Harbor Freight Tools Automobile Parts 92923 User Manual

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  
 
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  
 
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  
 
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  
 
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  
 
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  
 
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  
 
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  
 
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  
 

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