BrakeVac II Operation Manual
Contents
1. ciis eee eee ee eee rna KKR aene nan nnn 3 DIRUPO CUI NER ET mE 3 4 PONS RINO 20 00 RR ra est herd ander ta aaa i et e E na ce MCN a bd iat 4 Automatic low fluid level warning system and shut Off mea eee aaa ee a aaa oa aia aaa a a a at 4 EMONGO Ne Tarik anler 8901 Une 4 Tips for hydraulic brake bleeding eee HH nnne aaa 5 SUCTION hose filter assembly eee eee eee eee eee nnn en KKR KKR KR EE EES 5 Brake Vac System BOIS cenis dr aa an EA 6 8 NILE A r m mdtrI uee trt Toe info motorvac com www motorvac com Why should the Brake system be Flushed Brake fluid is hygroscopic meaning it can absorb moisture from the air resulting in a dangerous reduction of its boiling point Water contaminated brake fluid under repeated working pressure boils and creates air bubbles Under severe conditions this can result in complete brake system failure Water contaminated brake fluid causes electrolysis to occur inside the brake system The oxygen contained in the water droplets cause oxidation Electrolysis and oxidation corrodes the hydraulic master cylinder and wheel cylinders and steel brake lines from the inside Pressure bleeding has been proven the most effective method in flushing and bleeding hydraulic brake systems Flushing the brake system and replacing the dirty and contaminated brake fluid with fresh brake fluid can often avoid expensive repairs2. System Features Front view MOTORVAC BrakeVec 1 info motorvac com www motorvac com System Features Back view Waste used fluid capture tank M 2 info motorvac com www motorvac com Safety Information amp Precautions The following safety instructions should be observed at all times when opening the MotorVac BRAKEVAC II e Perform a visual inspection before each use If the unit shows defects or damage do not use Have your equipment repaired by an authorized MotorVac Service Center e he MotorVac BRAKEVAC II is to be used only in accordance with the operator s manual e he MotorVac BRAKEVAC II is to be used only for the maintenance and repair of hydraulic brake fluid and clutch systems e Fil the MotorVac BRAKEVAC II with BRAKE FLUID ONLY Do not mix the different DOT standards together Never use the unit with any fluid other than BRAKE FLUID e WARNING USE OF FLUIDS OTHER THAN BRAKE FLUID CAN DAMAGE THE SEALS IN THE PUMPS USE OF OTHER FLUID CAN VOID THE WARRANTY e Follow all instructions from the Brake Fluid Manufacturer Read all cautions on the container Use proper precautions when coming into contact with brake fluid e Keep your MotorVac BRAKEVAC II clean Wipe your bleeder with a clean rag and non flammable solvent Wipe all residual fluids from the bleeder before use e Do not put oil gasoline or solvent soaked rags on the bleeder as this will create a fire hazard e Use on
3. 15 8620 Fax 905 615 9745 www motorvac com
4. MOTORUM Brake Vac ii Brake Fluid Service System Part No 500 6100 500 6105 USER MANUAL 500 8100 Serial Numbers 8100 1200 and up 500 8105 Serial Numbers 8105 0700 and up C ISO 9001 CERTIFIED 1324 Blundell Rd Mississauga ON Tel 905 615 8620 Fax 905 615 9745 www motorvac com Introduction Congratulations you now own the cleanest most efficient and user friendly brake fluid service machine available today Your new electric pressure brake bleeder is designed specifically for modern hydraulic brake and clutch systems It is advised that only professional technicians perform brake system service The MotorVac BRAKEVAC II equipment has been designed for use on all hydraulic brake and clutch systems especially Anti Lock Braking Systems The simplicity of our pressure bleeder makes it very user friendly and elimi nates the need for hands on training The large capacity reservoir allows for a single service on any vehicle The fluid should be drained and kept in a sealed container between vehicle services as the onboard storage is not air tight The MotorVac BRAKEVAC II System allows years of clean safe one man operation brake services Thank you for choosing MotorVac Sincerely The MotorVac Team info motorvac com www motorvac com Table of Contents Why should the Brake system be Flushed ii SYSTEM ESE ori 1 2 Safety Information amp Precautions
5. essure setting Then turn on the Pressure pump and turn the regulator knob in clockwise when starting from 0 PSI on the pressure gauge until the proper pressure is reached Automatic low fluid level warning system and shut off The MotorVac BRAKEVAC II will shut off the clean fluid pump automatically when the fluid level in the tank reaches 0 8 liters This ensures that no air will be injected into the brake system The low level warning light will illuminate alerting you to the low level condition Remove the fill cap and add fluid and replace cap Continue bleeding where you left off Emptying the tank after each use Use the Pressure hose and attach an adapter that will allow brake fluid to be drained into a container Place the adapter in a fashion that will allow the brake fluid to drain into a clean capture tank or bottle Turn on the Pressure switch to drain the brake fluid Brake fluid will start to flow immediately when the Pressure switch is turned to the ON position The tank level switch will turn off the flow when the brake fluid tank is almost empty To drain the remainder of the brake fluid from the tank and hose press and hold the Drain Tank switch until the brake fluid tank and hose is completely empty Release the Drain Tank switch and turn off the Pressure switch After filling the tank with new fluid attach any adapter to the black hose coupler and direct the fluid flow to a capture c
6. ly manufacturer s recommended adapters and accessories Always follow the vehicle manufacturer s service and maintenance instructions Brake Flush Service Procedure 1 Remove the fill cap from the Motorvac BRAKEVAC II clean fluid tank and fill with new brake fluid You can observe the fluid level by looking at the level indicator window at the front of the unit Replace the fill Cap 2 Attach the power cord to a good 12 volt DC power source 3 Install the proper master oylinder reservoir adapter and connect the black pressure hose coupling to the adapter 4 Turn the pressure switch to the ON position and check for leaks 5 Adjust the pressure regulator until the desired pressure is reached 45 Ib maximum Do not over pressurize the reservoir as it may become damaged To set pressure relieve any residual pressure from the service hose by inserting the fill adapter into the coupler at the hose end Open the regulator valve counter clockwise before starting the pump If control knob is locked pull outward slightly until knob clicks off the locking tab After starting the pump adjust the regulator in clockwise until the correct pressure reading is obtained Control knob can be locked by pushing knob in towards control panel 6 Attach the transparent vacuum hose to the bleeder adapter and connect to the vehicle s first wheel bleeder valve in the sequence Turn on the Vacuum switch Open the bleeder valve and obser
7. nsion hold down Specially designed for clutch reservoirs BA 06 8 info motorvac com www motorvac com Parts Service parts for the BrakeVac ll Brake Fluid Flushing Machine Please refer to the part numbers below when ordering parts for this unit Part Description 010 0027 Wheel 8 x 1 75 040 0604 Cap Nut 1 2 push on 040 0507 Axle Bushing Black Nylon 010 6008 Axle rear wheels 1 2 011 0051 Hose Bracket 020 8207 Harness external power 020 0038 Circuit breaker 15 amp 020 0090 Relay ear mounted 200 8119 Pressure regulator assembly 050 1308 Pressure gauge 020 1205 On off switches 020 1201 Drain tank switch momentary 020 0063 Light amber 020 0073 Light green 020 0083 Light red 020 1402 Low level switch in tank 010 6060 Fluid tank cap 010 7050 Waste fluid tank I gallon 050 1009 ocreen filter 200 8111 Output pressure hose assembly 080 8101 Coupler only Output side 1 4 080 3102 Adapter brake bleeder 200 8112 Suction hose assembly ZIM13 00828 Operators Manual 200 8125 Pump Kit BrakeVac II ORDERING PARTS Parts for the unit may be ordered by calling MotorVac Customer Service at 800 841 8810 or 905 615 8620 Please have your model and serial numbers available www motorvac com info motorvac com n 9 info motorvac com www motorvac com e 10 info motorvac com www motorvac com ZIM13 00828 Rev2 1324 Blundell Rd Mississauga ON Tel 905 6
8. ontainer Turn on the Pressure switch to bleed all the air out of the black hose prior to beginning a new service The unit is now ready for the next service I 4 info motorvac com www motorvac com Tips for hydraulic brake bleeding After installing the correct master cylinder reservoir adapter and connecting the MotorVac BRAKEVAC II you can begin the bleeding process Open one bleeder at a time until the brake fluid flows clean and free of air bubbles To better observe the brake fluid flow and insure cleanliness of the shop we recommend using the MotorVac vacuum recovery This will allow you to observe the fluid color keep the fluid off the shop floor and allow for easy fluid disposal After a complete hydraulic brake system overhaul we recommend that all bleeders be opened simultaneously so the air can escape by the path of least resistance This process eliminates backpressure and the possibility of the new fluid mixing with contaminated brake fluid remaining in the system When the fluid flows clean and free from bubbles close the bleeder nipples and tighten them one after the other and double check tightness We recommend during this pressure bleeding process to slowly press the brake or clutch pedal a few times to insure complete purging of air and fluid between the primary and secondary master cylinder chamber Fixed calipers can be equipped with multiple bleeder valves which can require a larger volume of brake fl
9. s domestics with Bosch or Teves master Cylinders BA 05 066 6005 m Universal round adapter With chain tenslon hold down Fits round master cylinders with a diameter of 800 to 3 150 BA 07 Expandable O ring with hold down chain Fits Honda with diameter of 2 91 and some Isuzu BA 08 info motorvac com www motorvac com O BrakeVac System Accessories MOTORVAC PART amp NUMBER DESCRIPTION 066 6007 Fits Honda master cylinders with and Inside diameter of 2 11 to 2 17 BA 09 Expandable o ring with adjustable hold down tabs Fits Toyota amp Lexus with diameter of 1 69 BA 10 066 6009 Expandable o ring with adjustable hold down tabs Fits Toyota amp Lexus with diameter of 2 75 BA 11 066 6010 Twin cylinders with rubber cones connected together with common hose Chain tension hold downs Fits into the inlet holes at the bottom of GM and Chrysler plastic master cylinders BA 14 replaces ST 100 066 6012 Twist on 2 tab with expandable o ring Fits Ford BA 02 066 6013 NISSAN ALTIMA XTERRA BA 13 info motorvac com www motorvac com NI OPTIONAL ADAPTORS NOT INCLUDED IN KIT 200 3118 MOTORVAC PART amp NUMBER DESCRIPTION 066 1100 Honda Civic adapter Plate adapter with 2 hold down chains for rectangular cast iron master cylinders BA 12 066 6014 Clutch master slave adapter S 1 67 Small universal round adapter with chain te
10. uid Each bleeder valve must be bled one after another In brake systems with load sensitive brake force regulators the hydraulic flow to the wheel cylinders may be restricted when the axles are hanging during lifting In this case the axles must be put under load Consult manufacture s repair manual for proper brake bleeding or brake fluid replacement procedures Caution In brake systems with a hydraulic brake booster the brake system operates with brake fluid and the hydraulic booster system operates on hydraulic fluid The two fluids must not be interchanged Suction hose filter assembly Filter screen must be cleaned routinely to avoid loss of suction gt Elbow part number 030 4814 Filter part number 050 1009 Unscrew cap to clean filter screen 5 info motorvac com www motorvac com BrakeVac System Accessories Basic Adaptor Kit 200 3118 Standard Adapter kit for BRAKEVAC II The following is a list of the adaptors included with your BrakeVac ll unit MOTORVAC PART amp NUMBER QTY DESCRIPTION 066 6000 Chrysler with twin caps 2 piece 3 tabs expandable O rings BA 01 066 6002 3 Tab twist on with Expandable o ring Fits Ford Hyundai Chrysler Kia Mazda Pontiac Nissan and Subaru BA 03 066 6003 Three tab twist on with expandable o ring Fits GM Chevrolet Cadillac Mazda Pontiac and Daewoo BA 04 066 6004 Threaded screw cap Fits all European makes as well a
11. ve the fluid flow When the fluid is clean close the bleeder valve 7 Bleed the brake system according to manufacturer s recommended sequence by moving the vacuum E IEEE e info motorvac com www motorvac com Brake Flush Service Procedure Cont d hose from bleeder to bleeder in the proper sequence 8 When finished turn the Pressure switch and the Vacuum switch to the OFF position The pressure will automatically relieve from the new fluid hose When the pressure on the gauge reaches O psi disconnect the new fluid hose from the master cylinder adapter Adjust the fluid level using adapters in either vacuum or pressure hoses as required 9 Remove master cylinder adapter 10 Reinstall the original master cylinder cover 11 Empty the waste capture tank into a recycle container 12 Empty the new fluid back to a sealed new brake fluid container to keep it dry and ready for the next vehicle service Note If the Pressure Bleeder does not operate when the switch is in the ON position check the circuit breaker mounted in the front of the unit Replace if necessary or contact your MotorVac BRAKEVAC II service center Adjusting the pressure regulator The pump has a preset pressure of 45 PSI or 3 bar by the manufacturer In some cases the recommended procedure may call for a lower pressure Release the locking knob by pulling outward then turn the knob counter clockwise to open the regulator to the lowest pr
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