Test Brake System With Pressure Tester For Leaks - Ar42.10-D-0015TS

Model 907 

Shown on model 907, left side of vehicle 

	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
	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
	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
	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
	Notes on externally invisible brake fluid loss		AH42.10-P-9406-02A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Brake fluid notes		AH42.50-P-0001-01A
	Remove
1	Raise vehicle.		AR00.60-D-1000-04TS
	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	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.	WS42.00-P-0014B
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	Fig 1
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	Fig 1
		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	Fig 1
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	Fig 1
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 If the pressure drops, ↓ determine leakage point and replace damaged component parts.	Fig 1
15	Remove brake pedal jack between brake pedal and driver's seat.	Brake pedal jack	Fig 1
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.	After the check, bleed only the brake caliper to which the pressure tester (2) was connected.	AR42.10-D-0010TS

CHECK VALUES FOR HYDRAULIC BRAKING SYSTEM

Number	Designation			Model 907
BE42.50-N-1001-01A	Low-pressure test of brake system	Test pressure	bar	2...5
		Test duration	min	5
		Max. pressure loss	%	-

CHECK VALUES FOR HYDRAULIC BRAKING SYSTEM

Number	Designation			Model 907
BE42.50-N-1002-01A	High-pressure test of brake system	Test pressure	bar	50...100
		Test duration	min	10
		Max. pressure loss	%	10

FRONT AXLE BRAKE CALIPER

Number	Designation		Model 907
BA42.10-N-1002-10TS	Vent valve at front axle brake caliper	Nm	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

Fig 1: Brake Pedal Jack (000 589 18 31 00)

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01