Service Information System Page 1 of 3

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

i07081696

E525 High Brake Pump Pressure

SMCS - 4014-035

Table 1
Problem: EID 525 High Brake Pump Pressure Event is active if the brake pump pressure is greater than 20684 kPa (3000 psi)
for more than 90 seconds.
Component Possible Component Non-Component How to Diagnose Corrective Action
Root Causes Root Causes
Solenoid Valve Open circuit/short to ground fault codes
(Brake Pump Harness connector logged in Cat® ET. Measure coil Replace Solenoid Valve
Unloader) damaged or not resistance when cool (20° C (68° F)). (Brake Pump Unloader).
locked in place The resistance should be close to 32 +/- 2
Valve improperly ohms.
installed causing screen
Stuck Closed: Measure actual brake
damage Contamination: pump pressure. Install 35000 kPa
Brake system oil (5000 psi) gauge on brake pump pressure
dirtier than ISO tap. Brake pump pressure at
18/15 22408 ± 345 kPa (3250 ± 50 psi) relief
pressure constantly.
Remove the access plug for OR1. Install
Locking tab broken
a 35000 kPa (5000 psi) gauge. Pressure
Partially stuck closed on mating
at OR1 is the same as pump pressure
connector.
(stuck closed)

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Bent or damaged Remove the access plug for OR1. Install Make sure that oil is ISO
solenoid valve. a 35000 kPa (5000 psi) gauge. Pressure 18/15 or better. If more
at OR1 is the same as pump pressure than 18/15, kidney loop
(stuck closed). Remove solenoid and machine and change
visually inspect screen for damage. With filter. If kidney loop not
solenoid removed apply 24V and verify available, change oil.
that valve actuates.
Stuck Closed: Measure actual brake
pump pressure. Install 35000 kPa
(5000 psi) gauge on brake pump pressure Replace Valve (Brake
tap. Brake pump pressure at Pump Unloader).
Contamination: 22408 ± 345 kPa (3250 ± 50 psi) relief
Valve(Brake pressure constantly.
Brake system oil
Pump Stuck Closed
dirtier than ISO Make sure that oil is ISO
Unloader)
18/15 Remove the access plug for OR1. Install 18/15 or better. If more
a 35000 kPa (5000 psi) gauge. At low than 18/15, kidney loop
idle pressure at OR1 is less than brake machine and change
pump pressure. filter. If kidney loop not
available, change oil.
Harness connector With machine off, verify that the sensors
not locked in place are reading less than 517 kPa (75 psi).

Brake Install 35000 kPa (5000 psi) gauge on

Failed In Range /Stuck at the brake accumulator pressure taps to Replace Brake
Accumulator one pressure (sensor tells
Locking tab broken verify that the accumulator pressure Accumulator Pressure
Pressure ECM to continue to
on mating matches the gauge pressure. With Sensors.
Sensors charge when in fact it
connector. machine running at low idle check to see
should be telling the
ECM to cut out) if the gauge matches the sensor in Cat®
ET.
Brake Pump Failed In Range /Stuck at Harness connector With machine off, verify that the sensors Replace Brake Pump
Pressure one pressure not locked in place are reading less than 517 kPa (75 psi). Pressure Sensors.
Sensors
Install 35000 kPa (5000 psi) gauge on
the brake accumulator pressure taps to

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Locking tab broken verify that the accumulator pressure

on mating matches the gauge pressure. With
connector. machine running at low idle check to see
if the gauge matches the sensor in Cat®
ET.
Orifice plug loose Remove OR1 Access plug and inspect.
Measure actual brake pump pressure.
Install 35000 kPa (5000 psi) gauge on Remove OR1 Plug and
OR1 Orifice brake pump pressure tap. Brake pump basket screen from port.
Seal damaged
pressure at 22408 ± 345 kPa Replace O-ring on plug
(3250 ± 50 psi) relief pressure and reinstall.
constantly.
Remove filter element and inspect for
damage and loose pieces of yellow
System Contact product support
Filter Element Damaged on Installation plastic. Remove and inspect
Overheating through the DSN.
Accumulator purge solenoid screens for
debris.

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