Service manual

TC Series Hydraulic Brake ABS System
030.1-9
DO NOT USE OR MIX DIFFERENT
TYPES OF HYDRAULIC FLUID. THE
WRONG HYDRAULIC FLUID WILL
DAMAGE THE RUBBER PARTS OF THE
BRAKE CALIPER AND CAN CAUSE
DAMAGE, LOSS OF BRAKING AND
SERIOUS INJURY.
Do not allow brake fluid to touch any painted
surfaces, as it will remove the paint. Brake
fluid may also damage certain non-metal
surfaces. Do not allow fluid to get on brake
pads, shoes, rotors, or drums.
Hydraulic ABS System Bleeding Procedure
This procedure specifies how to bleed the hydraulic
ABS modulator in case of unwanted air in the
modulator and/or suction area of the pump system.
The ignition must remain off throughout the duration
of the manual bleeding of the system, energizing of
the unit during bleeding, unless specified.
Note
During bleeding procedure, reservoir fluid
is not permitted to fall below the MIN
level. Observe the level regularly and
replenish if necessary to the MAX level
marked on the reservoir.
1. Required bleed and fill equipment
•
Clean glass or plastic bottle/receptacle
•
Rubber/plastic bleed hose
•
Suitable bleed spanner
•
Manufacturer’s recommended brake fluid,
approximately ½ gallon
•
Electronic controller or manual modulator
actuator
2. Master Cylinder Filling and Bleeding
•
Replenish reservoir with the specified brake
fluid.
•
Depress braking pedal 5 times in 5 seconds
using only the stroke between 1/3 of maximum
value.
•
Release the pedal for 5 to 10 seconds Air
bubbles will rise into the reservoir.
•
Repeat all these steps 3 times until sufficient
resistance is felt at the pedal.
3. Brake Circuit Bleeding
•
Fit bleed hose onto one of the bleed screw
nipple.
•
Submerge free end of bleed hose into the
brake fluid of the bleed bottle.
•
Actuate the brake pedal several times then
depress and hold firm.
•
Open the bleed screw of the longest brake
circuit to be bled, often with the RR
•
Allow fluid to flow until no air bubbles or
fluid flows into the bleed bottle.
•
Close the bleed screw prior to the final release
of the brake pedal.
•
Repeat step 3 until fluid flows without any air
bubbles.
•
Repeat step 3 on other three brakes, in order
of longest to shortest circuit from the
modulator, Rl, FR, and FL.
4. Modulator Pump System Filling and Bleeding
•
Pulse the inlet and outlet solenoids of brake
circuit being bled and activate the pump motor
using the ABS switch box. Start with the
longest brake circuit, typically the right rear.
•
Perform conventional bleeding procedure,
section 3, while activating solenoids and pump
motor for all brake circuit.
•
Repeat steps in section 4 until no air is
present, typical four times.
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