Approved Test Media

WARNING: This page is about a different variant/trim than selected.

Test medium	Designation	Composition/purity
Helium He (gaseous, compressed)	4.6 (minimum quality) 5.0, etc. Not balloon gas	99.996 volume % (4.6) He 99.999 volume % (5.0) He
Forming gas	Forming gas 5	95% nitrogen N₂ and 5% hydrogen H₂
Leak-locating spray	e.g. TEGA test spray TPS 674	Request safety data sheet Address: Technische Gase u. Gastechnik GmbH, Werner-von-Siemens-Strase 18, 97076 Wurzburg

WARNING: Highly inflammable or explosive materials

Danger of fire or explosion
→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapours.

→ Attach warning sign in a clearly visible position.

→ Contain leaked media using non-flammable absorbent material and put it in a container designed for this purpose for disposal in accordance with local requirements.

→ Secure collection containers/vessels to prevent them from tipping over.

Attach warning sign -1- in a dearly visible position on the vehicle or position it in the immediate working area.

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Example of warning sign when working on the fuel system
Open plug-in coupling -1- for fuel low-pressure lines -2 and 3- in the engine compartment if it is not yet open.
Carefully pull red lock -arrow- down using a small slotted screwdriver and pull line connection apart.

CAUTION: Risk of damage!

Catch escaping fuel with a cloth and remove cloth.

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Fuel low-pressure line plug-in coupling connection
WARNING:
Leaking fuel supply lines
- Emerging fuel
- Risk of fire
  → Perform leak test.
Connect adapter hose -1- to the plug-in coupling on the low-pressure line.
Connect compressed air connection of filling unit to the adapter.

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Connecting test adapter to fuel line (similar to illustration)
Fit pressure reducer -3- onto gas bottle -1- and connect to connecting line of filling unit -4- .
Check threaded connections on pressure reducer are seated securely.

Check that compressed air adapter is seated securely.

Screw gas bottle onto screw plug -2- anti-clockwise by 2-3 turns.

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Tester on the vehicle
CAUTION:
Test pressure is exceeded
- Risk of damage to high-pressure pump
  → The test gas test pressure must not exceed a maximum pressure of 10 bar.
  
  → The setting is made at the pressure reducer.
Set the test pressure on the pressure reducer to between 7 and 9 bar (corresponds to a flow volume of approx. 26 - 28 litres of test gas -arrow- ).

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Adjusting pressure reducer tester settings
Using the test gauge -1- apply the ideal pressure to the closed fuel system.

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Test gauge

> Pressure 8 bar +/- 1 bar
Coat connections with commercially available leak-locating spray (see recommendation).
Leaks are identifiable from bubbling and can also be heard as a hissing sound.

There must be no pressure drop at the test gauge.
Leaks could be caused by a damaged sealing cone, loose connections or incorrectly fitted union nuts (damaged thread), for example.
Determine causes and correct immediately.
Remove test tools.
The test gases evaporate after a short time.