Remove/install brake lines

AR42.10-D-0020TS

Remove/install brake lines

09.03.2020

Model

907, 910

Modification notes

12.12.2019

Work procedure revised.

The whole document

Shown on brake line (2) with line diameter 4.75 mm(d)

1

Retaining screw

2

Brake line

a

F-flange (115°)

d

Line diameter (Ø 4.75 mm)

d2

Flange diameter (Ø 7.1 0.18 mm)

X

Flange height (2.3 0.3 mm)

 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.Model 910 with engine 780.703

AS00.00-Z-0035-01A

 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

 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

 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 vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment

Model 910 with engine 780.703

AH00.00-Z-0300-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A

General information on malfunctions in the brake system

AH42.30-N-2007-01A

Notes on inspecting corrosion on brake lines

AH42.50-Z-0002-01A



Remove

1

Raise vehicle.

AR00.60-D-1000-04TS

Topical note

Special instructions for lifting and supporting vehicle

AH00.60-N-0100-01TS

2

Remove lower engine compartment paneling.

Model 907
with code XM1 (Noise reduction)
Model 910 with engine 651
with code XM1 (Noise reduction)
Model 910 with engine 780.703

AR61.20-D-1105TS

3

Remove underbody paneling.

Model 907
with code XM1 (Noise reduction)
Model 910 with engine 651
with code XM1 (Noise reduction)
Model 910 with engine 780.703

AR61.30-D-1001TS

4

Remove underfloor paneling from high-voltage battery module.

* Applies to Europe only

Model 910 with engine 780.703

AR61.30-D-1002TE

5

Define length of new brake line (2) to match old brake line (2).

If brake line (2) is partly replaced.


The separating points must be in perfect condition.
Malfunctions may occur otherwise.


Select separating points at an easily accessible point or remove brake line (2) if access is difficult.
Malfunctions may occur otherwise.

 The lines of the master brake cylinder to the hydraulic unit, plastic-coated lines and lines with flexible component are excluded from the repair.

 Two additional separating points per brake line (2) are permissible for partial replacement of a brake line (2).



Clean

6

Clean repair area thoroughly.


Thoroughly clean area around connecting points before opening hydraulic system.
Otherwise minute dirt particles in the hydraulic component parts can result in malfunctions and total failure of the hydraulic system.


Only use clean, lint free rags and cleaner free of mineral oil.
Otherwise, there may be malfunctions to and total failure of the hydraulic system.

 Clean brake line (2), brake line connections and immediate surrounding area on vehicle.

Assembly cleaner

*BR00.45-Z-1028-04A



Remove

7.1

Remove brake line (2).

If brake line (2) is completely replaced.

 Seal connections on vehicle.

 Collect escaping brake fluid.

 Commercially available devices/tools
Collection bowl

 Record plug

*129589009100

7.2

Disconnect brake line (2).

If brake line (2) is partly replaced.

 Seal connection on vehicle.

 Collect escaping brake fluid.

 Commercially available devices/tools
Collection bowl

 Flaring tool

*000589209900

 Record plug

*129589009100

8

Remove remaining piece of old brake line (2).

If brake line (2) is partly replaced.

 Seal connection on vehicle.

 Collect escaping brake fluid.

 Commercially available devices/tools
Collection bowl

 Record plug

*129589009100



Install

9

Determine line diameter (d) of new brake line (2).

If brake line (2) is partly replaced.

10

Match length of new brake line (2) to old brake line (2) with the pipe cutter.

If brake line (2) is partly replaced.

 Flaring tool

*000589209900

11

Slide retaining screws (1) onto brake line (2).

If brake line (2) is partly replaced.

 Use specified threaded collars only.

12

Flange on new brake line (2).

If brake line (2) is partly replaced.

AR42.10-S-0027-01E

 Only use brake lines (2) with F-flanges (115°) (a) as per Deutscher Industrie-Norm (DIN)  74234.

 Stamp holder in flanging tool kit (pre-flanging)

*BA42.00-P-1001-05A

 Stamp holder in flanging tool kit (post-flanging)

*BA42.00-P-1002-05A

 Screw, clamping plate to flanging tool kit

*BA42.00-P-1003-05A

ATE brake cylinder paste, article no.: 03.99020501.2

*BR00.45-Z-1078-06A

Assembly cleaner

*BR00.45-Z-1028-04A

 Flaring tool

*000589209900

13

Make flange on brake line (2) remaining in vehicle.

If brake line (2) is partly replaced.

AR42.10-S-0027-01E

 Make flange on corresponding sections of remaining brake line (2) depending on separating points.

 Stamp holder in flanging tool kit (pre-flanging)

*BA42.00-P-1001-05A

 Stamp holder in flanging tool kit (post-flanging)

*BA42.00-P-1002-05A

 Screw, clamping plate to flanging tool kit

*BA42.00-P-1003-05A

ATE brake cylinder paste, article no.: 03.99020501.2

*BR00.45-Z-1078-06A

Assembly cleaner

*BR00.45-Z-1028-04A

 Flaring tool

*000589209900

14

Adapt new brake line (2).

If brake line (2) is partly replaced.


Adapt brake line (2) according to old path using bending tool. A bending radius of 13 mm must not be dropped below.
Damage and malfunctions can otherwise occur.

 Flaring tool

*000589209900

15

Install new brake line (2).

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW


When routing the brake line (2) make sure there is sufficient distance to other components. There must be no kinking and no line narrowing on the brake line (2).
Damage and malfunctions can otherwise occur.

 Install brake line (2) free of tension and with correct torque on threaded connection.

 Retaining screw, brake line to brake hose

*BA42.10-N-1001-14TS

 Retaining screw, brake line to hydraulic unit

*BA42.10-N-1003-14TS

 Retaining screw, brake line to master brake cylinder

*BA42.10-N-1004-14TS

 Retaining screw, brake line to brake line threaded socket

*BA42.10-N-1005-14TS

 Box wrench socket

*000589770300



Check

16

Check surface of brake line (2) for signs of scratches and paint damage.

If necessary,



Repair any scratches or paint damage.

Zinc dust paint spray can

*BR00.45-Z-1055-07A



Install

17

Apply preservation agent thoroughly to brake line (2) after installation.

Cavity preservation (free of solvents), 1 liter

*BR00.45-Z-1011-05A

18

Install underfloor paneling on high-voltage battery module.

* Applies to Europe only

Model 910 with engine 780.703

AR61.30-D-1002TE

19

Install underbody paneling.

Model 907
with code XM1 (Noise reduction)
Model 910 with engine 651
with code XM1 (Noise reduction)
Model 910 with engine 780.703

AR61.30-D-1001TS

20

Install lower engine compartment paneling.

Model 907
with code XM1 (Noise reduction)
Model 910 with engine 651
with code XM1 (Noise reduction)
Model 910 with engine 780.703

AR61.20-D-1105TS

21

Bleed brake system.

AR42.10-D-0010TS



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

22

Check brake system for leaks.

AR42.10-D-0100-01TS

23

Perform brake test on test stand.



Brake test

AP42.00-D-4290TS

 Tightening torques for tools

Number

Designation

Model all (CAR, Light transporter)

BA42.00-P-1001-05A

Stamp holder in flanging tool kit (pre-flanging)

Nm

20

 Tightening torques for tools

Number

Designation

Model all (CAR, Light transporter)

BA42.00-P-1002-05A

Stamp holder in flanging tool kit (post-flanging)

Nm

40

 Tightening torques for tools

Number

Designation

Model all (CAR, Light transporter)

BA42.00-P-1003-05A

Screw, clamping plate to flanging tool kit

Nm

15

 Brake lines, brake hoses

Number

Designation

Model 907, 910

BA42.10-N-1001-14TS

Retaining screw, brake line to brake hose

Nm

14

 Brake lines, brake hoses

Number

Designation

Model 907, 910

BA42.10-N-1003-14TS

Retaining screw, brake line to hydraulic unit

Nm

14

 Brake lines, brake hoses

Number

Designation

Model 907, 910

BA42.10-N-1004-14TS

Retaining screw, brake line to master brake cylinder

Nm

14

 Brake lines, brake hoses

Number

Designation

Model 907, 910

BA42.10-N-1005-14TS

Retaining screw, brake line to brake line threaded socket

Nm

14

Repair materials

Number

Designation

Order number

BR00.45-Z-1011-05A

Cavity preservation (free of solvents), 1 liter

A 000 986 72 70 10

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01

BR00.45-Z-1055-07A

Zinc dust paint spray can

A 000 986 82 42 09

BR00.45-Z-1078-06A

ATE brake cylinder paste, article no.: 03.99020501.2

ATE, a brand of the Continental Corporation
http://www.ATE.de
http://www.ATE.de/kataloge/online-kataloge