Test brake system with pressure tester for leaks

AR42.10-S-0015S

Test brake system with pressure tester for leaks

26.11.2019

Model

636.705/813

Model

639.601/603/605/701/703/705/711/713/811/813/815

2

Pressure tester



Check

 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

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

 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

Topical note

General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

AH00.00-Z-0300-01A

Topical note

Notes on externally invisible brake fluid loss

AH42.10-P-9406-02A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A

1

Raise vehicle with vehicle lift

AR00.60-S-1000S

2

Unscrew vent valve on brake caliper

3

Connect pressure tester (2) with connection fitting to brake caliper


Do not use pressure testers for hydraulic fluid. Otherwise the brake fluid can become mixed with mineral oil.
This results in brake failure.

4

Lower vehicle with vehicle lift

5

Bleed pressure tester (2)

 See manufacturer's operating instructions.

6

Produce vacuum for the brake booster

 Without code (MA0) E-CELL 60 kW, allow engine to run at a moderate rotational speed and generate as high a vacuum as possible by suddenly releasing accelerator pedal and then switch off engine again.
With code (MA0) E-CELL 60 kW, switch on ignition and switch off again after approx. 15  s.

7

Install brake pedal jack with adapter between brake pedal and driver seat

 Ensure that brake pedal jack is seated correctly.

 Brake pedal jack

*000589183100

 Adapter for brake pedal winch

*211589003100

8

Depress the brake pedal as far as possible with the brake pedal jack and observe the pressure drop

 During the test duration of 5  min, the pressure drop may not be more than 5  % of the value displayed at the start.

9

Remove brake pedal jack with adapter between brake pedal and driver seat

10

Operate brake pedal several times and reduce vacuum by doing so

11

Install brake pedal jack with adapter between brake pedal and driver seat

 Ensure that brake pedal jack is seated correctly.

 Brake pedal jack

*000589183100

 Adapter for brake pedal winch

*211589003100

12

Reset brake pedal jack to test pressure

 Turn back brake pedal jack until a test pressure of 3 bar is shown on the pressure gauge. During the test duration of 2 min, the line pressure must not drop off.

13

Remove brake pedal jack with adapter between brake pedal and driver seat

14

Raise vehicle with vehicle lift

15

Disconnect pressure tester (2) with connection fitting from brake caliper

16

Screw in vent valve on brake caliper

 Bleed valve on floating caliper (front axle)

*BA42.10-N-1001-03A

 Vent valve on rear axle floating brake caliper

*BA42.10-N-1003-12H

 Torque wrench

*001589752100

17

Bleed brake system

Bleed brake system

AR42.10-S-0010S

 After the test, only bleed the brake caliper to which the pressure tester (2) was connected.

18

Bleed brake system with STAR DIAGNOSIS

AR42.10-S-0012S


Only perform
if the ventilation remains insufficient after the normal method

 Front axle floating caliper

Number

Designation

Model 636.705/813

Model 639.601/603/605/701/703/705/711/713/811/813/815

BA42.10-N-1001-03A

Bleed valve on floating caliper (front axle)

ITT

Nm

–

–

Bosch

Nm

10

10

Brembo

Nm

–

10

 Rear axle brake caliper

Number

Designation

Model 636.705/813

Model 639.601/603/605/701/703/705/711/713/811/813/815

BA42.10-N-1003-12H

Vent valve on rear axle floating brake caliper

Nm

10

10