Inspect condition of brake disks

AP42.10-P-4258BP

Inspect condition of brake disks

28.06.2017

Model

203

Shown on perforated brake disk (1)

010

Vernier caliper

1

Brake disk

2

Crack length

 Danger

Risk of death caused by vehicle slipping or toppling off during lifting

Only lift vehicle at the lift support points specified by the vehicle manufacturer.

AS00.00-Z-0032-01A

 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

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A



Remove

1

Remove wheel-and-tire assembly

AP40.10-P-4050Z



Check

2

Check brake disks (1) on front and rear axle for score marks and cracks

 Cracks can occur due to high stress.

 Brake disks (1) do not need to be replaced, if the crack length is (2) max. 25 mm. On brake disks with perforated or countersunk holes (1) measure the length of the cracks (2) including the hole diameter.

If the cracks are open or the score marks are deeper than 0.5 mm



Replace brake disks (1) subject to separate repair order.



Measure

3

Measure brake disk thickness on front axle using vernier caliper (010)

Brake disk thickness

*BE42.10-P-1001-08K

 Caliper gauge

*140589001900

Observe recommended limit dimensions. If the wear limit has been exceeded or will be exceeded before the next brake pad change.



Replace brake disks (1) subject to separate repair order.

4

Measure brake disk thickness on rear axle using vernier caliper (010)

Brake disk thickness

*BE42.10-P-1001-09P

 Caliper gauge

*140589001900

Observe recommended limit dimensions. If the wear limit has been exceeded or will be exceeded before the next brake pad change.



Replace brake disks (1) subject to separate repair order.



Install

5

Mount wheel and tire assembly

AP40.10-P-4050Z

Check values for front axle brake disks

Number

Designation

Model 203.004/006/035/045/204/206/235/245/706/735/745 with code 494/498/625

Model 203.004/006/204/206 except code 494/498/625/949/950 model 203.035/045/235/245/706/735/745 except code 494/498/625

BE42.10-P-1001-08K

Brake disk thickness

New

mm

25

25

Wear limit

mm

22

22,4

Check values for front axle brake disks

Number

Designation

Model 203.004/006/204/206 with code 949/950

Model 203.007/008 except code 949, except code 950

BE42.10-P-1001-08K

Brake disk thickness

New

mm

28

25

Wear limit

mm

26

22,4

Check values for front axle brake disks

Number

Designation

MODEL 203.016/064/216/264/747 except CODE 494, except CODE 498, except CODE 625

Model 203.016/064/081/216/264/281 with code 494/498/625

BE42.10-P-1001-08K

Brake disk thickness

New

mm

28

28

Wear limit

mm

25,4

26

Check values for front axle brake disks

Number

Designation

Model 203.018/065/076/218/265/276

MODEL 203.020/220 except CODE 949, except CODE 950

BE42.10-P-1001-08K

Brake disk thickness

New

mm

30

28

Wear limit

mm

27,5

26

Check values for front axle brake disks

Number

Designation

Model 203.020/220 with code 949/950

MODEL 203.040/240 except CODE 494, except CODE 498, except CODE 625, except CODE 949, except CODE 950

BE42.10-P-1001-08K

Brake disk thickness

New

mm

30

28

Wear limit

mm

28

25,4

Check values for front axle brake disks

Number

Designation

Model 203.040/240/740/747 with code 494/498/625

Model 203.040/207/208/240 with code 949/950

BE42.10-P-1001-08K

Brake disk thickness

New

mm

25

28

Wear limit

mm

22,4

26

Check values for front axle brake disks

Number

Designation

Model 203.042/043/046/243/246/707/708/742/743/746 model 203.207/208/242 except code 949, except code 950

Model 203.052/252 except code 494, except code 498, except code 625, except code 949, except code 950

BE42.10-P-1001-08K

Brake disk thickness

New

mm

25

28

Wear limit

mm

22,4

25,4

Check values for front axle brake disks

Number

Designation

Model 203.052/252 with code 494/498/625

Model 203.052/242/252 with code 949/950

BE42.10-P-1001-08K

Brake disk thickness

New

mm

25

28

Wear limit

mm

22,4

26

Check values for front axle brake disks

Number

Designation

Model 203.054/254 except code 949, except code 950 model 203.056/256 with code 494/498/625

Model 203.056/256 with code 949/950

BE42.10-P-1001-08K

Brake disk thickness

New

mm

28

30

Wear limit

mm

25,4

28

Check values for front axle brake disks

Number

Designation

Model 203.054/254 with code 949/950 model 203.056/256 except code 49, except code 498, except code 625, except code 949, except code 950 model 203.756

MODEL 203.061/261 except CODE 49, except CODE 498, except CODE 625, except CODE 949, except CODE 950 MODEL 203.081/281 except CODE 494, except CODE 498, except CODE 625

BE42.10-P-1001-08K

Brake disk thickness

New

mm

28

28

Wear limit

mm

26

25,4

Check values for front axle brake disks

Number

Designation

MODEL 203.061/261 with CODE 494+949, with CODE 494+950, with CODE 625+949, with CODE 625+950

Model 203.061/261 with code 494/498/625

BE42.10-P-1001-08K

Brake disk thickness

New

mm

28

25

Wear limit

mm

26

22,4

Check values for front axle brake disks

Number

Designation

Model 203.084/087/092/284/287/292/752/764

Model 203.718

BE42.10-P-1001-08K

Brake disk thickness

New

mm

28

30

Wear limit

mm

25,4

28

Check values for front axle brake disks

Number

Designation

Model 203.730/731

MODEL 203.740 except CODE 494, except CODE 498, except CODE 625 MODEL 203.741

BE42.10-P-1001-08K

Brake disk thickness

New

mm

25

28

Wear limit

mm

22,4

25,4

Check values for rear axle brake disks

Number

Designation

Model 203.004/006/035/045/706/730/731/735/745

MODEL 203.007/008 except CODE 949+950

BE42.10-P-1001-09P

Brake disk thickness

New

mm

9

9

Wear limit

mm

7,3

7,3

Check values for rear axle brake disks

Number

Designation

Model 203.007/008 with code 949/950

Model 203.016/020/054/056/061/064/081/084/087/092/204/206/207/208/216/220/235/240/242/243/245/246/252/254/256/261/264/281/284/287/292/741/747/752/756/764

BE42.10-P-1001-09P

Brake disk thickness

New

mm

10

10

Wear limit

mm

8,3

8,3

Check values for rear axle brake disks

Number

Designation

Model 203.018/218/718

Model 203.040/740 except code 498, except code 625

BE42.10-P-1001-09P

Brake disk thickness

New

mm

22

10

Wear limit

mm

19,4

8,3

Check values for rear axle brake disks

Number

Designation

MODEL 203.040/740 with CODE 498/625 MODEL 203.707/708/742/743/746

Model 203.042/043/046 except code 949, except code 950

BE42.10-P-1001-09P

Brake disk thickness

New

mm

9

9

Wear limit

mm

7,3

7,3

Check values for rear axle brake disks

Number

Designation

Model 203.042/043/046 with code 949/950

Model 203.052 except code 494, except code 498, except code 625

BE42.10-P-1001-09P

Brake disk thickness

New

mm

10

10

Wear limit

mm

8,3

8,3

Check values for rear axle brake disks

Number

Designation

Model 203.052 with code 494/498/625

Model 203.065/076/265/276

BE42.10-P-1001-09P

Brake disk thickness

New

mm

9

22

Wear limit

mm

7,3

19,5