Motorvac BrakeVac-II User manual

1324 Blundell Rd. Mississauga ON Tel. [phone] Fax. [phone] www.motorvac.com
BrakeVac-II
Brake Fluid Service System
Part No. 500-8100/500-8105
USER MANUAL
500-8100 (Serial Numbers 8100-1200 and up)
500-8105 (Serial Numbers 8105-0700 and up)

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Introduction
Congratulations you now own the cleanest, most ecient and user-friendly brake uid service machine available
today. Your new electric pressure brake bleeder is designed specically for modern hydraulic brake and clutch
systems. It is advised that only professional technicians perform brake system service.
The MotorVac BRAKEVAC-II equipment has been designed for use on all hydraulic brake and clutch systems
especially Anti-Lock Braking Systems. The simplicity of our pressure bleeder makes it very user friendly and elimi-
nates the need for hands-on training.
The large capacity reservoir allows for a single service on any vehicle. The uid should be drained and kept in a
sealed container between vehicle services as the onboard storage is not air-tight.
The MotorVac BRAKEVAC-II System allows years of clean, safe, one-man operation brake services.
Thank you for choosing MotorVac.
Sincerely,
The MotorVac Team.

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Table of Contents
Page
Why should the Brake system be Flushed? .………….....…………………………...................................
System Features ………………………………………………............…….………................................…
Safety Information & Precautions ………………………………………………............…….…….......……
Brake Flush Service Procedure ………………………………………………............…….………..........…
Adjusting the pressure regulator ………………………………………………............…….…….........……
Automatic low uid level warning system and shut o …………………………............…….…….....……
Emptying the tank after each use …………………..............…………………………….....…….…………
Tips for hydraulic brake bleeding ………………………………………………............…….…........………
Suction hose lter assembly………………………………………………............…….……................……
BrakeVac - System Accessories ………………………………………………............…….………........…
Parts ………………………………………………............…….………................….................................
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1-2
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3-4
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6-8
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Why should the Brake system be Flushed?
Brake uid is hygroscopic meaning it can absorb moisture from the air resulting in a dangerous reduction
of its boiling point. Water contaminated brake uid under repeated working pressure boils and creates air
bubbles. Under severe conditions, this can result in complete brake system failure.
Water contaminated brake uid causes electrolysis to occur inside the brake system. The oxygen contained
in the water droplets cause oxidation. Electrolysis and oxidation corrodes the hydraulic master cylinder and
wheel cylinders, and steel brake lines from the inside. Pressure bleeding has been proven the most eective
method in ushing and bleeding hydraulic brake systems. Flushing the brake system and replacing the dirty
and contaminated brake uid with fresh brake uid can often avoid expensive repairs.
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System Features
Front view
Pressure switch
Vacuum switch
Pressure gauge
Clear vacuum hoseFluid level ‘window’
Drain Tank SwitchPressure Regulator
12 volt DC power cord
Black new uid hose
Circuit BreakerClean uid tank
Storage drawers
for adapters

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A
B G H
I
C
D
J
E
F
System Features
Back view
Waste (used)
uid capture
tank

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Safety Information & Precautions
The following safety instructions should be observed at all times when opening the MotorVac BRAKEVAC-II.
• Perform a visual inspection before each use. If the unit shows defects or damage, do not use! Have
your equipment repaired by an authorized MotorVac Service Center.
• The MotorVac BRAKEVAC-II is to be used only in accordance with the operator’s manual.
• The MotorVac BRAKEVAC-II is to be used only for the maintenance and repair of hydraulic brake uid
and clutch systems.
• Fill the MotorVac BRAKEVAC-II with BRAKE FLUID ONLY! Do not mix the dierent DOT standards
together. Never use the unit with any uid other than BRAKE FLUID!
• WARNING! USE OF FLUIDS OTHER THAN BRAKE FLUID CAN DAMAGE THE SEALS IN THE
PUMPS! USE OF OTHER FLUID CAN VOID THE WARRANTY!
• Follow all instructions from the Brake Fluid Manufacturer. Read all cautions on the container. Use proper
precautions when coming into contact with brake uid.
• Keep your MotorVac BRAKEVAC-II clean. Wipe your bleeder with a clean rag and non-ammable
solvent. Wipe all residual uids from the bleeder before use.
• Do not put oil, gasoline, or solvent soaked rags on the bleeder, as this will create a re hazard.
• Use only manufacturer’s recommended adapters and accessories. Always follow the vehicle
manufacturer’s service and maintenance instructions.
Brake Flush Service Procedure
1. Remove the ll cap from the MotorVac BRAKEVAC-II clean uid tank and ll with new brake uid. You
can observe the uid level by looking at the level indicator window at the front of the unit. Replace the ll
cap.
2. Attach the power cord to a good 12 volt DC power source.
3. Install the proper master cylinder reservoir adapter and connect the black pressure hose coupling to the
adapter.
4. Turn the pressure switch to the ON position and check for leaks.
5. Adjust the pressure regulator until the desired pressure is reached. (45 lb. maximum). Do not over
pressurize the reservoir as it may become damaged. To set pressure, relieve any residual pressure from
the service hose by inserting the ‘ll’ adapter into the coupler at the hose end. Open the regulator valve
‘counter-clockwise’ before starting the pump. If control knob is locked, pull outward slightly until knob
clicks o the locking tab. After starting the pump adjust the regulator in ‘clockwise’ until the correct
pressure reading is obtained. Control knob can be locked by pushing knob ‘in’ towards control panel.
6. Attach the transparent (vacuum) hose to the bleeder adapter and connect to the vehicle’s rst wheel
bleeder valve in the sequence. Turn on the “Vacuum” switch. Open the bleeder valve and observe the
uid ow. When the uid is clean, close the bleeder valve.
7. Bleed the brake system according to manufacturer’s recommended sequence by moving the vacuum
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hose from bleeder to bleeder in the proper sequence.
8. When nished, turn the “Pressure” switch and the “Vacuum” switch to the OFF position. The pressure
will automatically relieve from the new uid hose. When the pressure on the gauge reaches 0 psi
disconnect the new uid hose from the master cylinder adapter. Adjust the uid level using adapters in
either vacuum or pressure hoses as required.
9. Remove master cylinder adapter.
10. Reinstall the original master cylinder cover.
11. Empty the waste capture tank into a recycle container.
12. Empty the new uid back to a sealed new brake uid container to keep it dry and ready for the next
vehicle service
Note: If the Pressure Bleeder does not operate when the switch is in the ON position, check the circuit
breaker mounted in the front of the unit. Replace if necessary or contact your MotorVac BRAKEVAC-II
service center.
Brake Flush Service Procedure (Cont’d)
Adjusting the pressure regulator
The pump has a preset pressure of 45 PSI/ or 3 bar by the manufacturer. In some cases the recommended
procedure may call for a lower pressure. Release the locking knob by pulling outward then turn the knob
counter-clockwise to open the regulator to the lowest pressure setting. Then turn on the ‘Pressure’ pump
and turn the regulator knob in clockwise (when starting from 0 PSI on the pressure gauge) until the proper
pressure is reached.
Automatic low uid level warning system and shut o
The MotorVac BRAKEVAC-II will shut o the clean uid pump automatically when the uid level in the tank
reaches 0.8 liters. This ensures that no air will be injected into the brake system. The low level warning
light will illuminate alerting you to the low level condition. Remove the ll cap and add uid and replace cap.
Continue bleeding where you left o.
Emptying the tank after each use
Use the Pressure hose and attach an adapter that will allow brake uid to be drained into a container. Place
the adapter in a fashion that will allow the brake uid to drain into a clean capture tank or bottle.
Turn on the “Pressure” switch to drain the brake uid. Brake uid will start to ow immediately when the
“Pressure” switch is turned to the ON position. The tank level switch will turn o the ow when the brake uid
tank is almost empty. To drain the remainder of the brake uid from the tank and hose, press and hold the
“Drain Tank” switch until the brake uid tank and hose is completely empty. Release the “Drain Tank” switch
and turn o the “Pressure” switch.
After lling the tank with new uid, attach any adapter to the black hose coupler and direct the uid ow to a
capture container. Turn on the “Pressure” switch to bleed all the air out of the black hose prior to beginning a
new service.
The unit is now ready for the next service.
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Tips for hydraulic brake bleeding
After installing the correct master cylinder reservoir adapter and connecting the MotorVac BRAKEVAC-II you
can begin the bleeding process. Open one bleeder at a time until the brake uid ows clean and free of air
bubbles.
To better observe the brake uid ow and insure cleanliness of the shop we recommend using the MotorVac
‘vacuum’ recovery. This will allow you to observe the uid color, keep the uid o the shop oor and allow for
easy uid disposal.
After a complete hydraulic brake system overhaul we recommend that all bleeders be opened simultaneously
so the air can escape by the path of least resistance. This process eliminates backpressure and the
possibility of the new uid mixing with contaminated brake uid remaining in the system. When the uid
ows clean and free from bubbles, close the bleeder nipples and tighten them one after the other and double
check tightness.
We recommend during this pressure bleeding process to slowly press the brake or clutch pedal a few times
to insure complete purging of air and uid between the primary and secondary master cylinder chamber.
Fixed calipers can be equipped with multiple bleeder valves, which can require a larger volume of brake uid.
Each bleeder valve must be bled one after another.
In brake systems with load sensitive brake force regulators, the hydraulic ow to the wheel cylinders may be
restricted when the axles are hanging during lifting. In this case, the axles must be put under load. Consult
manufacture’s repair manual for proper brake bleeding or brake uid replacement procedures.
Caution:
In brake systems with a hydraulic brake booster, the brake system operates with brake uid and the
hydraulic booster system operates on hydraulic uid. The two uids must not be interchanged!
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Suction hose lter assembly
Filter screen must be cleaned routinely to avoid loss of suction.
Elbow part number
030-4814
Filter part number
050-1009
Unscrew cap to
clean lter screen

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BrakeVac - System Accessories
Basic Adaptor Kit: 200-3118
Standard Adapter kit for BRAKEVAC-II
The following is a list of the adaptors included with your BrakeVac-II unit.
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MOTORVAC PART & NUMBER QTY DESCRIPTION
066-6000
1
Chrysler with twin caps,
2 piece, 3 tabs, expandable
O-rings. (BA-01)
066-6002
1
3 Tab twist on with Expandable o-ring.
Fits Ford, Hyundai, Chrysler, Kia, Mazda,
Pontiac, Nissan and Subaru. (BA-03)
066-6003
1
Three tab twist on with expandable o-ring.
Fits GM, Chevrolet, Cadillac, Mazda,
Pontiac and Daewoo. (BA-04)
066-6004
1
Threaded screw cap. Fits all European
makes as well as domestics with Bosch or
Teves master Cylinders. (BA-05)
066-6005
1
Universal round adapter
With chain tension hold down.
Fits round master cylinders with a diameter
of .800” to 3.150”. (BA-07)
066-6006
1
Expandable O-ring with hold down chain.
Fits Honda with diameter of 2.91” and some
Isuzu. (BA-08)

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MOTORVAC PART & NUMBER QTY DESCRIPTION
066-6007
1Fits Honda master cylinders with and Inside
diameter of 2.11” to 2.17”. (BA-09)
066-6008
1
Expandable o-ring with adjustable hold
down tabs. Fits Toyota & Lexus with
diameter of 1.69” (BA-10)
066-6009
1
Expandable o-ring with adjustable hold
down tabs. Fits Toyota & Lexus with
diameter of 2.75”. (BA-11)
066-6010
1
Twin cylinders with rubber cones connected
together with common hose. Chain tension
hold downs.
Fits into the inlet holes at the bottom of GM
and Chrysler plastic master cylinders. (BA-
14)
(replaces ST-100)
066-6012
1
Twist on 2 tab with expandable o-ring.
Fits Ford. (BA-02)
066-6013
1NISSAN ALTIMA, XTERRA (BA-13)
BrakeVac - System Accessories

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MOTORVAC PART & NUMBER QTY DESCRIPTION
066-1100
1Honda Civic adapter
066-6011
1
Plate adapter with 2 hold down chains for
rectangular cast iron master cylinders.
(BA-12)
066-0020
1
Small universal round adapter with chain
tension hold-down. Specially designed for
clutch reservoirs.
(BA-06)
OPTIONAL ADAPTORS (NOT INCLUDED IN KIT 200-3118)

Parts
Service parts for the BrakeVac-II, Brake Fluid Flushing Machine.
Please refer to the part numbers below when ordering parts for this unit.
Part # Description
98064965 Hub Caps
98064967 Wheels 8” X 1.75” X 1/2” Rubber
010-6008 Axle, rear wheels (1/2”)
010-6060 Fluid tank cap
010-7050 Waste Tank 1 US gallon
011-0051 Hose Bracket
020-0038 Circuit Breaker -15 A
020-0063 Lamp Amber 1/2” Mount
020-0073 Lamp Green 1/2” Mount
020-0083 Light Red
020-0090 Relay-EAR Mount-8 Relay Trm
020-1201 Drain tank switch (momentary)
020-1205 Two Position ON/OFF Switch
020-1402 Low level switch (in tank)
020-8207 Power Cord
050-1009 Screen lter
050-1308 Pressure gauge
080-8101 Coupler only - Output side π”
080-8102 Adapter brake bleeder
200-8111 Output pressure hose assembly
200-8112 Suction hose assembly
200-8119 Pressure regulator assembly
200-8125 Pump Kit BrakeVac II
ORDERING PARTS
Parts for the unit may be ordered by calling MotorVac Customer Service at [phone] or
[phone]. Please have your model and serial numbers available.
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1324 Blundell Rd. Mississauga ON Tel. [phone] Fax. [phone] www.motorvac.com
ZIM13-00828 Rev3