Test brake system with pressure tester for leaks

AR42.10-P-0015A

Test brake system with pressure tester for leaks

18.11.09

29.7.09

Value changed: Bleed screw to brake caliper

Model 203

Model 209 209.377 except with code P98

*BA42.10-P-1004-10C



Checking

Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

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



Notes on externally invisible brake fluid loss

AH42.10-P-9406-02A



Notes on repairs to brake system

AH42.00-P-0003-01A



Notes on handling brake fluid

AH42.50-P-0001-01A

Danger!

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

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

AS00.00-Z-0010-01A

1

Lift/jack up vehicle

Except model 203, 209.3/4

Model 203, 209.3/4

AR00.60-P-1000P

2

Remove bleed screw at brake caliper and connect pressure tester (051)

 The pressure tester (051) for hydraulic fluid systems must not be used for systems with brake fluid otherwise the brake fluid is mixed with mineral oil which can lead to failure of the brake.

Pressure tester

3

Bleed pressure tester (051).

4

Switch off easy entry/exit function for driver seat and steering wheel

On vehicles with memory and multifunction steering wheel.

 Otherwise the driver seat and steering wheel move to a different position, e.g. when the driver door is opened/closed. The seat may be damaged when the brake pedal jack (080) is installed.

 See Operator's Manual



High-pressure check

5

Produce vacuum for the brake booster

 Allow the engine to run at moderate speed and by jerkily releasing the accelerator pedal, produce as high a vacuum as possible.

6

Install brake pedal winch (080) with adapter for brake pedal winch between brake pedal and seat

 Protect brake pedal and seat against damage.

Brake pedal jack

*000589183100

Adapter for brake pedal jack

*211589003100

7

Depress the brake pedal as far as possible with the brake pedal jack (080) and observe the pressure drop

 The pressure loss during the test duration of 5 minutes must not exceed 5 % of the regulated value.

 Brake pedal winch

*000589183100

Adapter for brake pedal jack

*211589003100



Low-pressure testing

8

Switch off engine and operate brake pedal until vacuum is reduced

9

Turn back brake pedal winch (080) until a line pressure of approx. 3 bar overpressure is still indicated on the pressure gauge

 The line pressure must not fall throughout the duration of the test (2 minutes).

 Brake pedal winch

*000589183100

Adapter for brake pedal jack

*211589003100

10

Disconnect pressure tester (051)

Pressure tester

11

Bleed brake system

Model 129, 140, 170, 202, 208, 210

AR42.10-P-0010A

Model 203, 209.3/4

AR42.10-P-0010P

 Only bleed the brake caliper which the pressure tester (051) was connected to.

Model 129, 140:

 Bleed screw to brake caliper

*BA42.10-P-1002-10I

Model 170:

 Bleed screw to brake caliper

*BA42.10-P-1002-10P

Model 202:

 Bleed screw to brake caliper

*BA42.10-P-1002-10K

Model 208:

 Bleed screw to brake caliper

*BA42.10-P-1002-10D

Model 203, 209:

 Bleed screw to brake caliper

*BA42.10-P-1004-10C

Model 210:

 Bleed screw to brake caliper

*BA42.10-P-1002-10F

Number

Designation

Model
129

Model
140 without special protection

Model
140 with
special protection

BA42.10-P-1002-10I

Bleed screw to brake caliper

Nm

7

7

7

Number

Designation

Model
170

BA42.10-P-1002-10P

Bleed screw to brake caliper

Nm

7

Number

Designation

Model
202.018/020/
022/023/033/
078/080/081/
083/087/093/
120/121/122/
125/133/134/
180/182/193/
194,
Model
202.028
up to 08/95

Model
202.024/025/
026/029/082/
085/086/088/
089/128/188,
Model
202.028
as of 09/95

BA42.10-P-1002-10K

Bleed screw to brake caliper

Nm

7

7

Number

Designation

Model
208

BA42.10-P-1002-10D

Bleed screw to brake caliper

Nm

7

Number

Designation

Model
203

Model
209
209.377
except with code P98

Model 209.377 with code P98

BA42.10-P-1004-10C

Bleed screw to brake caliper

Nm

14

14

17

Number

Designation

Model
210

BA42.10-P-1002-10F

Bleed screw to brake caliper

M8

Nm

7