Club Car Carryall 1500 2016 Maintenance And Service Manual Download

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HYDRAULIC BRAKE AND PARK BRAKE

SYSTEMS

Bleeding the Hydraulic Brake System

Remove the cap from the master cylinder reservoir and top off the master cylinder with fresh DOT 5 silicone brake
fluid.

NEVER

mix DOT 3, DOT 4, or DOT 5.1 with DOT 5 as it

IS NOT

compatible.

Place, but do not tighten, the cap on the master cylinder reservoir.

Vacuum Bleeding:

5.1.

Lift and support the vehicle and remove the wheels.

See Lifting The Vehicle on page 3-7.

5.2.

Connect the vacuum-type brake bleeder (CC P/N S0010702).

5.2.1.

Front Brakes Only:

Connect the two hose fittings from a vacuum type brake bleeder to the brake

bleeder valves on the back of each of the front caliper assemblies.

5.2.2.

Rear Brakes Only:

Connect the two hose fittings from a vacuum type brake bleeder to the top

brake bleeder valves on the back of each of the rear caliper assemblies.

5.3.

Connect an air hose to the vacuum brake bleeder. The air pressure must be regulated at 12 to 15 psig

(82.7 to 103.4 kPa).

5.4.

Press the handle on the brake bleeder to start the vacuum.

5.5.

With the vacuum running, open each of the top brake bleeder valves 1/4 turn on the front wheel calipers.

5.6.

Monitor the fluid as it flows through the tubes of the vacuum bleeder tool. Continue to run the vacuum until

there are no air bubbles in the hoses.

See following NOTE.

NOTE:

Do not allow the brake fluid in the master cylinder reservoir to fall below the MIN level mark at any time during

the brake bleeding procedure.

5.7.

With the vacuum still running, tighten the two top front brake bleeder valves to 25 in·lb (3 N·m).

5.8.

Allow the handle on the brake bleeder tool to open and turn the vacuum system off.

Manual Bleeding:

Manually bleeding brakes is not done by rapidly applying extreme pressure on the vehicle’s master cylinder.
It’s simply a function of gently moving fluid through the system to displace the air and contaminants that have
accumulated.

It is important to have the vehicle sitting level and safely supported on jack stands before the manual bleeding
procedure is performed.

See following WARNING.

WARNING

• Do not bleed brakes with only one end of the vehicle raised. To place vehicle on four jack stands,

lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor
jack) with 1000 lb (454 kg) minimum lifting capacity. Do not use the lifting device to hold vehicle in
the raised position. Use approved jack stands of proper weight capacity to support the vehicle.
See Lifting The Vehicle on page 3-7.

The following procedure will enable correct bleeding:

6.1.

Lift and support the vehicle and remove the wheels.

See Lifting The Vehicle on page 3-7.

6.2.

Start at the brake caliper farthest away from the master cylinder. Attach a clear plastic hose to the caliper’s

bleeder valve and place the other end into a clear container (a clean plastic 16 oz. (473 mL) soda bottle
works fine) filled with enough brake fluid to cover the end of the hose. This prevents air from being drawn
into the caliper during the bleeding process.

6.3.

Have an assistant

SLOWLY

depress and release the brake pedal repeatedly until resistance is encountered

when pushing the pedal.

DO NOT VIGOROUSLY PUMP

the brake pedal! Pumping the pedal can aerate

the brake fluid in the master cylinder and brake hoses.

6.4.

When resistance is felt at the pedal, have the assistant apply gentle downward pressure on the pedal and

hold while slowly opening the bleeder valve, then close the valve fully as the brake pedal reaches the end
of its travel. Continue this process until air bubbles no longer come out of the hose that is submerged into
the fluid in the bottle. Gently tap the caliper and the master cylinder with a plastic-tipped hammer and

2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual

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