Remove/install clutch operator protection valve

AR25.20-B-0140A

Remove/install clutch operator protection valve

12.02.16



Remove and install

 The here described hydraulic tubes are standard, various types of connections are detailed here, however, small differences may occur, due to differences in the tubes and their fastenings length, according to the type of vehicle and adopted gearbox.

The flexible hoses can have connections of the type (B) or (C), according to the application needs.

The metallic tubes have always connections of the (A) type, with rotary overlaid connections, this enables them to be connected easily with the fixed connections of the flexible hoses or cylinders.

1

Disconnect the general switch

2

Open the vehicle's front cover

Danger!

Risk of poisoning due to ingestion of brake fluid. Risk of injury due to contact of the skin and eyes with brake fluid

Drain and store brake fluid only in its original package. Wear protective clothes and goggles.

AS42.50-B-0001-01A

3

Remove by suction the brake fluid from the reservoir. Empty totally the hydraulic clutch actuation system

 Collect the fluid in an appropriate recipient and eliminate it in an environment friendly manner.

Utilize appropriate equipment for brakes, clutch and steering test and bleeding.

4

Remove the hydraulic reservoir (1)

Install: Utilize a new elastic ring (4) for the cylinder connection (5).

5

Unfasten the connections (A) from the metallic end (10) or intermediate tubes (8)

 The metallic tubes must not be folded or forced during their removal, handling or installation.

6

In the case there are clamps, remove the nuts (18), the bolts (16) with the flat washers (17) and remove the metallic tubes together with the clamps (12)

 Eventually the plastic clamps (11) that fasten the wiring harnesses or other tubes must be cut, if necessary.

Install: Utilize new plastic clamps (11).

7

Open slightly the clamps (12) and remove them from the metallic tubes

Install: Put new clamps (12).

8

In order to remove the intermediate hose (6.1)

 Hold the hose by the connections hexagonal part (C) and unfasten the overlaid connections (9) from the metallic tubes at (A).

9

Remove the hose (6) at the hydraulic sender cylinder (5)

 In order to remove, unfasten firstly the connection (A) from the metallic tubes (8) and remove it from the connection (C), and at last, remove the connection (B) from the cylinder (5).

In order to install the hose (6) connect it firstly to the cylinder (5) in the connection (B) and later connect the metallic tubes (C) holding (C) and screwing the connection (A).



Clean

10

Clean all the components and tubes with alcohol purchased in a drugstore

 The hydraulic components must not be cleaned with gasoline, kerosene or diesel oil. Petroleum by-products damage the rubber components.

 Put dry and clean compressed air in the tubes. If they will stay in storage, their ends must be covered with appropriate plastic plugs.



Check

11

Folded or deformed tubes or with connections in poor conditions must be replaced

12

Flexible hoses which have been used for a long time, those that are parched or damaged, must be replaced

13

Install in reverse direction

 Pay attention to have the tubes connected firstly to the hydraulic cylinders and among themselves, and, only thereafter, be placed, adjusting the clamps in the supports openings (13).

14

Replenish the hydraulic system with new brake fluid

 Use the specified brake fluid.

*BR00.45-B-1011-06A

15

Bleed the hydraulic system

AR25.20-B-0070B

16

Check the tightness of the system

17

Check the perfect operation of the clutch

Número

Denominação

Número de pedido

BR00.45-B-1011-06A

Brake fluid as per DBL 7760.30 (DOT 4)

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