Wynn's EW95501 User manual

40200757 (REV.03)
©2018 ITW Professional Automotive Products Inc. All rights reserved • 3606 Craftsman Blvd. • Lakeland FL 33803 • equipment.wynnsusa.com
EW95501
Brake Fluid Exchange Machine
Operations Manual

1
TABLE OF CONTENTS
INTRODUCTION TO THE MACHINE ........................................ 2
CUSTOMER SERVICE CONTACT INFORMATION ................. 2
SAFETY INFORMATION ........................................................... 3
MACHINE SPECIFICATIONS & FEATURES ............................ 9
MACHINE OVERVIEW .............................................................. 10
OPERATING INSTRUCTIONS .................................................. 11
MAINTENANCE ......................................................................... 14
REPLACEMENT PARTS ........................................................... 15
WARRANTY INFORMATION .................................................... 17

2
INTRODUCTION to the
Wynn’s Brake Fluid Exchange Machine
Congratulations on the purchase of your Wynn’s Brake Fluid Exchange Machine!
Brake service is now more profitable, since we have eliminated the need for a
second technician when performing a brake bleeding service.
This machine provides the shop with the ability to service and pressure test a
brake system faster and easier than ever before with a combination of speed and
effectiveness.
Please take time to read through this manual to familiarize yourself with the
machine before performing your first brake fluid exchange.
CUSTOMER SERVICE CONTACT INFORMATION
For product information, tech support, or to order replacement parts,
please call: 833-303-4644
or visit: equipment.wynnsusa.com

3
IMPORTANT SAFETY NOTICE
For your safety, read this manual thoroughly before operating this machine. Your machine
is intended for use by properly trained, skilled professional automotive technicians. The
safety messages presented below and throughout this user’s manual are reminders to the
operator to exercise care when using this unit. Before using your machine, always refer to
and follow the safety messages and applicable service procedures provided by the
manufacturer of the vehicle being serviced.
• Read All Safety Instructions
Read, understand and follow all safety messages and instructions in this manual. Safety
messages in this section of the manual contain a signal word with a three-part message
and, in some instances, an icon.
• Signal Words
The signal word indicates the level of the hazard in a situation:
Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury to the operator or to bystanders.
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury to the operator or to bystanders.
Indicates a potentially hazardous situation which, if not avoided,
may result in moderate or minor injury to the operator or to bystanders.
Indicates a situation which, if not avoided, may result in damage
to the machine, or the vehicle being serviced.
• Safety Messages
Safety messages in this section contain three different type styles:
• Normal type states the hazard.
• Bold type states how to avoid the hazard.
• Italic type states the possible consequences of not avoiding the hazard.

4
• Safety Symbols
A safety symbol, when present, gives a graphical description of the potential hazard,
and how to avoid the hazard:
Risk of Fire Read Instructions Before Use
Risk of Explosion Mandatory Eye Protection
Risk of Entanglement Mandatory Protective Gloves
Dangerous Fumes Mandatory Protective Clothing
Do Not Pull or Move Risk of Burns

5
IMPORTANT SAFETY INSTRUCTIONS
Engine exhaust contains toxic gases.
• Vent vehicle’s exhaust away from work area.
• Do not breathe exhaust.
Exhaust gases will cause injury or death.
Improper use and operation.
• Read, understand and follow all safety messages and operational procedures in this
manual before operating this machine.
• This equipment should be operated only by qualified personnel.
• Use this equipment only as described in this manual.
Improper use and operation of this product can result in injury.
Engine systems can malfunction expelling fuel, oil vapors, hot steam, hot toxic exhaust gases and
other flying particles.
• Wear safety goggles and protective clothing, user and bystander. Everyday eyeglasses
only have impact resistant lenses, they are NOT safety glasses.
• Do not position head directly over or in front of carburetor or throttle body. Engine
backfire can occur when air cleaner is out of normal position.
• Make sure gauge reads zero before connecting or disconnecting hose connections to
adapters.
• Make sure cooling system pressure has been relieved before connecting or
disconnecting hose connections and adapters.
• Keep a dry chemical (Class B) fire extinguisher rated for gasoline, chemical & electric
fires in the work area.
Fire, explosion, or flying particles may cause serious injury.
Risk of expelling pressurized fluids.
• Wear safety goggles and protective clothing, user and bystander.

6
• Engine systems can malfunction, expelling fuel, oil vapors, hot steam, hot toxic exhaust
gases and other debris.
• Always unplug the machine from its power source when not in use.
• Keep the service hoses away from hot or moving engine parts. Hoses can split or burst
causing fluid to be expelled.
• Avoid contact with brake fluid.
• Treatment methods are as follows:
Eyes: Flush eyes with plenty of water.
Skin: Wash with soap and water.
Inhalation: Move to uncontaminated area.
Ingestion: If large amount, get medical attention.
If any irritation persists, get medical attention.
• Dispose of used fluid according to environmental laws and regulations.
Fuel, oil vapors, hot steam, hot toxic exhaust gases, pressurized fluid, and other debris can cause
serious injury.
Risk of unexpected vehicle movement.
• Block drive wheels before starting vehicle’s engine to begin an exchange.
• Unless instructed otherwise, set parking brake and put gear selector in park.
• Do not leave a running vehicle unattended.
• If vehicle has an automatic parking brake release, disconnect release mechanism for
testing and reconnect when testing is completed.
A moving vehicle can cause injury.
Risk of entanglement. Engine has moving parts.
• Do not place tools on fenders or other places in engine compartment.
• Keep yourself, clothing, battery cables and service hoses clear of moving parts such as
fan blades, belts, pulleys, hood and doors.
• Barriers are recommended to help identify danger zones in test area.
• Prevent personnel from walking through immediate test area.
Contact with moving parts can cause injury.
Risk of fire or explosion.
• Do not operate in the vicinity of open containers of flammable liquids such as gasoline.
• Keep hoses and jumper cables away from heat sources and sharp edges.
• Do not operate equipment with damaged cords or hoses until they have been examined
by a qualified serviceman.
Fire or explosion can cause injury.

7
Risk of fire or explosion. Gases produced by a battery are highly explosive.
• Wear safety goggles and protective clothing, user and bystander.
• This machine is equipped to operate on 12-volt DC power only. A power source greater
than this can result in serious injury to the user as well as damage to the machine.
• Do not smoke, place metal tools on battery or allow a spark or flame in vicinity of battery.
• Clean battery terminals before hooking the machine’s battery clips to them. During
cleaning, keep airborne corrosion from eyes, nose and mouth.
• Be sure both battery cables are tightly connected to the battery terminals as instructed
before proceeding with a fluid exchange.
• Never remove battery cables from the battery terminals while the machine is operating.
Battery explosion can cause injury.
Risk of burns.
• Wear gloves when handling hot engine components.
• Do not touch hot exhaust systems, manifolds, engines, radiators, etc.
Hot engine parts may cause injury.
Battery acid is a highly corrosive sulfuric acid.
• Wear safety goggles and protective gloves, user and bystander.
• Have plenty of fresh water and soap nearby. If battery acid contacts skin, clothing, or
eyes, flush exposed area with soap and water for 10 minutes.
• While cleaning battery’s terminals, keep airborne corrosion from eyes, nose and mouth.
• Do not touch eyes while working near battery.
Battery acid can burn eyes and skin.
Risk of burns.
• Wear gloves when working near hot engine components.
• Do not touch hot exhaust systems, manifolds, engines, radiators, etc.
• The fluid coming from the vehicle along with some of the machine’s components that the
fluid comes into direct contact with (i.e. hoses and fittings) may reach temperatures
uncomfortable to the touch. Exercise caution in avoiding contact with these items.
Hot components can cause injury or discomfort.

8
Risk of injury.
• This equipment should be operated by qualified personnel only.
• Use this equipment only as described in this manual.
• Always unplug the machine from its power source when not in use.
• Loop the power cord loosely in its proper location when machine is not in use.
• Do not operate equipment with a damaged battery cables or hoses, or if the equipment
has been dropped or damaged, until it has been examined by a qualified service
representative.
• Care should be taken to arrange the battery cables and service hoses so that they will
not be tripped over or pulled.
• Never pull on the power cables or service hoses to transport the machine. Damage may
occur to these components, or machine may tip over.
• Keep area of operation clear of unnecessary tools and equipment. Utilize recessed tool
storage areas on the top of the machine.
• Never leave the machine running unattended.
• The machine is not designed for any other purpose than the servicing of automotive
brake systems.
Operation of this machine by anyone other than qualified personnel may result in injury.
Misdiagnosis may lead to incorrect or improper repair and/or adjustment.
• Do not rely on erratic, questionable, or obviously erroneous test information or results. If
test information or results are erratic, questionable, or obviously erroneous, make sure
that all connections and data entry information are correct and that the test procedure was
performed correctly. If test information or results are still suspicious, do not use them for
diagnosis.
Improper repair and/or adjustment may cause vehicle or equipment damage or unsafe operation.
Risk of equipment damage.
• Connect battery cables to a 12-volt power source only (i.e. vehicle’s battery).
• Servicing, transporting, or storing this machine in an attitude other than the normal
operating position can result in fluid spillage and/or component damage.
• Never pull on the power cables or service hoses to transport the unit. Damage may occur
to these components, or machine may tip over. Always use the handle to move.
• Periodically clean the machine by wiping down with a clean, soft, dry cloth.
Improper operation of equipment may result in damage to machine or components.
SAVE AND FOLLOW THESE INSTRUCTIONS!

9
MACHINE SPECIFICATIONS
Dimensions: 38” H x 18” W x 28” D
Weight: 60 lbs.
Waste Fluid Bottle: 4 Qt.
Power: 12V DC Power
FEATURES
The Wynn’s Brake Fluid Exchange Machine provides a complete brake fluid exchange,
simultaneously filling and vacuuming the brake system for a fast, effective service. It delivers
brake fluid into reservoir, at same time vacuums system and reduces the introduction of air all
while providing a constant supply of new brake fluid into the system..
✔Complete Brake System Fluid Exchange
✔Combo of Pressure at Master Cylinder & Vacuum at Wheels
✔Handles High Pressure Hybrid Vehicle Brake Systems
✔Pressure Regulator & Gauge for Proper Fluid Pressure Setting (1-49 PSI)
✔Ease of “Remove” and “Top Off” of the Master Cylinder Reservoir
✔Pressure-Free Service Hose Removal
✔Up to 18’ Coiled Hose
✔Removable Waste Fluid Container
✔Convenient, Portable Roll-Around Unit

10
MACHINE OVERVIEW

11
OPERATING INSTRUCTIONS
SAFETY RECOMMENDATIONS
Safety glasses and gloves should be worn
during the service.
Never raise the vehicle when it is occupied.
Always inspect braking system for leaks
prior to service.
Road test the vehicle to test the braking
system.
PREPARATION
Confirm bleeder screws on vehicle can be opened
and are not seized.
Penetrating fluid may need to be applied.
Attach brake bleed boot at the end of the fluid
removal line to the bleeder screw on wheel being
serviced.
Support the coiled hose using a convenient point
on underside of vehicle to remove strain on boot.
Bleeder valves should be closed, but ready to be
opened.
Connect battery cables.
Attach NEW FLUID pickup to appropriate Wynn’s
Brake Fluid Bottle.
Remove master cylinder cap.
Attach open ended hose to coiled waste hose.
Set switch to REMOVE position.
Place open ended hose into master cylinder
reservoir, open ball valve and evacuate OLD
FLUID.
When empty, close valve, set switch to OFF
position.
Connect open ended hose to YELLOW pressure
hose and place in master cylinder reservoir
Set switch to EXCHANGE position and slowly
open the ball valve.
When filled, close the ball valve, set switch to OFF
position and remove open ended hose.

12
Find correct master cylinder adapter from adapter
kit and attach to master cylinder reservoir.
Connect YELLOW pressure hose to master
cylinder adapter.
PERFORMING AN EXCHANGE
Set switch to EXCHANGE position.
Use the pressure regulator to increase the
pressure to the desired amount. A typical brake
service should not require more than 12 psi (see
manufacturer’s recommendation).
Slowly open the ball valve on the YELLOW
pressure hose, while checking for leaks around
the master cylinder adapter.
Slightly open the bleeder screw on the wheel
being serviced until fluid begins to flow into
removal hose.
Continue until old dark brake fluid is removed.
Close bleed valve.
Repeat for remaining wheels, starting at the wheel
farthest from the master cylinder reservoir and
working progressively closer.
If the fluid level in the NEW FLUID bottle runs low,
the machine will indicate this with a tone and a
warning indicator light.
Set switch to OFF position and replace with full
bottle.
Continue service by setting switch back to
EXCHANGE.
When service is complete, set switch to OFF
position.

13
Press and hold the PRESSURE RELEASE
BUTTON to relieve pressure.
Close the ball valve on the YELLOW pressure
hose.
Disconnect the YELLOW pressure hose from the
master cylinder adapter.
TOP OFF / REMOVE FLUID
If required, the fluid level can be raised by
inserting the open-ended adapter into the end of
the YELLOW pressure hose to fill the reservoir.
Make sure the ball valve is closed on the
YELLOW pressure hose.
Set the switch to the EXCHANGE position.
Adjust the regulator pressure to 5-10 psi.
Slowly open the valve on the YELLOW pressure
hose. Fill to desired level and close valve.
Remove pressure, then remove adapter.
To remove fluid, use the same procedure as
above, except use the removal hose to remove
the fluid. Set switch to REMOVE, place open
ended hose into reservoir and slowly open valve
to remove fluid to desired level. Close valve and
set switch to OFF position. Remove adapter.

14
DISCONNECT
Ensure machine is switched off and pressure is
removed by pressing the PRESSURE RELEASE
BUTTON.
Disconnect cables and hoses. Replace master
cylinder cap.
MAINTENANCE
To keep your machine working properly…
• Keep debris out of new fluid.
• Avoid spilling fluid on the control panel.

15
REPLACEMENT PARTS

16
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1
941252
REAR CABINET SUPPORT - RED
1
2
941447
REDUCER - 3/8 MPT X 1/4 FPT
4
3
941500
ADAPTER - BRAKE BLEED NIPPLE LARGE
1
4
941524
WAND ADAPTER - NEW FLUID
1
5
941540
YELLOW SERVICE HOSE
1
6
941545
VACUUM PUMP
1
7
941546W
BATTERY CABLES
1
8
942137W
WHEEL ONLY 4" CASTERS
4
9
944037W
SWITCH ONLY - CONTROL PANEL
1
10
945000
NEW FLUID PUMP
1
11
945002
PRESSURE REGULATOR
1
12
945003
GAUGE - PANEL MOUNT 2.5 0-60PSI
1
13
945004
FITTING - 5/16 PUSH EP SEALS
2
14
10600016
90 DEGREE ELBOW
1
15
40100074
COILED FLUID REMOVAL HOSE ASSEMBLY
1
16
40200334
5/16 TUBE X 1/8 NPT
3
17
40200336
5/16 TUBE UNION TEE
2
18
40200338
5/16 TUBE X 1/4 NPT ELBOW
10
19
40200339
1/4 BRASS BULKHEAD FITTING
4
20
40200340
3/8 JIC MALE X 1/4 NPT ELB 6 CTX-S
1
21
40200343
VALVE WITH SWITCH
1
22
40200438
1 GALLON WASTE FLUID BOTTLE
1
23
40200439
CAP FOR 40200438 WASTE BOTTLE
1
24
40200440
2 GALLON MOLDED TRAY
1
25
40200444
LEVEL SWITCH
1
26
40200445
ELECTRONICS PACKAGE
1
27
40200662
1/4 X 1/4 SLEEVE LOCK HOSE SOCKET
1
28
40300297
CONTROL PANEL - OVERLAY ASSEMBLY
1
29
40300304
SERVICE PANEL - OVERLAY ASSEMBLY
1
30
P941530
SHEPHERD HOOK - BLACK
2
31
P941538
ADAPTER BRACKET - BLACK
1
32
R940750
CHASSIS - BLACK
1
33
R940751
CONSOLE - BLACK
1
34
R942118
CASTER 4" W/BRAKE
2
35
R942137
CASTER 4" SWIVEL
2

17
Wynn’s Equipment Limited Warranty Terms and Conditions
(1 Year on Equipment / 2 Years on Parts)
Seller warrants to its distributors that under normal use, care and service, the Equipment (except
as otherwise provided herein) shall be free from defects in material and workmanship for One (1)
year from the date of original invoice (unless a machine was put into inventory and later sold
(such sale from inventor to occur no later than [six (6) months] after the date of original invoice),
and a distributor can provide proof of sale and registered warranty card, then the one-year
warranty will begin on the registration date) for all Equipment with an additional 12 months of
coverage for parts only. External hoses, remote control modules, adapters and all other
attachments, supplies and consumables (except as otherwise provided herein) are warranted for
90 calendar days from the date of original invoice. Filter elements are not warranted. Printed
circuit boards purchased from Seller will be warrantable for a period of one (1) years from original
purchase date, and any repair services for machines under warranty or to a purchased circuit
board by an ITW employee or authorized representative shall be reimbursed.
SELLER'S OBLIGATIONS UNDER THIS WARRANTY ARE LIMITED SOLELY TO THE
REPAIR OR, AT SELLER'S OPTION, REPLACEMENT OF EQUIPMENT OR PARTS, AND
LABOR COSTS ASSOCIATED WHICH TO SELLER'S SATISFACTION ARE DETERMINED TO
BE DEFECTIVE AND WHICH ARE NECESSARY, IN SELLER'S JUDGEMENT, TO RETURN
THE EQUIPMENT TO GOOD OPERATING CONDITION. NO OTHER WARRANTIES
EXPRESS OR IMPLIED OR STATUTORY, INCLUDING WITHOUT LIMITATION ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL
APPLY AND ALL SUCH WARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED.
This warranty does not cover (and separate charges for parts, labor and related expenses shall
apply to) any damage to, malfunctioning, inoperability or improper operation of the Equipment
caused by, resulting from or attributable to (A) abuse, misuse or tampering; (B) alteration,
modification or adjustment of the Equipment by anyone other than Seller's authorized
representatives; (D) improper or negligent use, application, operation, care, cleaning, storage or
handling; (E) fire, water, wind, lightning or other natural causes; (F) adverse environmental
conditions, including, without limitation, excessive heat, moisture, corrosive elements, or dust or
other air contaminants, radio frequency interference, electric power failure, power line voltages
beyond those specified for the equipment, unusual physical, electrical or electromagnetic stress,
and/or any other condition outside of Seller's environmental specifications; (G) use of the
Equipment in combination or connection with other equipment, attachments, supplies or
consumables not manufactured or supplied by Seller; or (H) failure to comply with any applicable
federal, state or local regulation.
Repairs or replacements qualifying under this Warranty will be performed on regular business
days during Seller's normal working hours within a similar timeframe and process as BUYER
already has in place, to be accomplished by Wynn’s/QMI distributors with the support and
cooperation of the SELLER, or by SELLER or SELLER’s subcontractors if that is acceptable to
the BUYER following Purchaser's request or if agreed to between Seller and Buyer by
Purchaser’s/ ITW staff if necessary. All requests for Warranty service must be made during the
stated Warranty period. This warranty is non-transferable.