section 5 for procedures Proceed with pressure filling and bleeding the brake caliper circuits and the SAHR circuit if applicable Refer to Section 5 for procedures Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 4 Removal and Installation Removal Master Cylinder Replacement Information Before removing the master cylinder assembly or the master cylinder reservoir verify the components to be replaced Master cylinder and reservoir e Master cylinder only reusing reservoir e Master cylinder reservo
205. up to 0 04 inch 1 016 mm is allowable Reattach the sensor cable to the cable clamps or clips CAUTION Overtightening the tie wraps may damage the cables Fasten the sensor cable with tie wraps every 12 inches Do not overtighten the tie wraps Correctly bundle and store excess cable in the sub frame Figure 4 65 8 Use TOOLBOX Software to remove the error code from the ECU memory 9 Replace the tire and remove the safety stands Lower the vehicle and remove the blocks from the front tires 10 Test drive the vehicle Refer to the test drive procedure in Section 3 of this manual Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 5 Brake Bleeding Procedures Hazard Alert Messages The following brake bleeding procedures explain how to bleed the hydraulic power brake system during installation or in the event of air in the brake system When performing bleed procedures read and observe all Warning and Caution hazard alert messages in this publication They provide information that can help prevent serious personal injury damage to components or both WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service 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 persona
206. upports under the rear axle Depress the brake pedal Attempt to turn the rear wheels one at a time They should not move with the brakes applied Connect the vehicle to a PC with TOOLBOX Software installed Use TOOLBOX Software to activate the solenoid valves for the left rear wheel You should be able to turn this wheel by hand when the solenoids activate Repeat this check for the right rear wheel Go to Step 6 Remove the axle stands from under the rear axle to lower the vehicle Remove the blocks from the front tires and place them in front of the rear tires Raise the front tires Place supports under the front axle Repeat Steps 4 and 5 Remove the axle stands from under the front axle to lower the vehicle Make any necessary repairs If any plumbing changes were made bleed the system again Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Meritor WABCO Vehicle Control Systems 2135 West Maple Road Printed in USA Troy MI 48084 7121 866 Onlrac1 668 7221 Copyright 2015 Revised 07 15 MERITOR WABCO meritorwabco com Meritor Inc Maintenance Manual MM 0401 16579
207. use the HPB Programmer on a brand new ECU that has not had the parameters downloaded into it yet The HPB Programmer is not a part of TOOLBOX M Software It has its own Icon and is a separate stand alone software program The HPB Programmer has several versions based on the OEM vehicle and issue If you need the HPB Programmer to resolve an issue contact the OEM or Meritor WABCO to obtain the correct version Obtaining and Installing the HPB Programmer To obtain the HPB Programmer you must contact the OEM or Meritor WABCO Once the file has been obtained use the following procedure to install it 1 Save the piz file to your computer Rename the extension from piz to zip Unzip the zip file j m Once the files are extracted run the setup exe Once the setup is complete the HPB Programmer icon will appear on your desktop Figure 4 25 4 Removal and Installation Programmer 4011930a Figure 4 25 Run the HPB Programmer 1 10 11 Once the correct HPB programmer has been installed on to the computer determine if the vehicle has an ammeter e lf the vehicle has an ammeter Refer to the OEM schematics and remove the fuse for the ammeter e Ifthe vehicle does not have an ammeter Continue to the next step Connect the computer to the vehicle Click on the HPB Programmer icon on your desktop and run the HPB Programmer When the window opens verify that the correct Communica
208. usually the default setting 5 Click Save The parameter file will now be saved to the computer Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Extract the File and Save It to the ABS ECU Use the following procedure to extract the file from the computer and save it to the ABS ECU 1 the ignition on 2 Connect the computer to the vehicle 3 Open TOOLBOX Software and go to the HPB main page and click on Parameters in the toolbar 4 Adrop down menu will appear Click on Write Parameters 5 A window will appear displaying the VIN verify the VIN number Is correct 6 Click the Download button Once the process is complete a message of Success will appear 7 Close out of TOOLBOX M Software and turn the ignition off for a few minutes Verify the Parameters Use the following procedure to verify the parameters were saved correctly 1 the ignition on 2 Connect the computer to the vehicle 3 Open TOOLBOX Software and go to the HPB main page and click on Parameters in the toolbar 4 Click on Read Parameters and compare the parameters that are displayed with the parameters that were entered They should be identical 5 lest drive the vehicle Refer to the Test Drive procedure in oection 3 of this manual Password Failed If during the Parameter download process a Password Failed message should appear it indicates several attempts have been made on the same ke
209. vel must not 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 fluid from a sealed container Prepare the pressure bleeder device according to the instructions provided with the equipment NOTE The pressurized fill and bleed equipment used can be either air over fluid or fluid over air type Install a suitable adapter from the fill and bleed equipment to the master cylinder reservoir filler neck Verify that the adapter and bleed equipment are securely tightened onto the master cylinder reservoir filler neck NOTE If all wheel ends are to be bled use the following bleeding order right rear left rear right front left front Fit the bleeder hose onto the caliper bleeder screw at one wheel end submerge the free end of the bleeder hose into the bleed bottle Apply 35 psi 2 4 bar of pressure from the fill and bleed equipment to the master cylinder reservoir 12 5 Brake Bleeding Procedures Open one caliper bleeder screw until fluid begins to flow 3 4 turn Allow the fluid to run until 8 5 ounces 250 cc has been collected Take note of the fluid level in the bottle before starting Figure 5 2 Lx z D TZ 10047 10 Figure 5 2 14 13 If no further air bubbles enter the bleed bottle close the bleeder screw Remove the bleeder hose and tighten the bleed
210. y be replaced without replacing the entire The relay valve is mounted on the bottom of the HCU and may replaced without replacing the entire HCU HYDRAULIC COMPACT UNIT WITHOUT PRESSURE SUPPLY VALVE DUAL CIRCUIT f RESERVOIR MOTORS 2 ACCUMULATORS 4004476b Figure 1 4 2 Meritor WABCO Maintenance Manual MM 0401 Revised 07 15 Master Cylinder Assembly The dual circuit master cylinder in conjunction with a relay valve provides the translation of brake pedal force into hydraulic braking pressure and sends the driver s demand signal to the HCU Figure 1 5 The foot brake switch provides brake status to the ECU and eliminates the need for a brake light switch The master cylinder reservoir holds the additional hydraulic brake fluid The fluid sensor switch monitors fluid level in the master cylinder reservoir The master cylinder reservoir and both master cylinder switches may be replaced without replacing the entire master cylinder The master cylinder cap provided by Meritor contains a special gore material that allows the reservoir to breathe and serves as a filter to help prevent contaminants from getting into the reservoir This is the only cap approved for use with Meritor WABCO HPB NOTE The ability of the master cylinder cap to breathe is critical to correct brake system function If the cap becomes contaminated it will need to be replaced MASTER CYLINDER ASSEMBLY
211. y cycle To correct this issue close out of TOOLBOX Software and cycle the key off for a few minutes and reattempt downloading the parameters System Check Status ABS and or ATC Lamps Flashing after Downloading the Parameters After downloading the parameters there may be no active or stored 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 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 lick on the word Utility and a drop down menu will appear 4 Scroll through the menu and click on System Check Status 5 he System Check Status window will appear showing the Current Status which will display Status Not Set 6 Click on the Set Status button and the lights will stop flashing The lamps may remain on solid until the vehicle sees wheel speed above 4 mph 7 Close out of TOOLBOX M Software and cycle the key off for a few minutes 8 Test drive the vehicle Refer to the Test Drive procedure in section 3 of this manual Using the HPB Programmer 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
212. y valve from the HCU to gain access to the pump Do not kink or bend the brake lines while removing the relay valve Prepare the replacement pump Lubricate both pump O rings with brake fluid Actuate the pump several times by depressing the spring loaded pump button by hand The initial force required to actuate the pump and depress the pump button may be high at first However after the first actuation the force should be reduced Usea 6 mm hex head socket wrench to remove the pump retaining plug from the cavity To minimize fluid spill keep the replacement pump within reach and prepared for installation Figure 4 32 40062038 Figure 4 32 CAUTION 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 Q E yee JEN EAT i 2 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 13 Install the replacement pump Refer to the installation procedure If you are replacing both pumps do not remove the second p

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