Bleed clutch operating system

AR25.20-G-0070BB

Bleed clutch operating system

19.06.2018

Model

405.100/101/102/103/120/121/122/123/200/201/220/221

with code G48 (Electronic automated gearshift (EAS))

Shown except code (C50) Vario Pilot, right/left transferable steering

1

Trim

2

Expansion reservoir

3

Emergency clutch pedal

3.1

Release

Shown with code (C50) Vario Pilot, right/left transferable steering

1

Trim

2

Expansion reservoir

3

Emergency clutch pedal

3.1

Release

4

Vent valve

5

Clutch booster

6

Vent valve

7

Bleed valve (slave cylinder)

8

Vent valve

9

Vent valve

B23

EAS clutch actuator

Y39

EAS protection valve

Y39y1

Protective preselect valve 1

Y39y2

Protection preselect valve 2

Y39y3

Clutch protection valve

Bleeding

 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

 Caution

Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

Notes on bleeding clutch operating system

AH25.20-N-0002-01BC

1

Open engine hood

AR88.40-G-1000B

2.1

Tilt cab

With platform body

AR60.80-G-0005B

2.2

Raise and secure dumper flatbed

Without platform body

 See operator's manual.

2.3

Open engine hood

Without platform body

AR88.40-G-1000B

3

Replacing brake fluid of clutch operating system

Only if the brake fluid has not been changed within the last three years.



Clutch actuation - replace brake fluid

AP25.20-G-2981BB

4

Fill compressed-air system up to cutoff pressure and switch off engine

5

Remove trim (1)

6

Install sieve in expansion reservoir (2)

Up to VIN end no. 212869

 If there is no sieve in the expansion reservoir (2), it has to be retrofitted.

7

Connect filling and bleeding device to expansion reservoir (2)

Topical note

Brake fluid notes

AH42.50-P-0001-01A



000 588 01 82 00 Filling unit

WS25.00-P-0016B

 To ensure that bleeding is performed properly, only the approved filler/bleeder units should be used.
Pay attention to manufacturer's operating instructions. The filler/bleeder unit must be completely full.

 On vehicles with code (C50) Vario Pilot, right/left transferable steering, poor accessibility means that the expansion reservoir (2) must be detached beforehand and then reattached afterwards.

 Hose connection

*000589022500

 Vent fitting

*000589032500

Observe Specifications for Operating Fluids for brake fluid:





Brake fluids (DOT 4 plus)

BB00.40-P-0331-00A

8

Secure bleed hose to bleed valve (4) of clutch booster (5) using a hose clamp

9

Operate release (3.1) and fold out emergency clutch pedal (3)

10

Switch on ignition

 During this procedure, the protection preselect valve 1 (Y39y1) on the EAS protection valve (Y39) is energized and the system is switched to the pedal circuit.

Bleed pedal circuit

11

Switch on filler/bleeder unit

 Adjust the bleeding pressure to max. 2.7 bar. The bleeding pressure must not drop below 1.5 bar. The filler/bleeder unit remains switched on during the entire bleeding procedure.
Bleeding volume for the entire bleeding procedure min. 1 l to max. 3 l.

12

Open bleed valve (4) on clutch booster (5) and allow brake fluid to flow through

 Brake fluid which has been removed must not be reused.
During the bleeding procedure, depress the emergency clutch pedal (3) slowly several times until the brake fluid is discharged without bubbles. Always wait for 5 seconds each time the clutch pedal is depressed.

13

Perform bleeding procedures in sequence at bleed valve (6) of clutch booster (5), then at bleed valve (7) of slave cylinder and finally at bleed valves (8, 9) of EAS protection valve (Y39)

 Brake fluid which has been removed must not be reused.
Secure the bleed hose to each bleed valve (6, 7, 8, 9) using a hose clamp.
During the bleeding procedure, depress the emergency clutch pedal (3) slowly several times until the brake fluid is discharged without bubbles. Always wait for 5 seconds each time the clutch pedal is depressed.

 Bleed valve to protection valve

*BA25.20-N-1008-01I

Bleed the automatic circuit

14

Switch off ignition

 The instrument must be completely Off.

15

Operate release (3.1) and fold in emergency clutch pedal (3)

16

Switch on ignition

 During this procedure, the clutch protection valve (Y39y3) on the EAS protection valve (Y39) is energized and the system is switched to the automatic circuit.

17

Perform bleeding procedures in sequence at bleed valves (4, 6) of clutch booster (5), then at bleed valve (7) of slave cylinder and finally at bleed valves (8, 9) of EAS protection valve (Y39)

 Brake fluid which has been removed must not be reused.
Secure the bleed hose to each bleed valve (4, 6, 7, 8, 9) using a hose clamp.

 During the bleeding procedure, press the function button (left button) on the gearshift lever, push the gearshift lever forwards and release again.
Repeat this process several times for each bleed valve (4, 6, 7, 8, 9) until the brake fluid is discharged free of bubbles. Always wait for 5 seconds between each process.

 Bleed valve to protection valve

*BA25.20-N-1008-01I

18

Carry out the bleeding processes in the reverse order

 Brake fluid which has been removed must not be reused.

 Sequence of bleeding procedures:
First bleed at bleed valve (9) and then at bleed valves (8, 7, 6, 4).
Secure the bleed hose to each bleed valve (9, 8, 7, 6, 4) using a hose clamp.
Open bleed valves (9, 8, 7, 6, 4) only briefly (approx. 2 s) and close again.

 Bleed valve to protection valve

*BA25.20-N-1008-01I

19

Switch off filler/bleeder unit and put in its unpressurized state

 In order reach the unpressurized state, the plug socket must be separated from the breather connection.

 Vent fitting

*000589032500

20

Carry out function test in automatic mode

 To do this, attempt to engage a gear with the ignition switched on (the gear indicator may flash). If it is not possible to engage a gear, the clutch system must be bled again completely (attach the plug to the breather connection and repeat operation steps 6 to 17).

 Vent fitting

*000589032500

21

Check emergency clutch actuation



Electronic automated gearshift - check clutch emergency actuation

AP25.20-G-2956BB

 The compressed-air system must be filled again up to the cutoff pressure.

22

Detach filler and bleeding unit

 Pay attention to manufacturer's operating instructions.

 Hose connection

*000589022500

 Vent fitting

*000589032500

23

Check fluid level in expansion reservoir (2); correct if necessary



Clutch mechanism - inspect fluid level, adjust to correct level

AP25.20-G-2910BB

24

Install cover (1)

25.1

Lower cab

With platform body

Overview - Tilt cab to repair position and tilt it back to normal position

AR60.80-G-0005B

25.2

Release and lower dumper flatbed

Without platform body

 See operator's manual.

26

Close engine hood

Without platform body

AR88.40-G-1000B

27

Operate the parking brake when the engine is switched off and engage gear

 Ignition switched on.

28

Operate release (3.1) and fold out emergency clutch pedal (3)

29

Fully depress emergency clutch pedal (3) slowly until it pushes back at end position; hold pedal at this position

30

Shift gearshift lever to "Neutral", switch off ignition and release emergency clutch pedal (3)

31

Operate release (3.1) and fold in emergency clutch pedal (3)

32

Perform long initialization sequence

AR54.21-G-0007-02BB

 Clutch operating system

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA25.20-N-1008-01I

Bleed valve to protection valve

Nm

15