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USERS MANUAL - Phoenix Systems

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1. PHOENIX SYSTEMS The Worlds Bes ee ror sie ng Clutches Bral USERS MANUAL U One Tool Every Known Method of Bleeding PHOENIX INJECTOR f 7 RIP Pressure amp p Vacuum Bleeding Quick Flush ersten Pulse Generator General Instructions Troubleshooting See Quick Start pages 11 13 TABLE OF CONTENTS Warranty Information Phoenix Injector Features 10 Pak Module Smart Pak Module How To Use Fittings and Adapters Basic Function and Setup Modular Adapters Quick Start Prepare the Phoenix Injector Quick Start Basic Techniques for Bleeding and Flush Brake System Bleeding and Flushing Brake Bleeding Introduction Brake Bleed Open Top Reservoirs Brake Bleed Cast Iron or Screw Cap Reservoirs Brake and Clutch Special Applications Brake Fluid Testing m Reverse Fluid Injection Reverse Fluid Injection for Clutches Pulse Generator Quick Flush and Cross Bleed Cylinder Flush Bench Bleeding with the Phoenix Injector Troubleshooting Special Instructions Cleaning amp Re lubricating Exploded Views Frequently Asked Questions CAUTION TO AVOID PERSONAL INJURY AND OR VEHICLE DAMAGE Some precautions are specified in this manual and should be noted to avoid personal injury or vehicle damage It is not possible for these cautions to cover all c
2. 1 RFI or Pressure Techniques Injection Male F Vacuum Mal Luer Female 1 Connect to Black coupler To Hydraulic System The Injection and Vacuum couplers attached to the Injector are the male half of the coupler Since the adapter assemblies and Bottle Paks are equipped with the female half they can be alternated The Injector in the diagram is connected for RFI Pressure bleeding or Cross Bleed Vacuum App Injection Male Luer Female Connect to Black coupler Luer Female From Hydraulic System The Injector in this diagram is connected for Vacuum bleeding or flushing by simply reversing the connections 10 QUICK START Prepare the Phoenix Injector Step 1 Fill the Bottle 1 Fill bottle with 120z a of new approved j f brake fluid Nees 2 Never remove fluid below Minimum mark or injector may draw air L Minimum Fluid Mark Step 2 Remove and Measure Fluid Fill reservoir to proper level and submerge vacuum coupler into reservoir Squeeze injector handle to pump fluid from master reservoir into designated container Use a separate bottle for used fluid Measure the fluid removed This will help determine the maximum injection amount during RFI Measure the fluid removed by counting the number of strokes Remember each Injector barrel is graduated Discard old fluid in approved manner Remove old fluid from Injector and lines Inj
3. BOTTLE LEAKS TROUBLESHOOTING POSSIBLE CAUSE AERATED FLUID AIR TRAPPED IN HYDRAULIQ SYSTEM INSUFFICIENT RFI UNIQUE SYSTEM REQUIREMENTS LOSS OF COMPONENT INTEGRITY BLEEDER VALVE CLOSED MASTER CYLINDER PISTON NOT RETRACTED BLEEDER VALVE CHECK VALVE DAMAGED OR PLUGGED LINE OR FITTING RESERVOIR CAP INSTALLED ANTI LOCK ACCESSORIES OR UNIQUE VALVING BOTTLE VENT IS OBSTRUCTED COUPLERS ATTACHED INCORRECTLY RECOMMENDED SOLUTION Utilize new fluid Minimize exposure to air Do not use INJECTOR to fill container Use slow steady injection strokes Do not agitate fluid When fluid is drawn into barrel itis momentarily placed under a slight vacuum Depending on the type of brake fluid minute gas bubbles may appear while under lower pressure These micro bubbles should be reduced when placed under pressure This is normal but take care Not to aerate fluid with repeated fluid transfer Make sure quick disconnects are secured and not leaking Use a combination of RFI pressure or vacuum bleeding techniques For vehicles with master cylinder angled upward it may be necessary to raise the rear of the vehicle to level master cylinder to prevent air from being trapped in end of master cylinder Repeat RFI bleeding procedure Review manufacturer s recommended bleeding procedure There may be a specific task that must be completed prior to using any method Inspect hydraulic system compon
4. Difference Between Bleed and Flush It is important to understand the difference between brake system bleeding and flushing Brake system bleeding is the process of removing air from the brake system If a sufficient amount of air is present in a hydraulic system the brake pedal may feel spongy or not work at all Air is compressible fluid is not The air will compress prior to the force being applied to the hydraulic components That is why pumping the brake pedal improves its response It is important to remove as much air as possible The ultimate goal of brake bleeding is to remove all the air The Phoenix Injector is your best weapon at achieving a firm pedal and removing the maximum amount of air Contamination Brake system flushing is the process of removing old brake fluid and contaminants from the brake system Contamination is simply defined as any substance present in a system that is not designed to be present There are two types of contamination Normal and Abnormal Normal contamination of brake fluid includes many substances that are found in the normal break down of brake fluid such as dissolved metals oxidation of rubber and plastics moisture dirt and air Abnormal contamination of brake fluid includes other automotive fluids like power steering fluid transmission fluid and oil In the case of Abnormal contamination it is recommended to completely flush the hydraulic system and replace all rubber components th
5. If fluid will not inject in reverse manner 1 Make sure reservoir cap is removed 2 Remove the bleeder valve and inspect for blockage 3 Check for check valve in bleeder valve 4 Clutch master cylinder may have faulty check valve Make sure pedal is not hanging Any one component of the clutch system can be bled independently Some Mazda or other vehicles are equipped with a check ball in the bleeder valve The check ball must be removed prior to RFI and reinstalled after system in bled Due to the small volume of the clutch master reservoir it is helpful to gravity bleed the clutch first Some clutches may require 2 RFI procedures to remove trapped air Increasing injection pressure on clutch systems will assist removal of trapped air Ifyou are having trouble with a Ford Ranger unbolt master cylinder and turn upward If replacing the master cylinder bleed system prior to mounting Use of short rapid strokes Pulse Generator Technique is most effective for difficult bleeding jobs Your Injector has an adjustment to change the stroke of the piston It may also be necessary to raise the front of the vehicle to improve angle of master cylinder 26 CLUTCH BLEEDING Difficult Systems i e Ford Ranger Explorer Fire wall Location of trapped air Location of retaining clip Notice angle of master cylinder Bleeder valve j Line connector Remember when i
6. RESERVOIR TO WHEELS LOW PRESSURE AREA DIRTY FLUID CUP SEAL The low pressure area of the primary and secondary pistons is not effected unless the brake pedal is depressed If the brake pedal is not depressed the fluid path is from the reservoir through the vent port and then to the wheels This leaves a large volume of old fluid in the system a S 5i A PRIMARY CUP SEAL CLEAN FLUID MOVED FORWARD The added step of depressing the brake pedal moves the primary cup seals past the vent ports This changes the fluid path The fluid now flows from the reservoir through the replenishing port over the primary cup seal and then to the wheels This step ensures all the old fluid is removed from the master cylinder 17 BRAKE BLEEDING OPEN TOP RESERVOIRS Pressure Bleeding During pressure bleeding the fluid in the reservoir is pressurized The pressurized fluid is allowed to pass through the master cylinder to the bleeder valves When the bleeder valves are opened the pressurized fluid and air will be forced out the bleeder valves NOTE Adapters are available that will allow the Phoenix Injector to pressure bleed almost any master cylinder One available adapter is called the Universal Cap Adapter UCA Bladder Inflates To Seal Almost Any Reservoir YES iim This is a cut away view of a screw cap master Cylinder reservoir Notice how the bladder expands to seal the opening Fluid passes through the c
7. 2 prior to using this procedure There is a retaining clip accessible from the passenger compartment which holds master cylinder piston in place With this clip removed the piston can be quickly removed and reinstalled Fluid will leak out and the air bubble will be forced out It is not easy to get to the retaining clip Use this procedure as a last resort New Style Clutch Some GM and Ford applications do not utilize a conventional Luer Male bleeder Taper Tip attach taper adapter to Luer male fitting and insert Recessed bleed screw Hes Slave Bleed hole 27 PULSE GENERATOR A unique feature which separates Phoenix Injectors from other hydraulic bleeders is the ability to generate pulses within a system A technique developed by Phoenix Systems uses the Injector to create pulsations which generate a force within the system which acts to overcome the surface tension of the trapped air This Pulse Generation helps to force trapped air out of a system This technique is a Phoenix Systems exclusive It s like tapping on a caliper slave master or line at the same time 1 Adjust stroke setting to 2 3 ml to limit the maximum stroke As an option you can set the Injector at its full dosage and manually short stroke the Injector 2 Use quick short injections Inject 2 3 ml of fluid approximately two to four times per second Inject a total of 10 15 short strokes These quick short
8. FASCAR rating system provides you with an accurate method to suggest or recommend a brake system flush Brake fluid will yield a FASCAR rating of 50 75 or above when it s ability to protect the hydraulic system has been compromised This provides the technician with an accurate tool to sell a brake system flush NOW and prevent a more costly repair in the future The Phoenix Systems FASCAR test system is the simple solution to prove when brake system flush is required 23 REVERSE FLUID INJECTION RFI TM Reverse Fluid Injection or RFI injects fluid at the low points the n slave bleeder valves RFI takes advantage of the laws of Physics air rises in fluid The complete system is bled by forcing the air up and out the master cylinder reservoir The brake fluid then fills the reservoir RFI AND ABS SYSTEMS Some technicians are concerned about the possibility of pushing contaminates up stream to the brake valving ABS modulator or master cylinder during RFI bleeding Phoenix has had extensive research done in this area The main difference between the RFI process and that of pushing caliper pistons in without opening the bleeders is the pressures being produced and the amount of fluid movement On the left we see the RFI process taking place while being able to see the pressure generated at the master cylinder When used properly the pressures are well below 10psi On the right side is the process of pu
9. NOT USE THE PHOENIX INJECTOR WITH PETROLEUM BASED FLUID LIKE GASOLINE TRANSMISSION FLUID OR OIL UNLESS THE INJECTOR IS EQUIPPED WITH PETROLEUM O RING PETROLEUM BASED FLUIDS WILL CAUSE BRAKE FLUID O RINGS TO SWELL VOLUME CONVERSION TABLE When you know Multiply by To Find 1cc cubic centimeter 1 1ml millileter Fluid ounces 30 ml or cc Fluid ounces 0 03 Liters Liter 1000 ml or cc Quarts 0 95 Liters Liters 0 47 Pints Quart 32 Ounces Pint 16 Ounces 37 V 12 1 2 3 V 20 ev 1 SPECIAL INSTRUCTIONS Universal Cleaning Instructions For Brake Fluid Uses Compatible fluid types 1 Pump clean brake fluid through the Injector until all traces of contaminates are removed 2 Flush Injector again with clean fluid For Alternating Non Compatible Fluid Types 1 Pump and remove old fluid from Injector lines and container 2 Utilizing Denatured Alcohol flush Injector lines container and adapters until all traces of old fluid are removed Pump alcohol from Injector and lines until fluid is replaced by air Flush traces of alcohol from Injector system using new fluid Bo Tubing and Injector seals are not rated for extended contact with solvents Do not allow contact over 5 minutes Only disassemble Injector in the event of check valve failure Pump clean brake fluid through the Injector until all traces of contaminates are removed Flush Injector again with clean fluid Acetone or
10. injections create the pulsations which reduce the surface tension of the trapped air 3 Inspect reservoir fluid level and empty as needed Finish bleeding with a full injection Stroke The Pulse Generator technique was performed on a clear master cylinder model so trapped air could be easily seen The small bubbles in Step 1 were left after conventional bleeding methods had been performed The Pulse Generator Technique was performed and the bubbles were quickly dislodged and forced out the master reservoir in Steps 1 2 3 The effectiveness of this procedure is clearly demonstrated in the technical video 28 QUICK FLUSH AND CROSS BLEED Use this Quick Flush method on front rear split or diagonal systems to remove contaminated fluid and sediment from wheel pistons and interconnecting lines Use Cross Bleed as an excellent bleeding method when calipers or cylinders are replaced When performing Quick Flush or Cross Bleed use a brake pedal depressor to hold the brake pedal approximately 1 down to prevent the return of fluid and contamination to the master cylinder Simply open a wheel piston bleeder valve and attach a capture container to collect old fluid Then inject new brake fluid into opposing wheel cylinder bleeder valve The newly injected fluid will remove contaminated fluid and sediment from wheel pistons interconnecting lines and be deposited into the capture container Cross Bleed Quick Flush 1 Install brake pedal depres
11. inlet fitting 13 to piston 4 The outlet valve 19 can be checked by unscrewing the front barrel cap 16 Remove injection attachment 22 and rinse valve and spring and replace cap and injection attachment onto gun 38 SPECIAL INSTRUCTIONS Relubricating If Injector becomes sluggish it is necessary to relubricate the V 12 piston The V 12 Injector has the addition of a felt washer 12 that lubricates the barrel after each dose 1 Remove cylinder barrel 2 from body nozzle and cap may be attached 2 Squeeze handle to expose piston O ring 11 and felt washer 12 3 Dip piston in clean brake fluid to soak the felt washer with the fluid 4 Replace barrel and pump a few times to lubricate the barrel V 20 The V 20 Injector has the addition of a felt washer 9 that lubricates the barrel after each dose 1 Remove cylinder barrel 7 from body nozzle and cap may be attached 2 Squeeze handle to expose piston O ring 8 and felt washer 9 3 Dip piston in clean brake fluid to soak the felt washer with the fluid 4 Replace barrel and pump a few times to lubricate the barrel MAXIJECT PRO LA Remove cylinder assembly by screwing cylinder cage 15 counterclockwise it may be necessary to use pliers wrench It is not necessary to remove cage lock nut 13 2 Squeeze handle to expose piston washers 4 3 Dip piston in clean brake fluid to soak with the fluid 4 Replace barrel and pump a few tim
12. of the hydraulic system and renders it unfit for its intended use We use the term as it is applied to brake fluid Examples of contamination are air H2O solids from component wear sludge engine oil power steering or transmission fluid QUESTIONS 1 have a pressure or a vacuum bleeder why do need a Phoenix Injector You might want to keep your vacuum or pressure bleeder to use for flushing the hydraulic system Flushing the brake system requires pumping large amounts of fluid as much as 2 quarts to completely remove contaminants While the Phoenix Injector is primarily designed as a bleeding tool it can perform both pressure and vacuum flushing capabilities Hand fatigue may result from using the Phoenix Injector to pump the large amounts of fluid required for proper system flush The pneumatic Power Ject is more suited for vacuum or pressure flushing because it eliminates hand fatigue The Phoenix Injector is the only tool in the world capable of performing every known bleeding or flushing method including pressure vacuum and RFI Reverse Fluid Injection and more No tool produces a hard pedal quicker for both brake and clutch system than the Phoenix Injector The bottom line the Phoenix Injector will allow an undercar technician to beat the flat rate schedule and the shop manager to more productively and profitably use both his people and his service bays Please Note GM has issued specific information t
13. on the system from each of the bleeder valves This negative pressure or vacuum draws the fluid from the reservoir through the system and out the bleeder valves 20 BRAKE BLEEDING CAST IRON OR SINGLE INLET RESERVOIRS The second group of vehicles are 2 those that have either single inlet reservoirs or cast iron body master cylinders with the reservoir as part of the casting To pressure bleed single inlet reservoirs the Universal Cap Adapter is required If the vehicle being bled falls into this category and the UCA is not available use Vacuum or RFI bleeding Cast iron reservoir By simply reversing the modular connections the Injector can be used to vacuum bleed or flush To perform vacuum bleeding like pressure bleeding make sure the master cylinder is full before bleeding the system If the reservoir is not full fill it before continuing Drain and clean the reservoir where possible Take note of the amount of fluid that was removed You will use this to avoid draining too much fluid from the reservoir during the bleed process VACUUM BLEEDING Fill to the full level with new brake fluid Raise the vehicle 1 2 to a suitable work height Starting with the first wheel in the bleed sequence open the bleeder screw If the bleeder screw is loose fitting then remove it and apply a film of silicone lubricant to the threads This helps form a seal Where possible leave the bleeder wrench on the bleeder before a
14. on the chassis and place it into a capture container Loosen either rear caliper bleed valve and attach the Injector as described earlier in this manual Aggressively inject fluid 6 to 8 strokes for disc type brakes and 4 strokes for drum style brakes Tighten the bleeder valve remove the Injector apparatus and reattach the flexible line Follow the same procedure on the other rear cylinder When finished flushing bleed the entire system using the method of your choice as directed in this manual WARNING WEAR EYE PROTECTION Flexible hose Connection Pitias H Bleeder valve Metal line Capture Container 30 BENCH BLEEDING WITH THE PHOENIX INJECTOR RFI m i The goal of bench bleeding is to remove all of the air from the component prior to its installation The master cylinder is usually placed in a vice and a combination of RFI and Pressure bleeding is usually used The Phoenix Injector is unparalled in bench bleeding any master cylinder especially 2 and 4 outlet quick take up master cylinders used by Ford GM Chrysler and some imports Pressure 31 BENCH BLEEDING WITH THE PHOENIX INJECTOR One of the most effective uses of the tool is in bench bleeding master cylinders Even the most difficult master cylinder can be bench bled in minutes We will cover the bench bleeding of the following styles of master cylinders Standard 2 amp 4 outlet master cylinders Conventional cast iron tandem ma
15. performed when fluid is injected into the system low points the slave bleeder valves h burp The RFI System takes advantage of the Laws of Physics air rises in fluid The slave cylinders Br Men n p Pam lines and master cylinder are bled by pushing the air up through the master cylinder reservoir Prior to closing bleeder Use same procedure on brakes and clutches See manual RFI for Brakes valve See page 44 1 Removereservoircap and open the Injector slave bleeder For brakes start at the wheel furthest from the master cylinder Refer to OEM sequence Lightly squeeze Injector handle prior to attachment to fill void between adapter and bleeder valve then attach adapter Gently depress the Injector handle 3 10 times depending on fluid capacity For brakes Inject 50 more fluid in the first wheel 4 Remove adapter allowing a small Slave amount of fluid to drip causing caliper to burp any trapped air then close bleeder 5 For brakes repeat procedure following proper sequence for remaining wheels 6 Test the system and repeat the procedure if necessary For more information See Master Reservoir pages 24 26 WARNING WEAR EYE PROTECTION Fluid Source Trapped air For vehicles with master cylinder angled upward it may be necessary to raise the rear of the vehicle to level master cylinder to prevent air from being trapped in end of master cylinder 2 Pressure Blee
16. same basic equipment plus high tech rotating couplers Bottle Pak and additional adapters to attach to all known bleeder valves See the following pages for an overview of of the 10 Pak and Smart Pak Module 10 PAK MODULE The 10 Pak features the basic equipment required to perform RFI pressure and vacuum bleeding flush The 10 Pak was created by streamlining the Smart Pak module to include only the fittings and adapters most commonly used The 10 Pak is an economy package that will still allow the technician full use of Phoenix Injector features The unique modular coupler design allows easy conversion between RFI Pressure and Vacuum techniques Bottle Caps 7 8 Bottle caps are provided with a Luer lock quick coupler bottle vent and pickup tube that will attach to most brake fluid containers Luer Lock Quick Couplers w Adapters 2 3 Luer Lock couplers are provided to quickly attach to adapters and fluid containers Simply insert and with a twisting motion lock couplers together Universal Port Adapter 5 The Universal Port Adapter UPA is included to bench bleed master or slave cylinders and pressure bleed or flush the hydraulic system Taper Tips 4 Taper Tips provide access to clutch slave units that do not have a conventional bleeder valves Adapters Bleeder Adapters 1 2 3 6 are provided to connect to external bleeder valves from 1 8 to Y sizes Simply purchase a new bottle of brake fluid remove the cap and inst
17. vacuum 43 19 3 joonen gt B rors DARBNAS ono E DESCRIPTION Piston cap Inlet check valve spring Inlet check valve and seal ring Piston washer set of 2 Piston spacing washer Piston Push rod Outlet check valve and seal ring Outlet check valve spring Nozzle seal ring Injection attachment Luer adapter nut Nozzle nut Delivery cage lock nut Delivery cage Cylinder barrel cage Deleted Cylinder seal ring Cylinder barrel Adapter Lever Lever pad set of 2 Handle Dose adjuster screw and nut Return spring Return spring adjuster Return spring adjuster screw Lever screw Handle clamp screw Included in rebuild kit FREQUENTLY ASKED QUESTIONS TERMS RFI Reverse Fluid Injection Injecting brake fluid at the slave cylinder and forcing air up and out through the master cylinder reservoir Pulse Generator Freeing air bubbles trapped within the system by reducing their surface tension through short rapid strokes of the injector s handle Bleeding The process by which trapped air is purged from a hydraulic system Flushing The means by which contaminates are removed from the hydraulic system and replaced with new fluid Burping Process of removing air trapped in the top of a caliper or cylinder by removing adapter from bleed screw and allowing trapped air to escape before closing bleed screw Contaminants Contamination Anything that corrupts or compromises the integrity
18. Does a High FASCAR rating mean The FASCAR Rating scale from 0 to 100 gives the technician a way to determine the approximate age of the brake fluid and determine whether the brake fluid needs to be changed Age is important because we know that brake fluid wears over time Some vehicle manufacturers recommend changing the fluid every one to two years while others have no recommendation at all You can know for sure by using the Strip Dip The FASCAR rating will vary with brake fluid age vehicle mileage and environmental conditions FASCAR ratings of 50 75 or more indicate the brake fluid s ability to fight corrosion has been compromised For U S manufactuted vehicles with FASCAR ratings above 75 or imports above 50 we recommend a brake system flush What Happens When Brake Fluid s Ability to Protect is Impaired If you wait until your brake fluid fails a moisture test it may already be too late After brake fluid corrosion inhibitors are severely depleted corrosion of the internal components begin Corrosion can pit the metal bores of the master cylinder slave cylinders _ and ABS components This means that pistons cannot move freely seals can be damaged and cylinders can develop internal or external leaks A thorough brake fluid flush and fill seem like cheap insurance FASCAR Addresses Brake System Maintenance The Strip Dip using FASCAR technology focuses on the maintenance issues of brake fluid The
19. OF ASSEMBLED UNIT CHEM WAY ra F BRAKE FLUID Tomsons Sime DOTS m A Not an exact fit but cap will sufficiently secure to bottle SMART PAK MODULE The Smart Pak is designed with special assemblies for ABS applications to assist in bleeding and system flush Adapters are included that will attach the Phoenix Injector to all known bleeder valves High tech rotating quick couplers are used to provide easy connection to adapters and fluid sources Systems are fully portable featuring bottle holder magnetic securing device and belt attachment Bottle Pak 1 The Bottle Pak utilizes clear graduated fluid container equipped with Luer Lock rotating quick couplers The Bottle Pak is equipped with a bottle holder and magnetic securing device The two quick couplers in the Bottle Pak allow the use of fluid recirculation to fill the Phoenix Injector with fluid without any fluid loss Luer Lock Quick Couplers w Adapters 5 6 Luer Lock couplers are provided to quickly attach to adapters and fluid containers Simply insert and with a twisting motion lock couplers together Capture Assembly 14 To assist ABS service a new Capture Assembly is provided which allows the technician to perform a pressure or pedal flush prior to RFI A check valve in the assembly allows fluid flow in one direction only which prevents the drawing of air while pressure or pedal flushing the system This assembly is also used to attach the bleeder val
20. T 3 4 and 5 fluids with your injector YES All injectors are factory equipped for DOT 3 4 and 5 brake fluids 9 Will your injectors handle other kinds of fluids like power steering or ATF YES The V 12 and V 20 can be converted for use with any automotive fluid by simply flushing with denatured alcohol and changing two O rings included with the kit for the V 20 and one O ring for the V 12 NOTE A petrol based seal kit is available for the Maxi Ject Pro P N MAXPRO PET 10 Do you have repair kits YES They are priced between 13 00 and 30 00 and contain all wear components 11 Should buy a repair kit now with a new tool NO The seals and or O rings should last two years with normal use and care The most common cause for rebuild is seal exposure to other fluids like gasoline and oil 12 I just used your injector and it won t pump anymore Some early versions of Injectors contained a stainless steel filter located within a black and white Luer fitting found at the end of the 4 foot inlet hose where it connects to the bottle It is common for the filter to become clogged with contamination The filter s purpose is to protect seals and o rings within the injector Remove the Luer fitting from the hose and back flush the filter Reinstall the Luer fitting in the hose Your injector should now be operational Newer Injector models contain an external filter that is semi transparent so trapped contaminates can be seen It is also
21. alcohol can be used to clean Injector of brake fluid Do not allow contact over 5 minutes The check valves are not designed to be serviced on the V 12 Injector Repeat V 12steps 1 and 2 The inlet valve 12 13 can be checked by unscrewing the rear inlet hose barb 14 Rinse valve assembly and check there is no grit inside spigot Replace valve and spring and screw back onto rear of Injector The outlet valve 5 6 can not be removed from barrel Rinse valve and spring and replace cap and nozzle onto gun Maxi Pro Adapter 19 must be tuned 90 deg MAXIJECT PRO before it can be removed or damage will occur Repeat V 12 steps 1 and 2 2 The inlet valve 2 3 can be checked by unscrewing cylinder cage 15 and piston cap 1 counterclockwise exposing the spring valve and seal ring It will be necessary to prevent pushrod from turning while removing piston cap 3 Rinse valve assembly and check that there is no grit inside assembly Replace valve and spring and reinstall Do not cross thread cylinder cage to adapter 4 The outlet valve 8 9 can be checked by unscrewing the front nozzle nut 12 Rinse valve and spring and replace cap and nozzle onto gun Reinstall in reverse manner POWER JECT de Repeat V 12 steps 1 and 2 2 The inlet valve 12 can be checked by unscrewing inlet fitting 13 3 Rinse valve assembly and check that there is no grit inside assembly Replace valve and spring and reinstall Do not cross thread
22. all the appropriate 10 Pak cap in its place The bottle provides the fluid source for the Injector when performing RFI or pressure bleeding When vacuum bleeding attach the Phoenix Injector outlet to the bottle to capture the fluid removed from system Adapter Description of use 1 1 8 x 150 Adapter 90 Use for1 8 bleeder valves or 1 8 ports 2 Quick adapter assembly Quick couple assembly with 3 16 x 4mm Adapter 90 3 Quick adapter assembly Quick couple assembly use for 3 16 or 1 4 bleeder valves 4 Taper Tip Adapter 3 New clutch slave or special injection applications 5 Universal Port Adapter UPA Use for bench and pressure bleeding 6 3 16 x 4mm Adapter Straight adapter for custom application 7 28mm Bottle cap 28mm bottle cap for small neck brake fluid bottles See chart 8 33mm Bottle assembly 33mm bottle cap for brake fluid bottles See chart 10 PA CAP CHART 8 MANUFACTURER size CAPS 28mm 33 mm z CASTROL E F4 ie X a cwemwe LL A A a z QUAKER SUPREMEDOTS 1a A di moa DL Your Injector comes 14 4 with inlet and outlet f ak 120z hose assemblies dt PA Tir RESTONE zZ Ei J w J ALBANY 28MM CAP ie J consue a 7 mz A anar na A T gal Tr worin Ft Heavy amp Silicone s 1gal WAGNER Promium 1202 oF Premium Plus DOT3 4 amp 1a B Lockheed DOT 4 T 4 NEW BOTTLE
23. ase note we used the terms bleed and flush These terms are NOT interchangeable Consult the TERMS section so that no confusion remains as to when to perform which function 5 Okay your injector will bleed ABS but do need special clips NO RFI utilizes fluid paths in which enhanced braking mechanisms offer almost no resistance Metering valves proportioning valves and anti lock valving is designed to manipulate braking pressure while providing minimal resistance to fluid as it returns to the master cylinder following the release of braking pressure 6 Do I need a scan tool to bleed ABS MAYBE If the OEM bleeding instructions say to use a scan tool you should use a scan tool RFI does allow fluid to travel paths that traditional pressure or vacuum technique can not Some technicians report successful bleeding of ABS systems without the use of a scan tool It is important to remember that some ABS systems have a portion of the system that is isolated from the normal braking system During an ABS stop or specific system test these isolated system are engaged The OEM instructions must be followed to bleed or flush isolated parts of the system 45 FREQUENTLY ASKED QUESTIONS 7 Does the less expensive injector do everything the Pro model will do YES However certain luxuries are not available in less expensive models like adjustable spring force lever action metal construction and ease of use 8 Can use DO
24. at have come into contact with the contamination fluid Petroleum based automotive fluids are not compatible with the type of rubber used in brake systems The most common petroleum rubber materials are made from Viton amp or Nitrile amp The most common brake system rubber materials are made from EPDM EPR and some SBR Rubber designed for brake fluid will swell when it comes in contact with petroleum based fluids The Proper Flush A Gravity Flush is where the brake bleeder valves are opened and old fluid gravity bleeds out the system and new brake fluid is added A simple Gravity Flush will not remove contaminants that collect in the brake system In order to get a proper flush a sufficient amount of brake fluid must be flushed through a system with enough force to remove contaminants Some manufacturers recommend as much as 1 quart of brake fluid to be flushed through each wheel Pedal Flushing is still a common method of flushing the brake system There are several concerns with pedal flushing because the master cylinder piston is stroked beyond its normal wear stroke This can tear cup seals and generate other problems Vacuum Flushing is to be used only as a last resort Some manufacturers do not recommend vacuum flushing at all Brake systems are designed for pressure not vacuum It is often difficult to get a sufficient flush because of leakage around the bleeder valve threads Even if you seal the threads from leakage the amount of vacu
25. channel or clamping pliers without creating a pressure relief conduit and blocking flow to the master cylinder If the return path to the master cylinder is not blocked through the use of a line lock or brake pedal a massive high pressure surge through the brake system may occur which can dislodge contaminants and push them up into ABS valving NOTE Phoenix Systems does NOT RECOMMEND REVERSE FLUSHING hydraulic brake systems under any circumstances The Phoenix Injector will not harm ABS systems because of the way the tool is designed The problem with rapid collapse of the caliper is the amount of fluid injected upward in the system and the pressure the collapse generates Each Phoenix Injector has a small stroke 10 20 ml and between each injection there is a compose time A single 10 ml stroke will deliver 12 times less fluid then the caliper and the pressure generated during proper RFI is less then 10 psi The compose time between each stroke allows heavy contamination to remain at the low points ABS experts evaluated the Phoenix Injector and RFI and this is what they said The Phoenix Injector generates less than 10 psi during the RFI process Our testing has shown that this amount of pressure has no chance of forcing contaminates upstream to other brake components This combined with the fact that the process would be used after the system has been flushed virtually eliminates any threat Bill Williams President WISAT Ple
26. cuum to 125 psi Luer Lock Simply insert and twist a coupling about 1 2 turn to lock or unlock mechanism Luer Male iittm gt Luer Female Luer Lock Couplings How To Connect Tube Magnet I PREVENT BOTTLE FROM TIPPING Belt clip Nylon cord M Route the tubing through the magnet belt clip as shown This will keep the bottle vertical when the tubing is IS pulled Failure to route tubing in this 1 method can cause the bottle to ti exposing pickup tube to air Bottle Connections Each bottle is equipped with a black and white coupler or ring to identify proper connections The white coupler or The black coupler or ring ring is only used for is used to to draw fluid for fluid recirculation RFI and pressure uses During recirculation It is also used to capture the other coupler is fluid for vacuum or other also attached See uses page 11 Step 3 Failure to attach coupler correctly may cause fluid toleakout Black coupler The Smart Pak is equipped with dual male and female plugs and caps to prevent leakage from bottle or couplers when not in use MODULAR ADAPTERS All Injectors are designed for modular versatility Adapters can be used at either the Injection or Vacuum connections of the Injector In addition the bottle can be hydraulically connected to either side A wide range of Luer attachments are available such as the taper tip for new clutch systems without a bleeder valve
27. cylinder barrel 7 and set aside Tie handles 19 together using cable tie Press out pivot pin 18 from handle 19 using pliers remove pivot pin 18 and set aside Pull bottom of handle 19 while squeezing top of handle 19 and piston 10 will release Remove and replace piston O ring 8 piston felt washer 9 and rear piston o ring 11 with new from repair kit Pull bottom of handle 19 until inch of center tab is showing in body 15 Insert piston 10 and align center tab with slot in piston 10 Close handle 19 toward body 15 until holes align at bottom Reinsert pivot pin 18 until click is heard Cut cable tie Remove inlet check valve spring 12 and inlet check valve 13 from inlet assembly housing 14 Replace with new from repair kit Note closed end of inlet check valve spring 12 is placed onto long end of check valve 13 refer to exploded view Insert inlet check valve assembly into inlet assembly housing 14 Reinstall completed assembly through rear of injector body 15 and onto end of piston 10 Remove front end cap 1 from cylinder barrel 7 and set aside Reinstall new cylinder barrel 7 into body 15 and reinstall front end cap 1 onto new cylinder barrel 7 To test injector pressure place index finger tightly over outlet of cylinder barrel 7 and squeeze handle to check for pressure To test vacuum place thumb tightly over inlet rear of inlet assembly hous
28. d and Flush Pressure bleeding is performed when the Injector is outfitted with the proper adapters and fluid is injected from the master cylinder through the lines and out the slave bleeder valve into a capture container See p 6 to locate the anon capture assembly supplied in the Smart Pak Use this assembly to capture used fluid in an old container when pressure or vacuum bleeding 1 Install Universal Port Adapter UPA to injector 2 Insert adapter into master cylinder reservoir creating a seal independently at each opening at the base of reservoir If this is not practical remove brake line from master cylinder and install adapter fitting over brake line 3 Open bleeder valves in order and inject fluid from the master reservoir out the bleeder valve and into a capture container 4 Repeat procedure at each opening Remember to open respective bleeder valve associated with master cylinder chamber Formore information See pages 18 19 Capture container Black side of checkvalve must be attached to bottle For some applications a combination of bleeding techniques provides the best system bleed Unless otherwise directed use slow steady strokes when injecting or drawing fluid into or from a hydraulic system 12 QUICK START Bleed and Flush 3 Vacuum ed or Flush By simply reversing the modular adapters and connections the Injector can be used as a vacuum bl
29. e Will fit bottle or tube 7 HOW TO USE THE FITTINGS amp ADAPTERS Taper Adapter 13 Taper Adapter s Used to adapt Injector to hoses from 3 16 to 7 6 1D This end of the Taper Adapter can be installed directly into adapter 6 The Taper End can then be inserted into hose sizes from 3 16 to 7 16 This is excellent for pressure bleeding systems with remote reservoirs Taper Tip Adapter 7 Taper Tip adapters Primarily used to bleed new style clutch systems Option 2 Taper Adapter V 12 Barrel cami A hun End Cap Assembled Fitting The Taper Tip can be attached to the injector M m rien a eae simply tip or connected via Luer hose assembly at SOrew adapter mo iEne Van either the pressure or vacuum side a gt m Inlet Filter with quick coupler The arrow shows the direction of flow The black coupler attaches to the bottle or bleeder adapter for vacuum bleeding Attaches to inlet hose coupler and is used to filter inlet fluid BASIC FUNCTION amp SETUP irecti Determine the Injection and Vacuum Direction of flow ides of your Injector For RFI or Injection 4 ai Tp lt Pressure techniques attach the Injection Vacuum side of your Injector to the hydraulic system For Vacuum uses attach the Vacuum side to the hydraulic system How To Connect Quick Couplers Your Injector is equipped with Luer Lock couplers tested from va
30. e the amount of RFI required to prevent over filling reservoir 1 To perform RFI bleeding first drain and clean the master cylinder reservoir If necessary fill the reservoir before draining so an accurate measure of fluid can be taken Note the amount of fluid removed This will be necessary to avoid overfilling the master cylinder during the RFI bleeding process For vehicles with tilted master cylinders raise the vehicle to allow the master cylinder to level This will allow the air to exit the vent ports 2 Remember caution is to be used when raising the vehicle to avoid an unsafe condition or vehicle damage If the master cylinder cannot positioned in this manner get it to at at least a point where the body is level If this cannot be accomplished see Difficult Systems p 27 First follow directions for Priming the Injector and lines Connect the injection side of the tool to the slave bleeder and the input end to the fluid supply container making sure it is full 5 With the tool connected open the bleeder screw and stroke the handle until the reservoir is full The amount of fluid that could be injected was determined in Step 1 6 Once complete remove the adapter from the bleeder and let the slave cylinder burp or gravity bleed until a solid stream of fluid is achieved This will allow any air trapped at the top of the slave or bleeder valve to exit Close the bleeder 7 Check pedal and repeat if necessary Ap HELPFUL HINTS
31. easy to service See the Trouble Shooting section in Users Manual for more information 13 What else will the Phoenix Injector do The Phoenix Injector will bleed air from any accessible hydraulic system so it can be used to service the following A Motorcycles clutch brake bleed fork tubes B Trailers bleed electro hydraulic brake system C Lift trucks clutch brake steering and lift systems D Aircraft brakes and servo systems E Tractors clutch brake steering articulated attachments F Medium amp Heavy duty trucks brakes clutch steering articulated attachments G Mobile air conditioning charge cold compressor with 134 cleaning oil requires special seals 14 bled the system and my pedal is still spongy What can did do 46 FREQUENTLY ASKED QUESTIONS A Did you burp the caliper or wheel cylinders B Is the fluid aerated saturated with air bubbles C Did you open the ABS modulator bleeder valves D See the Trouble Shooting section in Users Manual 15 How long will it take for the tool to pay for itself We ship a lot of tools UPS Red because technicians have vehicles stuck in their shops In most cases the technician can solve the bleeding problem in minutes using the Phoenix Injector One technician called and said I just did in five minutes what couldn t do in five hours after using the Phoenix Injector to bleed a Ford Ranger clutch Do the math If that tech
32. ect 3 full strokes of new fluid through Injector to purge system Attach the Vacuum side coupler to the black bottle coupler and the Injector side coupler to the white coupler Depress handle to recirculate fluid back to container until the air in injector and lines is replaced with fluid Inspect for steady stream of fluid returning to container without air bubbles Use slow steady strokes so as not to aerate or agitate fluid Remove Injector coupler from white recirculation coupler at bottle and attach the desired adapter Connect to Connect to Black coupler White coupler Unless otherwise directed use slow steady strokes when injecting or drawing fluid into or from a hydraulic system Use only new approved fluids Never reuse fluids when bleeding or flushing any hydraulic system 11 Do not overtighten the Luer connections They may be difficult to disassemble If injector becomes sluggish it will be necessary to re lubricate the piston lube ring Remove injector barrel and submerge piston assembly into clean brake fluid and reassemble Ifa bubble is trapped in the Injector barrel it may be necessary to tip barrel upward and tap end of barrel causing bubble to rise to nozzle where it can be injected out WARNING WEAR EYE PROTECTION QUICK START Basic Techniques for DLE Page 11 for proper priming of Injector prior to RFI Rememberto allow caliper RFI is
33. eeder When the handle is depressed fluid will be drawn out of the bleeder valve and injected into bottle For more information Reservoir W See page 20 21 Brake Fluid Black coupl Fluid Air Capture bottle The Injector draws fluid from the hydraulic system and injects it into a capture container 1 Remove Injector vacuum side coupler from bottle 2 Remove the quick coupling and adapter assembly from the Injection side of the Injector and attach to vacuum side 3 Attach Injection side coupler to the black bottle coupler 4 Depress the handle to draw fluid out of bleeder valve and inject into bottle Bench Bleed 4 9 qn 1 Follow instructions in section Prepare the Phoenix Injector Gently place For more information See master cylinder in a vise pages 31 35 2 Remove the plug from the cylinder outlet and place the injector with Universal Port Adapter into outlet 3 Inject fluid until no air bubbles can be seen in front reservoir Replace plug into cylinder outlet 4 Repeat procedure to bleed rear section of master cylinder 5 Install cylinder to fire wall and remove plugs and loosely connect brake lines Allow fittings to drip then tighten fittings 6 TestBrakes In most cases this is all the bleeding necessary If further bleeding is necessary refer to manual RFI for Brakes page 23 13 BRAKE SYSTEM BLEEDING AND FLUSHING
34. eeder valve attach and secure capture container CYLINDER FLUSH FLUSHING DEBRIS FROM CALIPERS amp WHEEL CYLINDERS Fill the Injector with new approved brake fluid Front Wheels 1 Locate flexible brake hose that attaches to the calipers and the metal brake line at the chassis Remove the flexible line from the metal line on the chassis Place the open end of the flexible line in a capture container to collect old fluid Loosen the bleeder valve on the caliper and attach the Injector as previously described Aggressively inject new brake fluid for 6 to 8 strokes This will effectively flush old fluid and debris out the flexible line and into the capture container Tighten the bleeder valve remove the Injector apparatus and reattach the flexible line Follow the same procedure for the other front wheel When done flushing bleed the entire system using the method of your choice as directed in this manual Rear Wheels t Locate the flexible brake hose or hoses Your vehicle may have a flexible hose at each wheel that attaches to each rear caliper and then attaches to a metal brake line on the chassis If the vehicle does not have two then it will have one flexible line that attaches to the rear axle and then to a metal line on the chassis If the vehicle has two lines the procedure is identical to the front brake caliper flushing procedure If the vehicle has one flexible line remove it from the metal line where it attaches
35. elling its service technicians NOT to use vacuum bleeders Quoting from a 1994 GM Service Bulletin which covers Bleed Procedures Kelsey Hayes EBC4 4WAL ABS Used on current model GM van and light pickups IMPORTANT NOTES DO NOT use gravity or vacuum bleeding for this system DO NOT pump the brake pedal as fluid cavitation may occur DO NOT drive the vehicle until brake pedal feel is firm 2 Why do you make so many different Phoenix Injector models We created multiple models so that different users with different needs could apply the technology and advantages of the Phoenix Injector in a manner which from a cost standpoint works best for them 3 What is the difference between Maxi Ject Pro and the V 12 The Maxi Ject Pro made of steel and die cast aluminum is designed for heavy duty shop use It is our most versatile tool with a 15 ml stroke which effectively delivers more fluid each stroke 44 FREQUENTLY ASKED QUESTIONS It features spring force return adjustment and a two year warranty The lever action handle of the Maxi Ject Pro makes bench and pressure bleeding a one hand operation The V 12 is made of glass reinforced Zytel amp nylon delivers a 10 ml stroke and is designed for medium duty use It features a one year warranty 4 Will Reverse Fluid Injection RFI cause damage to my ABS system NO The most common risk of damage to the ABS system occurs when rapidly collapsing brake calipers using large
36. enter opening 18 BRAKE BLEEDING OPEN TOP RESERVOIRS PRESSURE BLEEDING 1 Install brake pedal depressor and prepare the tool for pressure bleeding Begin by draining the old fluid from the master cylinder Also See RFI for reservoir Additional 2 Next attach the vacuum side coupler to the black bottle coupler Bleeding of the new fluid source Then attach the injection side coupler Techniques to the capture container Stroke the injector handle slowly to pump the old fluid out of the pickup hose until only new fluid is in tool 3 Now remove the injector outlet hose and replace with the Universal Port Adaptor 4 Refill the new fluid source container if necessary 5 Open the bleeder on the first wheel in the bleeding sequence and attach the capture container making sure to use the one way check valve The one way check valve only allows fluid to travel from the bleeder to the capture tank preventing air from entering the system 6 Next insert the UPA adapter into the section of the reservoir that supplies the wheel being bled Stroke the injector handle slowly This creates pressure in the system and forces the old fluid and air out of the open bleeder into the capture container 7 Close the bleeder screw of the wheel being bled and repeat these steps at each remaining wheel until all air is removed 8 Fill master cylinder to proper level and test drive Depending on system design additional steps may be required Add
37. ents Repair as necessary Open bleeder valve It does not work like a zerk fitting Ifthe master cylinder piston is not fully retracted a check valve will prevent the return of fluid to the reservoir Check for hanging pedal or master cylinder failure Some import applications Mazda use check valves in the bleeder valve These must be temporarily replaced with conventional bleeders to use RFI Replace or repair as necessary Reservoir cap must be removed prior to RFI It is normal to experience extreme resistance in some anti lock brake systems like 4WAL anti lock systems Fluid is injected very slowly which may give the appearance that no fluid is injected Inspect vent in cap for obstruction See Manual and attach per instruction 36 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE RECOMMENDED SOLUTION INJECTOR LEAKING DEFORMED OR Contact manufacturer for possible replacement DAMAGED BARREL QUICK DISCONNECT Make sure quick disconnect is fully inserted and SEAL FAILURE locked Do not over tighten TUBING LEAK Inspect tubing for small holes or tears Repair as necessary INJECTOR FAILURE CHECK VALVE FAILURE See Special Instructions to make sure check valves are operating properly May need to be cleaned AIR BUBBLE TRAPPED INSUFFICIENT PURGE Hold Injector with the barrel pointing upward tap IN INJECTOR OF INJECTOR end of barrel forcing bubble into nozzle where it can be injected out CAUTION DO
38. eplacement parts shall be at Buyer s expense V 12 V 20 Brake Fluid Tester Adapters tube and fittings 1 Year Maxi Ject Maxi Ject Pro Power Ject 2 Years 2 Other Limits THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Manufacturer does not warrant against damages or defects arising out of improper or abnormal use or handling of the Products against defects or damages arising from improper installation where installation is by persons other than Manufacturer against defects in products or components not manufactured by Manufacturer or against damages resulting from such non Manufacturer made products or components Manufacturer passes on to Buyer the warranty it received Gf any from the maker thereof of such non Manufacturer made products or components This warranty also does not apply to Products upon which repairs have been effected or attempted by persons other than pursuant to written authorization by Manufacturer 3 Exclusive Obligation THIS WARRANTY IS EXCLUSIVE The sole and exclusive obligation of Manufacturer shall be to repair or replace the defective Products in the manner and for the period provided above Manufacturer shall not have any other obligation with respect to the Products or any part thereof whether based on contract tort strict liability or otherwise Under no circumstances whether based on this L
39. ervoir At the end of each wheel bleed remember to allow the caliper or wheel cylinder to gravity bleed 8 Once complete check and adjust the master cylinder fluid level and test the pedal If firm test drive Caution never drive a vehicle with an unsafe pedal caliper to bleed Kelsey Hates AWAL ABS brakes Helpful Hints If fluid will not inject in reverse manner 1 Make sure reservoir cap is removed 2 Remove the bleeder valve and inspect for blockage 3 Check for check valve in bleeder valve 4 Master cylinder may have faulty check valve Make sure pedal is not hanging 5 Check for hydraulic system malfunction Remember some ABS components allow very slow fluid movement Typical bleeding sequence _ Trapped air For vehicles with master cylinder angled upward it may be necessary to raise the rear of the vehicle to level master cylinder to prevent air from being trapped in end of master cylinder 25 RFI FOR CLUTCHES AIR RISES IN FLUID Paty t SOURCE MASTER FLUID DRECTION WARNINGI WEAR pem EYE PROTECTION The Maxi Ject Pro SLAVE BLEEDER using RFI to bleed VALVE the clutch on a late model GMC truck RFI CLUTCH BLEEDING RFI is a process where fluid is introduced at the slave cylinder and fed back up to the master cylinder T If the reservoir is very small like Ford Ranger it is helpful to allow the system to gravity bleed prior to Step 1 This will reduc
40. es to lubricate the cylinder POWER JECT 1 Remove cylinder barrel assembly by unscrewing barrel 15 counterclockwise 2 Squeeze handle to expose piston O ring 4 3 Dip piston in clean brake fluid to soak with the fluid 4 Replace cylinder barrel assembly and pump injector a few times to lubricate the cylinder Inspection for all Injectors V 20 example Inlet Check Valve 1 Remove tube from inlet connection 14 from a fluid filled Injector cylinder 7 2 Plug or cover Injector nozzle outlet 3 3 Squeeze handle and inspect inlet for fluid or air leaking back out inlet connection 14 through inlet check valve assembly 12 13 Only a slight amount of air leakage is okay Outlet Check valve 1 Remove tube from inlet connection 14 from an empty Injector cylinder 7 2 Plug or cover Injector inlet connection 14 3 Place Injector outlet nozzle 3 in fluid source 4 Squeeze handle and release NO fluid should be drawn into cylinder 7 if Injector draws fluid or air in through the outlet check valve assembly 5 6 into cylinder unit requires cleaning or rebuild 39 12EXPLODED VIEW REPAIR KIT INSTRUCTIONS Tools required slotted screw driver 1 Remove End Cap 1 and unscrew cylinder 2 as an assembly from the handle 2 Using a small screw driver carefully pry out inlet valve retainer 6 being careful not to damage the inside of piston rod 3 Tum Piston 10 upside down and gently
41. h piston spacing washer 5 in between and fit over the piston cap 1 Place them in the palm of your hand and carefully merge the push rod 6 onto the end ofthe piston cap 1 and tighten by turning the push rod until it stops 6 With a coin or wide flat screw driver snug the piston cap tight Do not overtighten as the piston washers may distort 7 Remove nozzle nut 12 and remove nozzle seal ring 9 and replace with new seal 8 Remove delivery cage lock nut 13 and remove delivery cage 14 from the cylinder 18 Remove cylinder seal ring 17 from the delivery cage 14 Replace cylinder seal ring 9 Insertdelivery cage 14 with new seal ring 17 into the cylinder 18 at the 2 5 ml end 10 Reinsert delivery cage cylinder assembly into cylinder cage 15 and reinstall delivery cage lock nut 13 finger tight 11 Insert new outlet check valve and spring 7 amp 8 spring pointing outward into the end of delivery cage 14 Install injection attachment assembly 10 onto the delivery cage 14 and tighten nozzle nut 12 12 Squeeze injector handle and install cylinder cage assembly 15 over piston into handle until threads meet Carefully align cylinder cage an adapter 19 and tighten 13 To test injector pressure place index finger tightly over outlet of injection attachment 10 and squeeze handle to check for pressure To test vacuum place thumb tightly over inlet rear of push rod 6 and squeeze injector Should feel
42. imited Warranty or otherwise shall Manufacturer be liable for incidental special or consequential damages 4 Other Statements Manufacturer s employees or representatives ORAL OR OTHER WRITTEN STATEMENTS DO NOT CONSTITUTE WARRANTIES shall not be relied upon y Buyer and are not a part of the contract for sale or this limited warranty 5 Entire Obligation This Limited Warranty states the entire obligation of Manufacturer with respect to the Products If any part of this Limited Warranty is determined to be void or illegal the remainder shall remain in fall force and effect PHOENIX SYSTEMS reserves the right to substitute alternate component parts of equal utility for those shown Copyright 1995 2001 by PHOENIX SYSTEMS LLC All rights reserved This volume may not be reproduced in whole or in part in any form without the written permission from the publisher 2 WHAT IS THE PHOENIX INJECTOR Each Phoenix Injector is a sophisticated hand pump capable of directly pumping liquids brake fluid and air at pressures from 20 Hg vacuum to 150 psi Graduated Cylinder dtt Suction side Dosage Ns ru Control Injection side Handle Spring Adjustment Simply squeeze the handle to inject fluid When the handle is released fluid automatically refills the cylinder Depends on Model Maxi Ject Pro shown PHOENIX INJECTO Y Problem Solver Never again spend hours attempting to get a firm clutch or brake pedal Save Ti
43. ing 14 and squeeze handle Should feel vacuum 41 o 18 PART DESCRIPTION Front end cap Luer adapter Injection attachment Deleted Outlet check valve spring Outlet check valve i Cylinder barrel A Piston O ring Piston felt washer 10 Piston 11 Rear piston o ring 12 Inlet check valve spring 13 Inlet check valve 14 Inlet assembly housing 15 Body 16 Dose selector 17 Handle spring 18 Pivot pin 19 Handle Included in rebuild kit POWER JECT EXPLODED VIEW i 11 ut ge e 7 8 16 REPAIR KIT INSTRUCTIONS No Tools required 1 Unscrew barrel cap 16 Remove injection attachment 22 and injection attachment O ring 21 and set aside 2 Remove outlet check 19 and spring outlet check 20 3 Reinstall new ball outlet check 19 spring outlet check 20 and injection attachment O ring 21 from repair kit into mouth of barrel 15 spring side out 4 Reinstall injection attachment 22 and barrel cap 16 onto mouth of barrel 15 5 Unscrew barrel 15 and remove Turn adjustment nut 3 to completely expose piston rod 5 6 Replace large O ring 4 with new from repair kit 7 While holding piston rod 5 unscrew inlet fitting 13 until resistance is felt Unscrew adjustment nut 3 completely and remove 8 Unscrew inlet fitting 13 and remove 9 Remove and replace inlet O ring 10 inlet spring 11 and inlet check ball 12 from inlet fitting 13 10 Remove p
44. is just one of the bleeding techniques that can be performed with the Phoenix Injector Sy PHOENI 7 2 e V fa i P dd Ir l d Toll Free 888 749 7977 www phxsyss com
45. iston rod 5 from main body Place piston rod 5 on table slide main body down onto piston rod 5 exposing 1 piston rod O ring 6 piston rod U cup 7 2 piston rod O ring 8 Remove and replace with new parts from repair kit Replace piston rod U cup 7 Remember piston rod U cup 7 is between piston rod O rings 6 8 and cup is down toward table 11 Slide all three down into main body 12 Slide main spring 9 down over piston rod 5 Pushing piston rod O rings 6 8 and piston rod U cap 7 into and seating in main body 13 Hold down on main spring 9 and screw on inlet fitting 13 being careful not to loosen inlet spring 11 and inlet check ball 12 tighten securely 4 Reinstall adjustment nut 3 Reinstall barrel 15 Included in rebuild kit 42 MAXDECT PRO EXPLODED VIEW Adapter 19 must be turned 90 deg before it can be removed or damage will occur REPAIR KIT INSTRUCTIONS Tools required slotted screw driver or coin and pliers 1 Unscrew cylinder cage 15 as an assembly from the handle 2 Hold body of push rod 6 firmly without damaging surface and using large flat blade screw driver unscrew piston cap 1 3 Remove piston washers 4 piston spacing washer 5 check valve 3 and spring 2 4 Toinstall new piston components insert check valve assembly 2 3 into the internal threaded end of push rod 6 Ensure that the spring is pointing outward 5 Align piston washers 4 wit
46. itional Steps On systems where the master cylinder is mounted at an angle there is a chance for air to be trapped in the end of the master cylinder Most master cylinders are designed so the outlets of the pressure chambers are at the highest point in the master cylinder But there are a number of designs where this is not so There is no way to tell by looking at the master cylinder where the outlet is located 1 To prevent air from being trapped raise the rear of the vehicle until the master cylinder is nearly level Extreme caution should be used not to raise the vehicle too high and put itin unsafe condition or possibly damage the vehicle With the vehicle in this position bleed the master cylinder outlets starting with the secondary side first 2 Crack the line loose and then use the Phoenix Injector to apply pressure to the system Close the fitting as you complete the stroke Repeat this process until no air is seen Now perform the same steps on the primary portion of the master cylinder Once the master has been bled then the vehicle can be raised normally and the steps outlined for pressure bleeding used For difficult systems use a combination of pressure and RFI bleeding See instruction for RFI bleeding Te p Level master cylinder Crack line amp apply pressure Insert UPA into reservoir BRAKE BLEEDING CAST IRON OR SINGLE INLET RESERVOIRS Vacuum Bleeding During vacuum bleeding negative pressure is exerted
47. ive attempting to get a firm pressure or vacuum clutch or brake pedal The reservoir tough the Vacuum During vacuum bleeding negative pressure Is ex erted on the system from each of the bleeder i m E t d out th Phoenix Injector is Bleeder vanes suited for multiple i Pressure uses including RFI vacuum bleeding pressure bleeding fun i alowed to pass i bench bleeding and more aE ives When It doesn t require electricity the bleeder valves are or compressed air allowing opened the pressurized fluid even the weekend mechanic to bleed like the pro s Even the toughest of brakes and clutches such as those found on Ford Rangers Jeeps or GM During pressure bleeding the fluid in the reservoir is pressurized The pressurized and air will be forced out the bleeder valve trucks can be effortlessly Bench E bled in minutes with the The goal of bench bleeding Is to remove all of the air Phoenix Injector from the component prior to its installation A combination of RFI and Pressure bleeding Is often used The Phoenix Injector is unparalled in bench bleeding any master cylinder BRAKE BLEEDING OPEN TOP RESERVOIRS Bleeding the brake system is most commonly associated with changing a hydraulic component such as a caliper It is very Corrosion important for proper system operation that both a bleed and flush are performed If only a bleed is done the old fluid in the 7 system will conti
48. jection applications 8 Luer Male female Plug Install in luer female fittings to plug and prevent leakage 9 Universal Port Adapter UPA Use for bench and pressure bleeding 10 3 16 x 4mm Adapter Straight adapter for custom application 11 3 16 x 150 Adapter Straight adapter for custom application 12 3 16 x 3 16 Adapter Straight adapter for custom application 13 Taper Adapter Taper Adapter adapts 3 16 tube end to 7 16 ID tube 14 Capture assembly Pedal Flush and Capture assy wicheckvalve amp quick couplers 15 28mm Botlle cap 28mm bottle cap for small neck brake fluid bottles 16 33mm Bottle assembly 33mm bottle cap and quick coupler 6 Your Injector comes with filter HOW TO USE THE FITTINGS amp ADAPTERS Bleeder Adapters 3 4 5 6 10 11 12 are provided to connect to all external bleeder valves 14 Capture Assembly attached to bottle Used for pressure bleeding and cross bleed flush Universal Port Adapter UPA 9 Universal Port Adapter cm Used for pressure and bench bleeding Injection Tip Assembled Fitting The V 12 has a special UPA adapter with a larger internal thread which allows the UPA to be screwed directly onto the cylinder Make Remove end nut and screw Universal port sure the UPA is tightly secured to prevent Adapter to Injection Tip threads leakage Luer Plugs am 8 Red luer plugs D P oy Used to plug Luer ends to prevent leakag
49. me Make Money One technician can bleed difficult systems in as little as 5 minutes Quick amp Portable Does not require electricity or compressed air so you can use it in the field Flexible Uses all known bleeding methods including RFI Pressure and vacuum Easy to use Simple modular design allows even the weekend mechanic to bleed like the Pro s ee h debo c wx Rebuild kits are available foreach Injector See Catalog or Manual exploded views for description and part number beginning at page 40 PHOENIX INJECTOR FEATURES MAXI JECT PRO V 20 INJECTOR V 12 INJECTOR Return Spring Adjustment Nut Maxi Ject Series Only osage Adjustment Hose Barb inder or Barrel jector Nut or End Cap and Injection Tip Handle Body Return Spring ADJUSTMENTS Toadjustreturn spring tension tighten or loosen 1 Return Spring Adjustment Nut Leave handle in relaxed position while adjusting Toadjust dosage rotate 2 Dosage Adjustment to desired position Notice graduations on cylinder or barrel ACCESSORY MODULES Each of our Injectors is packaged with an inlet and outlet hose assembly and an accessory module The 10 Pak Module which only comes with the V 12 contains the basic equipment required to perform RFI pressure and vacuum bleeding or flush Bottle caps are included which attach to 90 of all brake fluid containers The Smart Pak Module is the most popular it contains the
50. n a level position Install the m c bleeding kit not included into both secondary and primary m c outlets Route the bleeder kit hoses back into the reservoir Fill the reservoir with new fluid 2 Prepare the tool for vacuum bleeding Connect the input end of the tool to the secondary m c outlet Before beginning depress the m c piston about 7 so that the primary cup seals are past the vent ports This will ensure that the low pressure area of the m c is filled during the bleeding process Using slow steady strokes apply a vacuum to the m c Continue this process until no air is seen exiting the m c outlet Keep an eye on the fluid level and refill if necessary 3 Once the secondary portion of the m c is bled route the bleeder kit hose back into the secondary reservoir Repeat this procedure with the primary portion of the m c Note if m c is mounted at an angle then follow appropriate steps for bleeding the rest of the system See Brake Bleeding With The Phoenix Injector j 34 Depress piston amp Vacuum bleed BENCH BLEEDING WITH THE PHOENIX INJECTOR Bleeding the Ford QTU Master Cylinder Use this procedure if you do not have Phoenix Systems Universal Cap Adapter UCA The UCA will allow 90 of all screw cap reservoirs to be pressure bled 1 Plug the lower outlets of the m c 2 Begin by mounting the m c in a vise in a level Place in vise position Install the m c bleeding kit into both secondary and prima
51. nician spent those five hours at 55 hr he could have generated 275 income for his shop A qualified technician cannot be without a Phoenix Injector We have a question for you how much do comebacks cost 16 What is Phoenix Systems position on flushing brake fluid Phoenix Systems recommends flushing and replacing brake fluid at least every two years or 24 000 miles of normal motor vehicle use Age is important because we know that brake fluid wears over time Phoenix Systems developed a brake fluid test strip Strip DIp utilizing a new technology for testing brake fluid called FASCAR The wearing of brake fluid is accompanied by the accumulation of complex alpha or first contamination indicators FASCAR accurately measures these alpha contaminants Strip Dip is designed to interact with these alpha contaminants to determine the overall level of brake fluid contamination The resulting color of the test strip is an easy visually accurate method to prove the need for a brake system flush FASCAR will also measure the residual contamination left by an inefficient system flush Some vehicle manufacturers recommend changing the fluid every one to two years while others have no recommendation at all You can know for sure by using the Strip Dip 47 No technician should be without a Phoenix Injector THE RFI SYSTEM AT WORK R AND FLU The RFI system utilizes a basic physics law air rises in fluid RFI
52. ning so an accurate measure of fluid can be taken Note the amount of fluid removed This will be necessary to avoid overfilling the master cylinder during the RFI bleeding process For vehicles with tilted master cylinders raise the rear of the vehicle to allow the master cylinder to Sit higher at the primary end firewall than at the secondary end This will allow the air to exit the vent ports 2 Remember caution is to be used when raising the vehicle to avoid an unsafe condition or vehicle damage If the master cylinder cannot be positioned in this manner get it to at least a point where the body is level If this cannot be accomplished then combine RFI with pressure or vacuum bleeding to get the best results 3 First follow directions for Priming the Injector and lines Once the master cylinder has been positioned begin the bleeding process at the first wheel in the bleeding sequence 4 Connect the injection side of the tool to the wheel bleeder and the vacuum side to the fluid supply container making sure it is full 5 With the tool connected open the bleeder screw and then slowly stroke the handle Continue this at the wheel giving 3 to 4 strokes 6 Once complete remove the adapter from the bleeder and let the wheel cylinder burp or gravity bleed Close the bleeder 7 Repeat this process at each of the wheels remembering to watch the amount of fluid being used If the procedure is repeated it may be necessary to drain the res
53. nject fluid out the bleeder valve Repeat procedure at each brake line remember to open respective bleeder valve associated with hydraulic circuit If the reservoir is removed during cleaning the UPA coumnaTion adapter can be inserted directly into the exposed port s to pressure flush EAR system FRONT 22 BRAKE FLUID TESTING New FASCAR Technology FASCAR which stands for Fluid Analysis by Stimulation of Contamination Alpha Reactions is a simple visual test to determine the contamination level of your brake fluid To test immerse the new Strip Dip into vehicle s brake fluid for 1 second and within 30 120 seconds the reaction zone will change colors depending on the contaminant level in the brake fluid Use the FASCAR color scale to compare the reaction zone color to determine the FASCAR rating How Does FASCAR Work Brake fluid is formulated with corrosion inhibitors to protect the hydraulic system The wearing of brake fluid is accompanied by the accumulation of complex alpha or first contamination indicators FASCAR accurately measures these alpha contaminants Strip Dip is designed to interact with these alpha contaminants to determine the overall level of brake fluid contamination The resulting color of the test strip is an easy visually accurate method to prove the need for a brake system flush FASCAR will also measure the residual contamination left by an inefficient system flush What
54. nstalling a new master cylinder the clutch system can be bled prior to bolting ihe master Internal slave cylinder to the fire wall Tip the master cylinder upward Some clutch systems can be very difficult to bleed due to component orientation These procedures should bleed even the most difficult systems 1 a b ce Use Pulse Generator technique See p 28 Use quick short injections 2 3ml 2 to 4 times per second alternating with aggressive full injection strokes You may have to drain the reservoir and repeat This procedure requires two technicians Complete procedure 1 first One technician will depress clutch pedal 1 2 way down and hold This will close the master cylinder check valve not allowing any fluid movement With the clutch pedal depressed a second technician will squeeze the Injector handle building pressure in the system May require one hand to hold adapter to bleeder valve due to high pressure Slowly release clutch pedal while maintaining pressure in the system When the pedal is released opening the check valve a pressure surge will force trapped air out of system Repeat several times Ifthe clutch pedal is not firm after using the previous procedures try loosing the master cylinder retaining bolts and tip the master cylinder upward This will allow all trapped air to be easily removed from system The front end of the vehicle can be raised to assist Complete procedures 1 and
55. nue to cause internal corrosion to the hydraulic components and lower the boiling point of the brake fluid If the boiling point gets low enough and the brake fluid boils it will cause a condition called brake fade This is where the brake fluid becomes a gas When the fluid becomes a gas it compresses which causes the brake pedal to go to the floor causing the driverto lose some or all braking This is why regular Corrosion flushing of the system is necessary What most technicians have found is that not one bleeding method works on all vehicles Because of this the use of any one of the four methods or a combination of them may be necessary to achieve a firm pedal This is where the Phoenix Injector excels Because the Phoenix Injector can provide both positive and negative pressures it is a pressure and vacuum bleeder while at the same time allowing the technician to take advantage of the Reverse Fluid Injection RFI technique All this in one easy to use tool Phoenix Systems has had extensive research conducted on the process of brake bleeding and has incorporated the results of this research into procedures which ensure the best possible job is done in the shortest time possible The following section outlines the proper use of the Phoenix Injector when performing hydraulic brake service Because of the many different brake system configurations in use today there is no one way to bleed all systems The following procedures will a
56. onceivable ways in which service or testing might be done or all possible consequences of each way nor could PHOENIX SYSTEMS possibly know or investigate all such ways It is therefore the responsibility of anyone using this manual or any PHOENIX SYSTEMS product to satisfy themselves thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods selected Any such injury or damage is entirely the users responsibility This device is not to be used in any manner on the human body LI ITED WARRANTY Phoenix Systems LLC an Arizona Limited Liability Company warrants its products the Products as follows 1 Limited Warranty Manufacturer warrants that the Products sold hereunder will be free from defects in material and workmanship for a period from the date of purchase as shown below for ach product Ifthe Products do not conform to this Limited Warranty during the warranty period Buyer shall notify Manufacturer in writing of the claimed defects and demonstrate to Manufacturer satisfaction that said defects are covered by this Limited Warranty If the defects are properly reported to Manufacturer within the warranty period and he defects are of such type and nature as to be covered by this warranty Manufacturer shall at its own expense furnish replacement Products or at Manufacturer s option replacement parts for the defective Products Shipping and installation of the replacement Products or r
57. pply to the majority of the vehicles in use today Open Top Reservoirs Vehicles are grouped into one of two categories based on the design of the hydraulic system The first group of vehicles can be identified as those having open top plastic reservoirs The design of the master cylinder on these vehicles allows for the system to be pressure bled very easily using the Phoenix Injector Best Bleed and Flush The first step in bleeding these vehicles after the reservoir is drained is to install a brake pedal depressor so that the brake pedal is depressed approximately 1 inch This step is one of the results of the research that Phoenix Systems has done What we discovered is that regardless of which type of pressure bleeder you use the low pressure area of the primary and secondary pistons is not effected unless the brake pedal is depressed If the brake pedal is not depressed the fluid path is from the reservoir through the vent port and then to the wheels This leaves a large volume of old fluid in the system The added step of depressing the brake pedal moves the primary cup seals past the vent ports This changes the fluid path The fluid now flows from the reservoir through the replenishing port over the primary cup seal and then to the wheels This step ensures all the old fluid is removed from the master cylinder See the following page for illustration Primary cup seal moved forward 16 CLEAR MODEL OF GM QUICK TAKE UP MASTER
58. rimary reservoir to prevent draining The m c is now ready for installation 8 It should be noted many of these master cylinders are mounted at an angle on the vehicle The procedures given earlier should be used on these vehicles once the master cylinder is installed GM 4 outlet QTU Master Cylinder When dealing with the GM 4 outlet quick take up master cylinder that has the built in pressure differential switch there is an alternative bleeding method to raising the rear of the vehicle These master cylinders can be identified by the presence of a hex plug located at the end of the master cylinder The design of these master cylinders allows air to become trapped in the secondary portion of the master cylinder To remove the air from this style master cylinder Hex plug 1 Simply loosen the plug until fluid flow is established With the plug loose Pressure bleed the secondary end of the master cylinder 2 Tighten the plug as you end your last bleed stroke The primary side of the master cylinder can be bled at the line without leveling the master cylinder 3 Complete the bleed process following the recommended bleed procedure Bleeding the cast style tandem and s single inlet plastic reservoir type master cylinders 3 Place in vise Use this procedure if you do not have Phoenix Systems Universal Cap Adapter UCA The UCA will allow 90 of all Screw cap reservoirs to be pressure bled 1 Begin by mounting the m c in a vise i
59. ry m c outlets Route the bleeder kit hoses back into the reservoir Fill the reservoir with new fluid 3 Prepare the tool for vacuum bleeding Connect the vacuum side of the tool to the secondary m c outlet Before beginning depress the m c piston about so that the primary cup seals elie are past the vent ports This will ensure that the low pressure area of the m c is filled during the bleeding process Using slow steady strokes apply a vacuum to the m c Continue this Depress piston amp vacuum bleed process until no air is seen exiting the m c outlet Keep an eye on the fluid level and refill if necessary 4 Once the secondary portion of the m c is bled route the bleeder kit hose back into the secondary reservoir 5 For bleeding the primary side of the m c move m c body to an angled position in the vise reservoir top level Now prepare tool for RFI bleeding Attach the injection side of the tool to the primary bleeder kit adapter Leave the piston inits rest position while using slow steady strokes bleed the primary side of the master cylinder Because ofthe size of the low pressure chamber this will take approximately 12 to 15 strokes to remove all of the air Watch the primary reservoir for any signs of air as the process is completed For those systems not covered use the techniques outlined to accomplish similar results Use RFI on Primary side 35 PROBLEM SPONGY PEDAL DIFFICULTY INJECTING FLUID
60. s out upper outlet 2 3 Remove and place plug into lower outlet 1 Place the injector adapter nozzle into outlet 2 and inject fluid until stream of fluid fills front reservoir without air bubbles 4 Reinstall plug in outlet 2 and repeat procedure for rear section of master cylinder Install cylinder to fire wall 5 Remove front bottom plug and loosely connect brake line allow fitting to drip then tighten 6 Remove plug from front upper outlet 2 fitting and loosely connect brake line allow fitting to drip then tighten Repeat procedure for rear connections 7 Test Brakes In most cases this is all the bleeding necessary If further bleeding is necessary refer to RFI for Brakes WARNING WEAR 32 EYE PROTECTION BENCH BLEEDING WITH THE PHOENIX INJECTOR GM QTU Master Cylinder 1 VA VB RFI Primary side To bleed the GM quick take up 2 or 4 outlet master cylinder begin by mounting the master cylinder in a vise so that the mic body is level Install the master cylinder bleeding kit NOT INCLUDED IN SMART PAK in each of the outlets of the master cylinder On the 4 outlet master cylinder install plugs in the lower outlets Route the secondary bleeder kit hose back into the secondary reservoir Fill reservoir half full with new brake fluid Attach universal port adapter to injection side of gun Vacuum or input side of gun routed to new fluid container Push m c piston in approximatly 1 inch with appropria
61. shing a caliper piston back without opening the bleeder screw The pressures can exceed 70psi In addition 10 times more fluid is forced back in a single stroke than with the Phoenix injector Pressures this high as well as large amounts of fluid can disturb the sludge and corrosion that has built up in the system The disturbed old fluid from the wheels can then enter the master cylinder as the piston is pushed back carrying contaminates back into the brake valving abs modulator or master cylinder that could do damage to the seals or internal parts ABS and Accumulators In ABS systems that use Accumulators special precautions must be taken The accumulator is isolated from the braking system except under anti lock braking If air is trapped in the accumulator it may not be detected during normal driving but when an anti lock stop is initiated and the accumulator circuit is active trapped air will be forced into the system The result will be a spongy pedal after an anti lock stop It is necessary to follow OEM instructions for bleeding the accumulator using the Injector where instructions call for two man bleeding pressure or vacuum bleeding 24 REVERSE FLUID INJECTION RFI RFI BLEEDING RFI is a process where fluid is introduced at each wheel under low pressure and fed back up to the master cylinder 1 To perform RFI bleeding first drain and clean the master cylinder reservoir If necessary fill the reservoir before drai
62. sor to hold brake pedal 4 to 1 4 down 2 Open bleeder valve at desired wheel piston and attach Injector 3 Open opposing bleeder valve and attach and secure capture container 4 Usingslowsteady strokes inject fluid from one wheel piston through other until contaminated fluid is removed 5 After Quick Flush follow instructions RFI for Bleeding Brakes only inject 2 6 strokes at each wheel to remove any remaining trapped air The same procedure can be utilized on front or rear wheel pistons Complete the bleed and flush of the system using which ever method best fits the system being serviced Phoenix Injectors utilize pulsations to aid in system flushing It is important to remember if contamination is severe wheel pistons are being damaged and should be replaced or rebuilt Front Rear Split System Most rear wheel drive vehicles Install brake pedal Open opposing bleeder pes valve attach and secure capture container When installing new calipers use Cross Bleed first to remove most of the air and f finish with RFI i amp Open bleeder valve and inject fluid SMART PAK ONLY Diagonal Split System Most front wheel drive vehicles Open bleeder valve and inject fluid n many Diagonal split i L systems each wheel has a line which attaches independently to the master cylinder Use Pressure or Vacuum flushing for these systems Install brake pedal depressor Open opposing bl
63. ster cylinder and the single inlet plastic reservoir type The GM 2 amp 4 outlet quick take up master cylinder The Ford quick take up master cylinder Op The goal of bench bleeding the master cylinder is to remove all of the air in the shortest time possible The Phoenix Injector is unparalled in accomplishing this goal STANDARD 2 OUTLET MASTER CYLINDER 4 lt eR Universal Port Adapter 1 Followinstructions in section Prepare the Phoenix Injector page 11 Gently place master cylinder in a vise 2 Remove the plug from the cylinder outlet and place the injector with Universal Port Adapter into outlet 3 Inject fluid until no air bubbles can be seen in front reservoir Replace plug into cylinder outlet 4 Repeat procedure to bleed rear section of master cylinder 5 Install cylinder to fire wall and remove plugs and loosely connect brake lines Allow fittings to drip then tighten fittings 6 Test Brakes In most cases this is all the bleeding necessary If further bleeding is necessary refer to RFI for Brakes pages 23 25 STANDARD 4 OUTLET MASTER CYLINDER 1 Follow instructions in section Prepare the Phoenix Injector page 11 Gently place master cylinder in a vise and remove both plugs that come with the new cylinder from front section outlets 1 amp 2 2 Place the injector with Universal Port Adapter into lower outlet 1 Push gently injecting fluid until it drip
64. tap to remove Inlet Valve 8 and Spring 7 4 Insert new inlet check valve assembly containing parts 6 7 8 9 into Piston 10 until it snaps into place 5 Squeeze handle to improve access to the Piston O ring 11 and Piston Felt Washer 12 Remove and replace 6 Lubricate the Piston O ring 11 and Piston Felt Washer 12 with brake fluid prior to assembly 7 Install new cylinder assembly containing parts 2 3 4 5 PART DESCRIPTION 8 Reinstall End Cap 1 to Cylinder Assembly 1 End cap 9 Test Injector for proper operation 2 Cylinder barrel 10 Take right arm and bend at elbow and gently pat yourself 3 Outlet check valve spring on the back your done 4 Outlet check valve 5 Outlet check valve retainer 6 Intlet check valve retainer The V 12 is assembled with seals compatible with DOT q Inlet check valve spring 3 4 amp 5 fluids For extended use with gasoline trans gt Inlet check valve mission fluids solvents amp other petroleum fluids install 9 Inlet check valve cage the petroleum seal included with the kit 10 Piston rod 41 EPR O ring 12 Piston felt washer 13 Handle spring 14 Finger bar 15 12 5 ml selector 16 Rear handle 17 Finger bar handle cover 18 Rear handle cover 40 Included in rebuild kit REPAIR KIT INSTRUCTIONS Tools required 7 inch cable tie and pliers 1 2 3 4 12 13 V 20 EXPLODED VIEW Unscrew inlet assembly housing 14 and set aside Unscrew
65. te tool to expose low pressure chamber to both vent and replenishing ports With the tool set up for pressure bleeding pressure bleed the secondary portion of the master cylinder Use 4 to 6 full Steady strokes or until no air is seen in the bleeder kit hose For bleeding the primary side of the m c move m c body to an angled position in the vise reservoir top level Prepare tool for RFI bleeding Attach the output of the tool to the primary bleeder kit adapter Leave the piston in its rest position while using slow steady strokes bleed the primary side of the master cylinder Because of the size of the low pressure chamber this will take approximately 12 to 15 Strokes to remove all of the air Watch the primary reservoir for any signs of air as the process is completed An optional method is available which utilizes the UPA to bleed the primary side The UPA can be inserted directly against the primary outlet to form a seal as demonstrated for Standard 2 outlet Master Cylinder Use 12 to 15 strokes to remove all of the air Watch the primary reservoir for any signs of air as the process is completed This method can get a little messy in the following steps 4 outlet Install plugs Install UPA Pressure bleed secondary side BENCH BLEEDING WITH THE PHOENIX INJECTOR 7 When complete disconnect connector from tool output and let hose gravity bleed until a solid stream of fluid is seen Position the bleeder hose into the p
66. ttaching the bleeder adapter This makes closing the bleeder easier after the process is complete Attach the vacuum side of the tool to the bleeder using the appropriate adapter Attach the injection side of the tool to an empty capture container and slowly stroke the handle to create a vacuum in the system Depending on the bleeder screw fit it is normal to see some air in the fluid flow even if none is in the system The better the seal you form with the silcone lube the less air you will see Bleed the wheel until little or no air is seen coming from the system and the fluid is clean Repeat the process at the remaining wheels Monitor the fluid level in the reservoir so as not to remove too much fluid and introduce air If necessary refill the reservoir during the process Once complete test the pedal and if firm test drive the vehicle after completing job Caution never drive a vehicle with an unsafe brake pedal For difficult systems use a combination of vacuum and RFI bleeding See instruction for RFI bleeding 21 Fluid wil appear foamy na Sea Single inlet reservoirs Also See RFI for Additional Bleeding Techniques Bleed screw Air drawn past threads Maxi Ject Pro vacuum bleeding the caliper on 4WAL ABS system Fluid is deposited into capture container BRAKE CLUTCH BLEEDING SPECIAL APPLICATIONS The steps that have been outlined cover the majority of the
67. um force is limited Pressure Flushing uses sufficient force as much as 40 psi to force contaminants out of the brake system It is the preferred flushing method The Phoenix Injector can be used to perform Pressure Vacuum or Cross flushing Under no circumstance is RFI to be used as a flushing technique The most effective flushing methods are Pressure Flushing combined with Cross Flushing where applicable See pages 16 and 29 for more information It is always important to use enough brake fluid to thoroughly flush the system Strip Dip amp provides a good indicator to determine if a sufficient flush was performed After flushing the brake system take the vehicle for a drive then retest the brake fluid using a fresh strip If the FASCAR rating is above 20 the brake system should be flushed again Phoenix Systems provides the diagnosis and the cure 14 BRAKE BLEEDING INTRODUCTION The World s Simplest Fastest and Most Efficient Way To Bleed Clutch and Brake Systems Even ABS f RF A we Reverse Injection or RFI injects fluid at the low points the slave bleeder valves RFI takes advantage of the Law of Physics air rises in filuid The complete system Is bled by forcing the air up and out the master cylinder reservoir The brake fluid then fills the reservoir One person One Tool Ten minutes Our patented technology eliminates difficult bleeding Never again spend hours valves This negat
68. ve to a capture container Bottle Caps 15 16 Bottle caps are provided with a Luer lock quick coupler bottle vent and pickup tube that will attach to most brake fluid containers Universal Port Adapter 9 The Universal Port Adapter UPA is included to bench bleed master or slave cylinders and pressure bleed or flush the hydraulic system Adapters Bleeder Adapters 3 4 5 6 10 11 12 are provided to connect to all external bleeder valves Extra adapters are provided for custom applications Luer plugs 8 will prevent fluid leakage from Luer assemblies when not in use Taper Adapter 13 will attach bleeder adapters to hose sizes from 3 16 to 7 16 D Taper Tips 7 provide access to clutch slave units that do not have a conventional bleeder valves Tubing connectors 2 are provided for special applications and inlet and outlet hose AU 6 assemblies S 5 t s 4 Same fitting 5 has Luer pre installed Adapter Description of use 1 Bottle Pak Bottle Pak assembly w quick couplers magnet amp holder 2 Tube Connectors Tubing connectors supplied to customize application 3 1 8x 150 Adapter 90 Use for1 8 bleeder valves or 1 8 ports 4 3 16 x 4mm Adapter 90 Universal can be reversed for 1 8 or 3 16 valves 5 Quick adapter assembly Quick couple assembly with 3 16 x 4mm Adapter 90 6 Quick adapter assembly Quick couple assembly use for 3 16 or 1 4 bleeder valves 7 Taper Tip Adapter 4 New clutch slave or special in
69. vehicles in use today Ifthe vehicle s bleed process involves additional steps such as bleeding the modulator add those to the steps given Where the procedures call for pressure bleeding substitute the Phoenix Injector s pressure bleeding or vacuum bleeding depending on the type of system Additional steps may be required depending on system design Vehicles With Remote Reservoirs Remote reservoir The Taper Adapter can be installed directly into adapter 6 see p 6 8 The Taper End can then be inserted into hose sizes from 3 16 to 7 16 This is excellent for pressure Remove line here bleeding systems with remote reservoirs and insert taper This technique will work for brake or clutch systems It is also widely used for pressure bleeding the rear brakes on motorcycles Vehicles Without Accessible Reservoirs Some master cylinder reservoir outlets are not accessible through the cap If vacuum or RFI bleeding is not an option the following procedures can be used If the master cylinder is being replaced remove brake lines from master cylinder and install adapter fitting over brake line and follow previously described procedure For some lines the Universal Port Adapter UPA will be required 1 2 3 4 5 6 Remove lines from master cylinder Install Injector large bleeder valve adapter 6 Attach adapter to brake line Open bleeder valves in successive order and attach capture container I

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