Bleed clutch operating system

AR25.20-G-0070B

Bleed clutch operating system

22.03.2016

Model

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

except code G48 (Electronic automated gearshift (EAS))

1

Cover

2

Expansion reservoir

Shown on engine 906 up to vehicle identification number end no. 205303

3

Bleed valve (clutch slave cylinder)

4

Bleed valve (clutch booster)

5

Bleed valve (clutch booster)

Shown on engine 906 as from vehicle identification number end no. 205304

3

Bleed valve (clutch slave cylinder)

4

Bleed valve (clutch booster)

5

Bleed valve (clutch booster)

 Danger !

Risk of death. There is a risk of death to persons located within the tilting range or underneath the raised dump body during operation. Risk of injury There is a risk of body parts being crushed or pinched when the dump body is lowered.

All persons must remain outside the tilting range of the dump body during its operation. Always secure the dump body with dump body supports before starting any work underneath it.

AS55.20-Z-0001-01A

 Danger !

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 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



Brake fluid notes

AH42.50-P-0001-01A



Check

1

Check accessible components in clutch operating system for external leaks

If there are problems



Replace affected components.

Bleeding

2

Replacing brake fluid of clutch operating system

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



AP25.20-G-2981B

3

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

Only with installed clutch booster.

4

Remove trim (1)

5

Connect filling unit to expansion reservoir (2)



Brake fluids (DOT 4 plus)

BB00.40-P-0331-00A



000 588 01 82 00 Filling unit

WS25.00-P-0016B

 Pay attention to manufacturer's operating instructions. The filling unit must be completely full.

 Model 405 with code C50 (VarioPilot (right/left transferable steering))
Poor access means that the expansion reservoir (2) has to be unfastened beforehand and then tightened again.

 Vent fitting

*000589032500

6.1

Tilt cab

With platform body

Model 405

AR60.80-G-0005B

6.2

Raise and secure tipper platform

With tipper platform

 See operator's manual.

7

Switch on filling unit

 Adjust the bleeding pressure to max. 2.7 bar. The bleeding pressure must not drop below 1.5 bar. The filling unit remains switched on during the entire bleeding procedure.

8.1

Bleed clutch operator at bleed valve (3)

Model 405 with engine 900, 904

 Repeat the bleeding procedure until the brake fluid is discharged free of bubbles from bleed valve (3).
Brake fluid which has been removed must not be reused.

 Fully depress the clutch pedal once to support the bleeding procedure.

8.2

Bleed clutch operator first at bleed valve (3), then at bleed valve (4) and then at bleed valve (5)

Model 405 with engine 902, 906

 Repeat the bleeding procedure until the brake fluid is discharged free of bubbles at each bleed valve (3, 4, 5).
Brake fluid which has been removed must not be reused.

 Fully depress the clutch pedal once to support the bleeding procedure.

9

Switch off filling unit

10.1

Lower cab

With platform body

Model 405

AR60.80-G-0005B

10.2

Unlock and lower tipper platform

With tipper platform

 See operator's manual.

11

Remove filling unit

12

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



AP25.20-G-2910B

13

Check clutch operating system



AP25.20-G-2957B

14

Install cover (1)