Connecting and disconnecting testing unit

AR46.20-W-3055ZE

Connecting and disconnecting testing unit

07.08.2020

Model

949, 959

Connection scheme

1

Test line (oil pressure from power steering pump (3))

2

Test line (oil pressure to steering gear (5))

3

Power steering pump

4

Tester

5

Steering gear

6

Oil reservoir

a

Oil pressure line

b

Oil return line

c

Oil suction line

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Warning

Risk of injury to skin or eyes from hot hydraulic fluid spraying out under high pressure. Risk of burn injuries from contact with components heated by hot hydraulic fluid. Risk of poisoning from swallowing hydraulic fluid

Do not make any technical modifications to the pressure gauge or the test equipment. Check the pressure gauge and test equipment for mechanical damage each time prior to use. Observe the flow diagram when connecting the test equipment. Wear protective gloves, protective clothing and safety glasses.

AS46.00-Z-0003-01A

Topical note

Notes on maintenance and repair work

AH46.20-N-0001-01H

Topical note

Notes on handling test equipment for testing delivery rate and oil pressure of power steering pump

AH46.30-N-0001-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

Install

1

Open hood.

Model 959

AR88.40-W-1000Z

Model 949

AR88.40-W-1000R

2

Start engine and move steering to center steering position so that steering wheel is in center position and front wheels are in straight-ahead position.

3

Stop the engine and switch off the ignition.

4

Remove front section of front fender on driver's side.

Only on model 949

AR88.10-W-1500RE

5

Mount test lines (1, 2) onto test equipment (4).

Only if it is required.

 Steering test equipment

*765589012100

6

Disconnect oil pressure line between power-steering pump (3) and steering gear (5) at a suitable connection.

 Collect escaping oil in a suitable container.

7

Connect test line (1) to power-steering pump (3) and test line (2) to steering gear (5).

 Union nut, oil pressure hose/line to fitting for power steering pump

*BA46.30-N-1002-01ZE

 Union nut, steering gear oil line/hose

*BA46.25-N-1001-04B

8

Turn control wheel on test equipment (4) to left, up to end stop.

 This ensures that the valve in the test equipment (4) is fully open.

9

Connect test equipment (4) to battery.

 The test equipment (4) is designed for 12 V and 24 V operation.

10

Switch on test equipment (4) and wait until self-test has been completed.

 During the self-test, all segments in the test equipment display (4) are briefly actuated. After the self-test, all three green LEDs in the display must be lit, otherwise there is a fault in the test equipment (4). Refer to test equipment operator's manual (4).

11

Pour in steering gear oil and vent steering.

Model 959

AR46.25-W-3002Z

Model 949 with steering 765.82

AR46.25-W-3001ZEA

Model 949 with steering RB8098, ZF8098

AR46.25-W-3001ZE

 Model 949 with steering 765.82
Do not adjust the hydraulic steering limiter. When checking the power steering pump, the setting screw can remain screwed into the hydraulic steering limiter.

 Bleed steering until values in the test equipment display (4) fluctuate by max. 1 bar or 1 l/min.
Leave vehicle jacked up after bleeding. Do not close engine hood.

Remove

12

Check oil temperature of steering.

 Briefly switch on the test equipment (4), if necessary.

If the oil temperature is higher than 40 °C.



Wait until oil temperature drops below 40 °C.

13

Disconnect test lines (1, 2) from vehicle and seal off.

 Collect escaping oil in a suitable container.

14

Assemble oil pressure line between power-steering pump (3) and steering gear (5) at connection.

 Union nut, oil pressure hose/line to fitting for power steering pump

*BA46.30-N-1002-01ZE

 Union nut, steering gear oil line/hose

*BA46.25-N-1001-04B

15

Disconnect test equipment (4) from battery.

16

Disconnect test lines (1, 2) from test equipment (4).

Only if it is required.

17

Fill and bleed steering gear oil.

Model 959

AR46.25-W-3002Z

Model 949 with steering 765.82

AR46.25-W-3001ZEA

Model 949 with steering RB8098, ZF8098

AR46.25-W-3001ZE

 Do not close hood yet.

18

Check steering for leak tightness.

 Visual inspection.

19

Install front section of front fender on driver's side.

Only on model 949

AR88.10-W-1500RE

20

Close hood.

Model 949

AR88.40-W-1000R

Model 959

AR88.40-W-1000Z

 Hydraulic power steering

Number

Designation

Model 959

Model 949

BA46.25-N-1001-04B

Union nut, steering gear oil line/hose

Line Ø 12 mm

Nm

­

-

Line Ø 15 mm

Nm

60

60

 Power steering pump

Number

Designation

Model 959

Model 949 with engine 926.9

BA46.30-N-1002-01ZE

Union nut, oil pressure hose/line to fitting for power steering pump

Nm

60

60

 Power steering pump

Number

Designation

Model 949 with engine 457.9

BA46.30-N-1002-01ZE

Union nut, oil pressure hose/line to fitting for power steering pump

Nm

60