Test brake system with pressure tester for leaks

AR42.10-D-0015TS

Test brake system with pressure tester for leaks

06.03.2020

Model

907, 910

Shown on model 907, left side of vehicle

2

Pressure tester

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger

Risk of accident when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work.

Before starting the engine, actuate brake pedal several times until pressure is built up and maintained in the brake system.

AS42.50-Z-0002-01A

 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

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



Remove

1

Raise vehicle.

AR00.60-D-1000-04TS

Topical note

Special instructions for lifting and supporting vehicle

AH00.60-N-0100-01TS



Clean

2

Clean area surrounding bleed valve on a brake caliper.

Assembly cleaner

*BR00.45-Z-1028-04A

3

Remove bleed valve from cleaned brake caliper.



Check

4

Mount pressure tester (2) with connection fitting to cleaned brake caliper.



000 588 07 21 00 Test equipment

WS42.00-P-0014B


Do not use pressure tester (2) for hydraulic fluid.
The brake fluid can otherwise be mixed with hydraulic fluid, which can cause brake failure.

 Mount pressure tester (2) to brake caliper without bleed valve.

5

Lower vehicle.

6

Bleed pressure tester (2).

 See manufacturer's operating instructions.

7

Start engine and run at medium speed.

 This generates vacuum in the brake booster.

8

Install brake pedal jack between brake pedal and driver's seat.

 Make sure that the  brake pedal jack is correctly seated.

 Brake pedal jack

*000589183100

9

Depress brake pedal with brake pedal jack as far as possible and note pressure drop.

 During the test duration of 10 min, the pressure drop may not be more than 10 % of the value displayed at the start.

High-pressure test of brake system

*BE42.50-N-1002-01A

 Brake pedal jack

*000589183100

If pressure drop is > 10 %,



determine leakage point and replace damaged component parts.

10

Remove brake pedal jack between brake pedal and driver's seat.

 Brake pedal jack

*000589183100

11

Switch off engine.

12

Remove vacuum in brake booster.

 To do this, operate brake pedal several times.

13

Install brake pedal jack between brake pedal and driver's seat.

 Make sure that the  brake pedal jack is correctly seated.

 Brake pedal jack

*000589183100

14

Adjust test pressure.

 To do so, turn  brake pedal jack forward or back until test pressure of 5 bar is displayed on manometer. During the test duration of 5 min the line pressure may not drop off.

Low-pressure test of brake system

*BE42.50-N-1001-01A

 Brake pedal jack

*000589183100

If the pressure drops,



determine leakage point and replace damaged component parts.

15

Remove brake pedal jack between brake pedal and driver's seat.

 Brake pedal jack

*000589183100

16

Raise vehicle.

17

Remove pressure tester (2) with connection fitting from brake caliper.



000 588 07 21 00 Test equipment

WS42.00-P-0014B

18

Install bleed valve onto brake caliper.

 Bleed valve to brake caliper

*BA42.10-N-1003-12TS

 Vent valve at front axle brake caliper

*BA42.10-N-1002-10TS

19

Bleed brake system.

AR42.10-D-0010TS

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

Check values for hydraulic braking system

Number

Designation

Model 907

Model 910

BE42.50-N-1001-01A

Low-pressure test of brake system

Test pressure

bar

2...5

2...5

Test duration

min

5

5

Max. pressure loss

%

-

-

Check values for hydraulic braking system

Number

Designation

Model 907

Model 910

BE42.50-N-1002-01A

High-pressure test of brake system

Test pressure

bar

50...100

50...100

Test duration

min

10

10

Max. pressure loss

%

10

10

 Front axle brake caliper

Number

Designation

Model 907

Model 910

BA42.10-N-1002-10TS

Vent valve at front axle brake caliper

Nm

14

14

 Rear axle brake caliper

Number

Designation

Model 907
except code IT5 (5.0 tonner)

Model 907
with code IT5 (5.0 tonner)

BA42.10-N-1003-12TS

Bleed valve to brake caliper

Nm

14

14

 Rear axle brake caliper

Number

Designation

Model 910

BA42.10-N-1003-12TS

Bleed valve to brake caliper

Nm

14

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01