BRAKE FLUID EXCHANGER
92923
ASSEMBLY AND OPERATING INSTRUCTIONS
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
©
®
Copyright 2005 by Harbor FreightTools . All rights reserved. No portion of this
manual or any artwork contained herein may be reproduced in any shape or
form without the express written consent of Harbor Freight Tools.
For technical questions and replacement parts, please call 1-800-444-3353
Download from Www.Somanuals.com. All Manuals Search And Download.
5.
Use the right tool for the job. Do not attempt to force a small tool or attachment to do
the work of a larger industrial tool. There are certain applications for which this tool
was designed. It will do the job better and more safely at the rate for which it was
intended. Do not modify this tool and do not use this tool for a purpose for which it
was not intended.
6.
7.
Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Protective, electrically nonconductive clothes and nonskid footwear are
recommended when working. Wear restrictive hair covering to contain long hair.
Use eye and ear protection. Always wear ANSI approved impact safety goggles.
Wear an ANSI approved dust mask or respirator when working around chemical dusts
and mists.
8.
9.
Do not overreach. Keep proper footing and balance at all times. Do not reach over or
across running machines.
Maintain tools with care. Inspect tool cords and hoses periodically and, if damaged,
have them replaced, or repaired by an authorized technician. The handles must be
kept clean, dry, and free from oil and grease at all times.
10. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches
are removed from the tool or machine work surface before operating.
11. Avoid unintentional starting. Be sure the air pressure is in the Off position when not
in use and before making hose connections.
12. Stay alert. Watch what you are doing, use common sense. Do not operate any tool
when you are tired.
13. Check for damaged parts. Before using any tool, any part that appears damaged
should be carefully checked to determine that it will operate properly and perform its
intended function. Check for alignment and binding of moving parts; any broken parts
or mounting fixtures; and any other condition that may affect proper operation. Any
part that is damaged should be properly repaired or replaced by a qualified
technician. Do not use the tool if any control or switch does operate properly.
14. Replacement parts and accessories. When servicing, use only identical
replacement parts. Use of any other parts will void the warranty. Only use accessories
intended for use with this tool. Approved accessories are available from Harbor
Freight Tools.
15. Do not operate tool if under the influence of alcohol or drugs. Read warning
labels if taking prescription medicine to determine if your judgment or reflexes are
impaired while taking drugs. If there is any doubt, do not operate the tool.
16. Pacemaker safety warning. People with pacemakers should consult their
physician(s) before using this product. Electromagnetic fields in close proximity to a
heart pacemaker could cause interference to, or failure of the pacemaker. In addition,
people with pacemakers should adhere to the following:
- Caution is necessary when near the coil, spark plug cables, or distributor of a
running engine. The engine should always be off if adjustments are to be made to the
distributor.
Page 3
SKU 92923
For technical questions, please call 1-800-444-3353
Download from Www.Somanuals.com. All Manuals Search And Download.
17. Maintenance. For your safety, service and maintenance should be performed
regularly by a qualified technician.
Note: Performance of this tool may vary depending on variations in air pressure and compres-
sor capability.
Brake Fluid Exchanger Safety Precautions
Caution:This equipment is designed to be operated by qualified and trained personnel.
It should only be operated after reading and understanding the safety warnings and
operating procedures in this instruction manual and the vehicle’s service manual.
1.
2.
3.
4.
Wear ANSI approved safety goggles.
Do not smoke near this equipment.
Use in a well ventilated area.
When leaks are found in the equipment or hoses, immediately turn the air pressure off
and repair the leaks.
5.
6.
Immediately clean up any fluid spills or leaks.
Do not exceed the recommended operating air pressure. This could damage
equipment. See Specifications on page 2.
7.
8.
9.
Do not use any cleaning compounds in this system.
Keep an empty plastic bucket nearby in case of leaks.
Keep a type ABC fire extinguisher nearby in case of fires.
10. Prior to using the Brake Fluid Exchanger make sure to read and understand all
warnings, safety precautions, and instructions as outlined in the vehicle
manufacturer’s service manual. Every vehicle has specific brake bleeding
requirements. It is beyond the scope of this manual to properly describe the correct
procedure for each vehicle.
11. Prior to using the Brake Fluid Exchanger, make sure to place the vehicle’s
transmission in “PARK” (if automatic) or “NEUTRAL” (if manual). Then, set the
emergency parking brake and block the tires with chocks.
12. Use the Brake Fluid Exchanger only with brake fluid. Do not attempt to use the tool to
siphon any other liquids. Contamination of brake fluid and possible brake system
failure may result.
13. Follow guidelines for proper brake fluid disposal. Used brake fluid should be properly
disposed of or recycled. Many states require recycling. Contact your local solid/liquid
waste authority for information on recycling. Do not reuse old brake fluid.
14. Do not use pressurized air to blow off brake dust. Only use brake parts cleaner to
clean dust off of the brake calipers.
15. Be alert for hot brake components and other hot vehicle components to avoid
accidental burns.
Page 4
SKU 92923
For technical questions, please call 1-800-444-3353
Download from Www.Somanuals.com. All Manuals Search And Download.
16. Some brake pads contain asbestos. Asbestosis, a chronic lung inflammation, can
result from prolonged inhalation of asbestos particles. Accordingly, wear appropriate
ANSI approved respiratory devices and proper protective clothing when working near
any brake pads.
17. Always keep brake fluid from contacting the vehicle’s paint finish. Brake fluid will
damage the paint finish on vehicles.
Warning:The warnings, cautions, and instructions discussed in this instruction manual
cannot cover all possible conditions and situations that may occur. It must be under-
stood by the operator that common sense and caution are factors which cannot be
built into this product, but must be supplied by the operator.
Unpacking
When unpacking, check to make sure the following parts are included. If any parts are
missing or broken, please call Harbor Freight Tools at the number on the cover of this
manual as soon as possible.
Handle Bar (1)
Used Fluid
Collection Bottles
Fluid Hose (20)
Adapter Kit
Rubber Squeeze Dropper
SF20 Quick Coupler (21)
Plastic
Funnel
Operation
Preparation
1.
2.
3.
Place vehicle on a hoist or on secure vehicle stands in a well ventilated area.
Set vehicle emergency brake and turn the engine off.
Remove the wheels and locate the drain connection on the brake cylinders.
Refer to the vehicle manufacturer’s maintenance manual for their location.
4.
Turn on the air compressor (not supplied) and place its hose next to the Brake Fluid
Exchanger. (The air compressor should have a moisture filter installed on it. See
illustration on the top of page 6.)
REV 04/06
Page 5
SKU 92923
For technical questions, please call 1-800-444-3353
Download from Www.Somanuals.com. All Manuals Search And Download.
CONNECT TO THE QUICK
CONNECTOR (14) ON THE
BRAKEFLUIDEXCHANGER
Controls and Indicators
Air Connector Ball
Valve (15)
Air Hose
Quick Connector (14)
Fluid Hose (20)
Pressure
Add Brake
Fluid Here
Gauge (23)
Pressure
Adjust
Valve (16)
Tank Cap (2)
Air Release
Ball Valve (15)
Air Release Safety
Valve (18)
Bleeding Brakes and Adding New Fluid
WARNING: The vehicle engine must never be started in a closed garage, or any
other sealed structure. Carbon monoxide is produced during operation and is deadly
in a closed environment. Early signs of carbon monoxide poisoning resemble the flu,
with headaches, dizziness, or nausea. If you have any of these signs get fresh air im-
mediately.
1.
2.
3.
4.
Place the Brake Fluid Exchanger near the vehicle and remove the Tank Cap (2).
Open and secure the engine hood and find the Master Cylinder.
Remove the Master Cylinder Lid.
Open the Adapter Kit and find the Adapter Lid that looks like, and best fits, the Master
Cylinder.
Refer to the Adapter Kit Parts List at the end of this manual. The temporary Adapter
Lid should have the form of the Master Cylinder Lid with the addition of a connector
inlet for the Fluid Hose (20). In some instances, a universal Lid (E1, F1, or F2) may
need to be used where other Adapters will not fit. Use the mounting loop cables and
hardware provided with the Adapter to secure the universal Lid.
REV 04/06
Page 6
SKU 92923
For technical questions, please call 1-800-444-3353
Download from Www.Somanuals.com. All Manuals Search And Download.
5.
6.
Secure the Adapter Lid to the Master Cylinder.
Unscrew and remove the Tank Cap (2), then pour in the appropriate amount of new
brake fluid. Refer to the vehicle manufacturer’s service manual for the correct amount
and type of fluid. Screw in the Tank Cap (2) tightly.
7.
8.
Insert the Fluid Hose (20) Quick Connector (21) onto the temporary Master Cylinder
Adapter Lid. Make sure that it’s Ball Valve (15) is in the closed position (sideways to
the direction of the Fluid Hose).
Remove the Drain Screws from the rear left and right brake cylinders, and insert a
clear rubber tube (not supplied) into the drain holes. Press fit the rubber connector of
the Used Fluid Bottles into the other end of the clear rubber tube.
Note: The Used Fluid Bottles can be connected directly to the brake cylinders drain, but you
will not be able to see the color of the fluid filling the bottles (darker is old, lighter is new).
Clear RubberTube
(not supplied)
Master Cylinder
Used Fluid Bottle
Clear RubberTube
(not supplied)
Air Line from Compressor
Used Fluid Bottle
Brake Fluid Exchanger
Fluid Hose (20)
9.
Connect the air line hose (not supplied) to the Air Hose Quick Connector (14) on the
Brake Fluid Exchanger.
10. Set the Air Connector Ball Valve (15) to the On (vertical) position.
The Tank is now pressurized. No fluid is flowing, however, because the Fluid Hose
(20) Ball Valve (15) is still in the Off position.
11. Pull out on the Pressure Adjust Valve (16) knob, and while viewing the Pressure
Gauge (23), turn the knob to adjust the Tank pressure to between 20 to 40 PSI.
Caution: Never exceed 40 PSI or damage may occur to equipment and connection hoses.
12. Slowing open (in line with hose) the Fluid Hose (20) Ball Valve (15) on top of the
Master Cylinder.
This begins the process of forcing the new fluid in, and the oil fluid out and into the
Used Fluid Bottles. Check for leaks at all connection points. If leaks are found, turn
the Ball Valve (15) on the Master Cylinder to the Off (sideways) position. Correct the
leaks and continue.
13. During the fluid transfer, press in quickly on the brake pedal in the vehicle, and
release slowly. Do this a few times.
14. When the two Used Fluid Bottles are full, or the fluid color has changed from dark to
light as seen through the Clear Rubber Tubes, the transfer process is complete for the
rear two brake cylinders.
Page 7
SKU 92923
For technical questions, please call 1-800-444-3353
Download from Www.Somanuals.com. All Manuals Search And Download.
15. Remove the Used Fluid Bottles or Clear Rubber Tubes connected to the brake
cylinder and return screws to the drain holes.
16. Empty the Used Fluid Bottles into a fluid recycle tank, or in other bottles for proper
disposal
17. Repeat steps 8 through 15 for the front brake cylinders.
18. When the fluid transfer of the front brake cylinders is complete, turn the Ball Valve (15)
on the Master Cylinder to the Off (sideways) position, and remove the Fluid Hose (20)
from the Master Cylinder Lid.
Adding New Fluid to Vehicles with ABS Brake Systems
1.
2.
3.
Follow all the previous steps starting on page 6, with these exceptions.
Remove the drain screw for only one brake cylinder at a time, and drain that cylinder.
Place the vehicle transmission in Park, and start the engine during this process. When
adding new fluid is complete, turn the engine Off.
4.
5.
Remove the Used Fluid Bottle or Clear Rubber Tube connected to that brake cylinder
and return screw to the drain hole.
Repeat for each brake cylinder individually.
Steps When Finished Bleeding Brakes and Adding New Fluid
1.
2.
3.
Replace the original Master Cylinder Lid.
Remove the air input line from Air Hose Quick Connector (14) on the Tank.
Open the Air Release Ball Valve (15) on the Tank, and pull on the Air Release Safety
Valve (18) to depressurize the Tank.
4.
Empty the Used Fluid Bottles into a fluid recycle tank, or in other bottles for proper
disposal. Empty the Main tank of the exchanger if the unit is not to be used for a day or
longer.
WARNING:Before driving the vehicle, depress the brake pedal repeatedly until the brake
pedal feels firm. Check the brake calipers for leaks.Then, test the brakes thoroughly at
slow speed before operating the vehicle under normal conditions.
Maintenance
Caution: Before performing any maintenance on the Brake Fluid Exchanger, verify that
the Brake Fluid Exchanger is depressurized.
1.
2.
3.
Clean up any brake fluid oil that may have spilled.
Wipe down the Brake Fluid Exchanger components with a cloth.
Store the unit in a clean and dry location.
REV 06/05
Page 8
SKU 92923
For technical questions, please call 1-800-444-3353
Download from Www.Somanuals.com. All Manuals Search And Download.
Brake Fluid Exchanger Parts List
Part
1
Description
Qty Part
Description
Qty
17
1
Handle Bar (Steel)
Cap, Tank
1
1
13 Nut
2
14 Air Inlet Connector (Female)
15 Ball Valve,1/4"
3
O-Ring
1
3
4
Tank, Upper Half
Bolt
1
16 Pressure Regulator
17 1/4" Connector
1
5
13
1
1
6
Diaphragm
18 Safety Valve, Air Release
19 4-Way Connector
1
7
Tank, Lower Half
1/8"-1/4" Connector
1/8" Connector
1
1
8
1
20 Oil Delivery Tube (3m)
21 Quick Coupler, SF20
22 3-Way Connector (Cu)
23 Pressure Gauge w/Sleeve
1
9
1
1
10 Tube Lock
1
1
11 Ø8 Tube
1
1
12 Elbow Connector
1
NOTE:Some parts are listed and shown for illustration purposes only and are not available individually as replace-
ment parts.
Brake Fluid Exchanger Assembly Drawing
REV 03/06
Page 9
SKU 92923
For technical questions, please call 1-800-444-3353
Download from Www.Somanuals.com. All Manuals Search And Download.
Adapter Kit Parts List
PLEASE READTHE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE PARTS DIAGRAM INTHIS
MANUAL AS A REFERENCETOOL ONLY. NEITHERTHE MANUFACTURER NOR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR
SHE IS QUALIFIEDTO MAKE ANY REPAIRSTOTHE PRODUCT ORTHAT HE OR SHE IS QUALI-
FIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR
DISTRIBUTOR EXPRESSLY STATESTHAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD
BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER.
THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO
THE ORIGINAL PRODUCT OR REPLACEMENT PARTSTHERETO, OR ARISING OUT OF HIS OR
HER INSTALLATION OF REPLACEMENT PARTSTHERETO.
Page 10
SKU 92923
For technical questions, please call 1-800-444-3353
Download from Www.Somanuals.com. All Manuals Search And Download.
|