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4.5 Filling and bleeding the hydraulic disc brake

Note: The master cylinder is mounted in an upright position. This means that

filling and bleeding the system is only possible from the lowest point, which is

the brake cylinder assembly at the wheel.

Necessary tools:

1 open-end wrench 1/4" = 6.35 mm for the bleeder valve at the brake

calliper.

1 open-end wrench 11/16" = 18 mm.

2 Plastic syringes acid resistant, volume approx. 100 ml (6 cu.in.). Use this

syringe for brake fluid only! 1 bleeder assy Tost No. 075890.

1 m (3 ft.) transparent PVC hose inside diameter 8 mm (0.31 in.), fixed to

syringe and bleeder assy with hose clamps.

Brake-fluid DOT 3, DOT 4 or SAEJ 1703.

Preparations

- Raise the fuselage, extend the landing gear.

- Fix left wheel door in the fully open position.

- Set the airbrake control in the retracted position.

- Remove the baggage compartment floor and rear cover, check that the

actuating cable for the master cylinder is loose and if the piston rod of

the master cylinder is at its upper stop.

- Remove the main wheel according to section 4.4 A. Place the wheel so

that the brake hose makes no bow above or below the horizontal. If

necessary lift the fuselage even more.

Filling (empty system)

Warning: Brake fluid is poisonous! Protect your hands and clothes. Remove

all spilled brake fluid. Clean all parts which had contact with brake fluid with

alcohol, don't use fuel or solvents.

- Remove the cap and the membrane from the reservoir.

- Fill the first syringe (with hose and bleeder assy.) with brake fluid,

eliminate all air bubbles.

- Remove the protection cap from the bleeder valve at the brake calliper,

attach the bleeder assy. and fix it with the 11/16" wrench.

- Open the bleeder valve at the cylinder assy, use the 1/4" wrench, fill in

slowly the complete volume avoiding air bubbles.

- Fill the complete system up to 15 mm (0.6 in.) below the upper edge of

the reservoir, avoid over filling.

- Close the bleeder valve at the brake calliper.

- Use the second syringe to remove all brake fluid from the reservoir.

Issued: September 2011

Manual valid with the up-to-date cover page only

Maintenance Manual DG-500M

TN500/05

4.5