Hydro-Max Hydraulic Brake Booster

and Master Cylinder

Technical Manual

BOSCH

Important Service Notes

The information in this publication was current at the time of printing. The
information presented in this publication is subject to change without notice or
liability.
The information contained in this publication is intended for use by properly trained
and equipped professional technicians. It is NOT for the "Do It Yourselfer".
Failure to follow safety and repair procedures can result in personal injury, or
damage to vehicles, components and equipment.

Correspondence concerning this manual should be addressed to:

Robert Bosch LLC
Attn: Medium Truck Brake Engineering
3737 Red Arrow Highway
St. Joseph, Michigan 49085
This manual can be viewed or downloaded at:
http://www.bosch.us
Fax: 269-428-6704

August 2003

Hydro-Max Technical Manual

Table of Contents
GeneralDescription.............................................................................................................................1
Hydro-MaxTMBooster................................................................................................ 1
MasterCylinder.........................................................................................................1

PrincipleofOperation........................................................................................................................ 3
Hydro-MaxTMBooster................................................................................................ 3
MasterCylinder.........................................................................................................5
ElectricalOperatingSystem......................................................................................7
BasicOperationofBoosterandMasterCylinder......................................................8
ElectronicMonitorModule........................................................................................9

ApplicationInformation...................................................................................................................... 13
HydraulicFluids........................................................................................................13
BrakeFluidTubing,HosesandFittings....................................................................13
BoosterFluidTubing,HosesandFittings.................................................................14
BoosterFluidSource..................................................................................................15
InstallationRecommendations...................................................................................16
PedalReturnSprings.................................................................................................17
PedalStopandProperSpringLoad..........................................................................18

TroubleShooting..................................................................................................................................19

PrintedintheUnitedStatesofAmerica
2002RobertBoschCorp.
Allrightsreserved.

Hydro-Max Technical Manual

General Description
TheHydro-MaxTMisahydraulicallypoweredbrakeboosterwhichprovidespowerassistfor
applyinghydraulicbrakes.Aboostercombinedwithamastercylinder(refertoFigure1)formsthe
hydraulicbrakeactuationunit.AtypicalassemblyisshowninFigure1.Theboosterreducesthe
pedaleffortrequiredtoapplythebrakesascomparedtoanon-powersystem.

BRAKE FLUID RESERVOIR

FLOW SWITCH
INLET PORT

PEDAL ROD

OUTLET PORT

MOUNTING FLANGE

MASTER CYLINDER
HYDRO-MAXTM BOOSTER
SECONDARY OUTLET PORT
BACKUP PUMP

DIFFERENTIAL PRESSURE SWITCH

RELAY

FLUID LEVEL INDICATOR SWITCH

PRIMARY OUTLET PORT

Figure 1 Hydro-MaxTM

Booster and Master Cylinder Assembly

Hydro-MaxTM Booster
Thehydraulicboosteriscomprisedofanopencentervalveandreactionfeedbackmechanism,a
powerpiston,a12and24-voltbackuppumpandanintegralflowswitch.Itispoweredbyeither
thepowersteeringpumporotherhydraulicsource.Thebackuppumpprovidesasecondarypower
sourceforthehydraulicboosterandiscontrolledbytheintegralflowswitch.

Master Cylinder
Themastercylinderisasplitsystemtypewithseparatefluidchambers,pistonsandoutletportsfor
thefrontandrearbrakecircuits.Adifferentialpressureswitch,fluidlevelindicatorswitch,and
remotereservoirarealsoavailable.
AtypicalHydro-MaxTMboosterandmastercylinderassemblyinstallationinahydraulicbraking
systemisshowninFigure2.

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Hydro-Max Technical Manual

52

STEERING PUMP
RESERVOIR & FILTER

TO WARNING SYSTEM

TO WARNING SYSTEM

Figure 2

ABS UNIT

TO REAR BRAKES

TO REAR BRAKES

TO BATTERY

BRAKE SWITCH

Typical Booster and Master Cylinder Assembly Installation in a Hydraulic Braking System

TO FRONT BRAKES

TO FRONT BRAKES

STEERING GEAR

FLOW
N OF
CTIO
E
IR
D

GROUND

TO IDP

TO IGNITION

( OPTIONAL)
MONITOR MODULE

TO WARNING LIGHT
TO WARNING BUZZER

Principle of Operation
Hydro-MaxTM Booster
Duringnormalsystemoperation,(refertoFigure4)fluidflowfromahydraulicpowersource(usuallythe
powersteeringpump)enterstheinletportoftheHydro-MaxTMbooster,flowsthroughthepowerpiston,
aroundthethrottlevalveandthroughtheflowswitch,exitingthroughtheoutletport.
Forceappliedtothebrakepedalbythevehicleoperatorismultipliedbytheleverratioofthepedal
mechanismtomovethepedalrodofthebooster.Thismovementclosesthethrottlevalve,whichrestricts
flow.Thisrestrictionofflow,whichresultsinapressureincreaseactingonthepowerpiston,appliesan
amplifiedforcetothemastercylinderprimarypiston.Areactionpiston,insidethepowerpiston
subassembly,providesthedriver"pedalfeel"duringanapplicationofthebrakepedal.
Fluidflowthroughtheflowswitchopensthebackuppumpelectricalcircuitduringnormaloperation.A
separatecheckvalveinthebackuppumppreventsback-flowthroughthepumpduringnormalpower
applications.
Intheeventnormalflowfromthepowersourceisinterrupted,thebackuppumpprovidesthepowerata
reducedrateforstopping.SeeFigure3 forperformancecurve.Uponflowinterruption,theintegralflow
switchcloses,energizingarelay,providingelectricalpowertothebackuppump.
Duringbackupoperation,thepumpre-circulatesfluidwithintheboosterassemblywithpressurebuilton
demandviathethrottlevalve.Fluidisretainedwithintheboosterbytheinletportcheckvalve.
Figure3illustratesthetypicalrelationshipofmastercylinderpressureandinputforceofthebooster.

Figure 3

Typical Performance Curve

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Hydro-Max Technical Manual

47

Figure 4

PO WE R PISTON O UTPUT SHAFT

END CAP

CHE CK BAL L

Hydro-MaxTM Booster and Master Cylinder

BACKUP PUMP

REACTION PIN

GROMMET

PO WE R PISTON RETURN S PRING

VAL VE RETURN SPRING

POWE R PISTON

THROTTLE VALVE

REACTION PISTO N

PEDAL ROD

PO WE R PISTON INPUT SHAFT

PRESSURE REG UL ATO R SPRING

INP UT SHA FT SEALS & BUSHING

CHE CK VAL VE SEAT & O-RING

CHE CK BAL L

INL ET PORT

FIL TER

OUTLET P ORT

FLOW SWITCH ASS Y

( CLOSED)

FLOW SWITCH ASS Y

(O PEN)

FLOW SPRING

FLOW PISTO N

FLOW SWITCH

FLOW SWITCH ASS Y

Master Cylinder
Inthereleasedposition,(refertoFigure5)actuatorsofboththeprimaryandsecondarypistonsareinwith
theirrespectivecompensatingvalvestems,whichprojectintothecylinderbore.Thiscontacttiltsthevalves
toanopenposition,whichallowshydraulicfluidinthereservoirsectionstocommunicatewiththeprimary
andsecondarypressurechambers.Eachpressurechamberhasapiston/actuatorsubassemblycontaininga
preloaded(caged)springandreturnspring.
Initialforwardtraveloftheprimarypistonmovestheprimaryactuatorawayfromitscompensatingvalve,
permittingthevalvetoseat.Closureofthisvalveshutsoffthepassagebetweentheprimarypressure
chamberandthereservoirsectionservingtheprimarychamber.
Furthermovementoftheprimarypistoncreatespressureintheprimarypressurechamber,causingthe
secondarypistonandactuatortomove.Asthesecondarypistonandactuatormove,thesecondarycompensatingvalvecloses,shuttingoffthepassagebetweenthesecondarypressurechamberandthereservoir
sectionservingthesecondarychamber.Additionalmovementoftheprimarypistoncausesbothchambersto
buildpressure.
Whentheloadontheprimarypistonisremoved,fluidpressureineachchamber,combinedwithreturn
springforce,causestheprimaryandsecondarypistonstoreturntotheirinitialreleasedpositions.Each
actuatoropensitsrespectivecompensatingvalve,reopeningthepassagebetweentheindividualreservoir
sectionsanditsassociatedpressurechamber.
Shouldtherateofreleasebegreatenoughtocauseapartialvacuuminthechamber,thecompensatingvalve
willopentoallowreplenishmentoffluidintothecylinderbore.
Anyexcessfluidremainingattheendofthestrokedueto"pumping"and/orvolumechangeduetotemperaturefluctuationisreleasedtothereservoirasthecompensatingvalvesopen.
Theprimarycircuitisseparatedfromthesecondaryhydrauliccircuit.Hydraulicleakageinonecircuitdoes
notaffectthefunctionoftheothercircuit.
Afluidlevelindicatorswitchisavailable.Itilluminatesalightonthedashpaneltowarnoflowbrakefluid
levelinthemastercylinderreservoir.Alowfluidlevelcanresultfrombrakeshoeliningwear,oritcan
occurifthereisanexternalleakinthevehiclebrakesystem.
Adifferentialpressureswitchisavailable.Itilluminatesalightonthedashpaneltowarnwhenthereisa
pressuredifferentialbetweentheprimaryandsecondarybrakecircuitscausedbyaleakinonecircuit.This
mayoccurwhenonecircuitleaksorisimproperlybled.
Aremotereservoirapplicationisavailablewhereunder-the-hoodspaceconstraintsprohibittheuseofa
conventionalboosterandmastercylinderassembly.Inaremoteapplication,themastercylinderreservoiris
mountedseparatelyfromthemastercylinder.

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Figure 5 Master Cylinder

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Electrical Operating Systems

Figure 6 Schematic of Electrical Operating System

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10

Basic Operation of Hydro-MaxTM Booster Assembly and

Master Cylinder
ReferenceFigure6forthefollowingelectricalcomponentsoftheboosterandmastercylinder.
1. BackupPump:TheHydro-MaxTMhydraulicboosterhasabackuppumpwhichwillprovide
hydraulicboostatareducedrateifthenormalsourceoffluidisinterrupted(refertoFigure3).The
signalforoperationofthebackuppumpcomesfromtheflowswitch.Ifnormalflowisinterrupted,
theflowswitchwillcloseandactivatetherelay,whichwillturnonthebackuppump.Thebackup
pumpisavailablefor12and24-voltsystems.
The12-voltbackuppumpcandrawasteadystatemaximumof55ampsatapowersteeringfluid
temperatureof100F.The24-voltbackuppumpcanhaveasteadystatemaximumdrawof27.5
ampsat100F.
2. Relay:Anoptionalrelayisavailableforattachmenttothebooster.Therelayconnectstoasealed
andmechanicallylatchedwiringconnector.Thefunctionoftherelayistoprovidecurrenttothe
backuppumpwhentriggeredbytheflowswitch.
3. FlowSwitch:Thefunctionoftheflowswitchistoactivatetherelaywhennormalhydraulicpower
sourcefluidflowisinterrupted,turningonthebackuppump.Theflowswitchhastwoterminals
(AandB).Aispositive.Bisconnectedtotheboosterhousingandcanbeusedasanoptionalharness
ground.Theflowswitchitselfisgroundedthroughtheboosterhousing.Asealedandmechanically
latchedconnectorconnectstheflowswitchtothebackuppumprelaycircuitry.
4. DifferentialPressureSwitch:Thedifferentialpressureswitchreactstoalossofmastercylinder
hydraulicpressureineithersideofthesplithydraulicsystemandcanilluminateawarninglightatthe
instrumentpanel.Whenpressureislostineithertheprimaryorsecondarycircuitofthemaster
cylinder,theswitchcloses.Theelectricalswitchwillremaincloseduntilthemalfunctioniscorrected.
Whenbothsystemsdevelopnormalpressure,theswitchwillreturntocenterandopentheelectrical
switchcircuit.Amechanicallylatchedconnectorisattachedtotheswitch.Theswitchhastwotabson
acommonterminal(positive)andisgroundedthroughthemastercylinder.
5. FluidLevelSwitch:Whenthefluidreachesapredeterminedlevel(lowfluidlevel),theswitchcloses
andcanilluminateawarninglightattheinstrumentpanel.Asealedandmechanicallylatched
connectorisattached.Theswitchhastwoterminals,positiveandnegative,whichareinterchangeable.
6. ChassisGround:Theboosterandmastercylinderassemblymustbeprovidedwithagroundpaththat
willcarrythemaximumcurrentofthebackuppump.

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11

Electronic Monitor Modules

(12-volt only)

Boschrecommendsthatamonitormodulebeincludedtomonitortheelectricalintegrityof
thebackupsystem.Boschofferstwotypeswiththefollowingfeaturesandfunctions:

Monitor Module Type I

Features
1. Performsstart-upselftestforproperelectricalsignaltoreservebackuppump.
2. Continuouslytestforanopencircuitinbackuppump.
3. Turnsonvehiclewarninglightandbuzzerifanyoftheabovetestsindicateabackupsystem
electricalmalfunction.Thewarningsarecontinuousuntilthemalfunctioniscorrectedorthe
powerisshutoff.
4. Conveyssignaltoprovideelectricalpowertothebackuppumpviatherelay.
5. Providesacentralizedhousingfordiodes.
6. Includesanintegraldifferentialpressureswitchlightcheckatstartup.

Figure 7 Schematic of Electronic Monitor Module Type I

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12

Pin Functions
Pin

Function

a)Providespathtoflowswitchtogroundforpin2toallowtestofredlightduring
vehiclestartup.
b)Suppressesnegativevoltagetransientsintopin5fromtherelaycoil.

Providespathtopin1toflowswitchtovehiclegroundtoallowtestofredlightduring
vehiclestartup.
Note:Pin1and2areconnected,withadiodein-between.Withthekeyinthe"on"
position,thereddashpanellightshouldilluminateanytimehydraulicflow(fromthe
fluidpowersource)dropstoarangeof0.5to1.1gpm.(Therangeatwhichflowswitch
continuityoccurs).

Opencircuitwhenallisokay,butswitchestoground(pin4)duringvehiclestartorduringa
detectedfault.Connectiontogroundturnsonwarninglightandbuzzer.

Connectsmonitormoduletovehicleground.

Suppliespowerfrommoduletoamberlight,buzzerandrelaycoil.Currentflowthrough
thisterminalmustbelimitedto300mA.

a)Monitorsforvoltagetobackuppumpduringstartup.Ifnonedetected,pin3remains
grounded(connectedtopin4).
b)Monitorsforcontinuitythroughthebackuppumptovehiclegroundduringvehicle
operation(engineon).Pin3switchestoground(pin4)ifcontinuityislost.

Bringspowerintomodulefromignitionswitch.

Bringspowerintomodulefrombrakeswitch.Onlyneededwhenignitionswitchisoff.
Enablesbackuppumptooperatewhenignitionisoff.

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10

Monitor Module Type II

(12 volt only)

Features
1. Performsstart-upselftestforproperelectricalsignaltobackuppump.
2. Continuouslytestsforanopencircuitinbackuppump.
3. Testsforvoltageduringbrakeapplicationinbrakelightcircuitandbackuppumprelaycoil
circuitonvehiclesequippedwithdualbrakeswitches.
4. Turnsonwarninglight(s)andbuzzerifanyoftheabovetestsindicateabackuppumpsystem
electricalmalfunction.Thewarningsarecontinuousuntilthemalfunctioniscorrectedorthe
powerisshutoff.
5. Absenceormalfunctionofthemodulewillnotaffectbackupsystemoperation.
6. Turnsonlight(s)andbuzzerwhenintegraldifferentialpressureswitchisactivated.

Figure 8

Schematic of Electronic Monitor Module Type II

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14

Pin Functions
Pin

Function

SuppressesnegativevoltagetransientsintopinEfromtherelaycoil.

Notused.

Opencircuitwhenallisokay,butswitchestoground(pinD)duringvehiclestartupor
duringadetectedfault.Connectiontogroundswitchesonwarninglightandbuzzer.

Connectsmonitormoduletovehicleground.

PowerinputtomonitormodulefromignitionswitchorHydro-MaxTMbrakepedalswitch.

1)Monitorsforvoltagetobackuppumpduringvehiclestartup.Ifnonedetected,pinC
remainsgrounded(connectedtopinD).
2)Monitorsforcontinuitythroughbackuppumptovehiclegroundduringvehicleoperation
(engineon).PinCswitchestoground(pinD)ifcontinuityislost.

Monitorsoutputofthebackuppumpswitchthatturnsonthebackuppump,toallow
comparisonwithpinH.Ifdifferentfor>145seconds,thenpinCswitchestoground
(pinD)andlatches.

MonitorsoutputofstoplightswitchtoallowcomparisonwithpinG.Ifdifferentfor>145
seconds,thenpinCswitchestoground(pinD)andlatches.

Notused.

Notused.

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Application Information
Hydraulic Fluids
TheHydro-MaxTMboosterusespowersteeringfluidasthemediumoftransmittingpower.
ThemastercylinderusesDOT3brakefluidperSAEJ1703,unlessotherwisespecifiedonthetop
ofthereservoir.Servicemaintenanceofmotorvehiclebrakefluidinmotorvehiclebrakeactuating
systemsiscoveredinSAEJ1707informationreport.

Before using any other type of fluid in the booster or in the master cylinder, contact
the Bosch Hydraulic Actaution and Truck Brake Engineering Department.
(See inside of front cover).

The booster and the master cylinder use two (2) distinctly different incompatible
hydraulic fluids. They must not be mixed. Using the incorrect fluid will
permanently damage the seals and can cause the brakes to malfunction.

Brake Fluid Tubing, Hoses and Fittings

Brakefluidlines(tubingandflexiblehose)transmitfluidunderpressurebetweenthemaster
cylinderandthebrakes.Thehosesaretheflexiblelinksbetweenwheelsoraxlesandtheframeor
body.Thehosesmustwithstandfluidpressurewithminimalexpansionandmustbefreetoflex
withoutdamageduringnormalsuspensiondeflectionandwheelturns.ThefollowingSAE
specifications,ortheirsuccessorsifappropriate,arerecommendedforconsiderationasa
minimumrequirementwhenoutfittingavehiclewithbrakefluidtubing,hosesandfittings.The
hosesshouldconformtoSAEJ1401HydraulicBrakeHose-Automotive.Thetubingshould
conformtoSAEJ1047Tubing-MotorVehicleHydraulicBrakeSystem.Thefittingsshould
conformtoSAEJ516a-HydraulicHoseFittings,orSAEJ512-AutomotiveTubeFittings.
Contactthevehiclemanufacturerforspecificrequirementsforindividualapplications.

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16

Booster Fluid Tubing, Hoses and Fittings

Thepressurelinethatsuppliesfluidtotheboostermustbea1/2"diameterflexibleorrigidpressure
lineconformingtoSAEJ188andtypicallydesignedtorunfromthesteeringgeartotheHydroMaxTMinlet.TheHydro-MaxTMinletportutilizesatube"O"arrangementasshowninFigure9
(notsuppliedbyBosch).Fortubeflareconfigurationsee Figure10.

MINIMUM
THREAD

TUBE AND NUT ASSEMBLY

2771464 (TIGHTEN TO 22 - 34 Nm)

NOT SUPPLIED
BY BOSCH

O-RING 2772007

CHECK VALVE SEAT & O-RING

CHECK BALL

Figure 9 Tube"O" Fitting and O-ring Seal

TUBE O.D.

Figure 10 Tube Flare Configuration

Thereturnlinemustbea1/2"diameterhydraulichoseattachedtotheHydro-MaxTMoutletport
(SeeFigure11).Thereturnlineandclampmustbeselectedsothatitwillwithstandworstcase
vehicleoperatingconditions,suchasbackpressuresresultingfromstartupatextremelycold
temperaturesorfromdevicesinstalleddownstreamofthebooster.

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14

Figure 11 Outlet Port

Booster Fluid Source

Theboosterisdesignedtoperforminaflowrangeof3.2to5.0gpm.Flowratethroughthe
boostercanimpactvehiclestoppingdistance;therefore,thevehiclemanufacturermustdetermine
therequiredminimumflowrate.Flowratesbelow3.2gpmcancauseslowerresponsetimeswhen
theboosterisapplied.Flowrateshigherthan5.0gpmmaycontributetotheboosterself-applying,
whichwillcausebrakedragorfluidoverheating.
Thefluidpowersourcemustbecapableofsupplying1,000psitotheboosterplusanyadditional
pressurerequiredbyotherdevicesinthesystemsuchasapowersteeringgear.
Ifapowersteeringgearisused,thesteeringgearmustbe"balanced"sothatitcanhandlethe
pressuresgeneratedinthesteeringgearreturnline.Itmustalsohaveaninternalreliefvalve
settinglowerthanthepumprelieftoallowthesteeringgeartorelievebeforethehydraulicpump
does.Itmustalsohaveaninternalby-passtoallowmanualsteeringduringboosterbackupsystem
operation.ThemanufacturermustadheretotheflowpathillustratedinFigure2.

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Installation Recommendations
TheHydro-MaxTMboosterisgenerallymountedtoavehicle'sdashpanel.Ifnecessary,theHydroMaxTMboosterandmastercylindermaybemountedremotelyfromthevehicledashpaneland
actuatedbyappropriatelinkage.
Fourmountingholesareprovidedintheboosterhousingthroughwhichuptofourstudscanbe
pressed.Useof(Grade5)3/8-16orM10locknuts,havingself-containedprevailingtorquefeatures
thatarefrictionallyresistanttorotation,arerecommended.
SeeFigure12forthethreebasicpedalroddesignsoffered.Thethreadedpedalrodscrewsintothe
customersuppliedattachmenttothebrakepedal.Thepinthatattachesthepedalrodtothebrake
pedalmustinsertfreely.Theattachmentmechanismofthepedalrodshouldbeofsufficientstrength
topreventlinkagebinding.

THREADED

SINGLE EYE

CLEVIS

Figure 12 Basic Pedal Rod Designs

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19

ATTENTION
Regardlessofmountinglocation,thefollowingrequirementsmustbefollowed:
a. Mounttheunitsuchthatthepedalrod,throughoutfullpedaltravel,doesnot
articulatemorethanplusorminus5aboveorbelowboostercenterline.Thebrake
pedallevermustbealignedsidetosidewiththeboostercenterlinetoprevent
linkagebinding.
b. Thebrakepedalandmechanicallinkagemustprovideenoughtraveltofullystroke
bothboosterandmastercylinder,i.e.,thebrakepedalmustnotbottomonthefloor
ofthevehicle.Apedalratioofbetween2.8:1and3.3:1isrecommendedtoprovide
thedesired"pedalfeel".
c. TheHydro-MaxTMboosterandmastercylinderassemblymustbemounted
horizontally.
d. Thereservoirofthemastercylindermustbeupright.Thebackuppumpmust
alwaysbeatthebottomofthebooster.
e. Theunitmustbeprotectedfromenvironmentalandfluidtemperaturesover250F.

General Safety Note

UniqueusageorapplicationsoftheHydro-MaxTMboosterand
mastercylinderassemblyrequiresinputfromBoschand
validationbythevehiclemanufacturer.

Pedal Return Springs

AnyvehicleapplicationutilizingaHydro-MaxTMboosterandabrakepedalreturnspringmusthave:
1.Aproperlyadjustedpedalstop
2.Alimitedspringloadatthepedalreleasedposition.
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17

Pedal Stop and Proper Spring Load

Thepedalstopmustbeadjustedsuchthatwhenthebrakepedalisfullyreleased,thereisnoload
onthegrommetthatretainsthepedalrodtotheHydro-MaxTMbooster.Whenthebrakepedalis
fullyreleased,thespringloadmustnotbegreaterthanthatrequiredtosupportthepedalweight.
Thereasonforaproperlyadjustedpedalstopandforthelimitationonspringloadistoprevent
thespringfrompullingonthegrommetwithintheHydro-MaxTMboosteranddamagingthe
grommet.Thegrommetisnotdesignedtobeloadedinthismanner.
Anyadjustmentofthebrakeswitchandbackuppumpmustnotcompromisetheadjustmentofthe
pedalstop.

It is a commmon practice to stack vehicles on top of each other to deliver the

vehicles. An air cylinder is typically used to apply the brake pedals in the towed
vehicles. When installing such a cylinder, be sure that the backup pump turns off
when the towing vehicle brake pedal is released.

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TROUBLE SHOOTING
Condition
HardPedal

Excessive
pedaltravel
(pedalgoesto
thefloor)

Cause

Remedy

Bindingpedallinkage

Contactdealerforservice

Pedalmisaligment
(sidetoside)

Contactdealerforservice

Lowboostersupplyflow

Repair/replacepowersteering
pump,checktensioninbelt

Powersteeringpumpflow
controlvalve

Repair/replacepowersteering
pump,checktensioninbelt

Powersteeringpumprelief
valvesettingtoolow

Replacepowersteeringpump

Fluidcontamination

Seevehicleservicemanualfor
typeoffluidrequired.Drain,
flushandrefillsystem,replace
boosterormastercylinderas
appropriate,andpowersteering
reservoirfilterasnecessary

Mastercylinder

Replacemastercylinder

Booster

Replacebooster

Tubeandhosepassagesare
blockedshut

Replacepartscontaining
blockedpassages

Improperpedaladjustment

Seevehicleservicemanual
forpedalrodadjustment
(ifsystemisadjustable)

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22

TROUBLE SHOOTING
Condition

Cause

Remedy

Excessivepedal
travel
(pedalgoestothe
floor)

Externalleakinbrake
fluidsystem

Checkallfittingsand
connectionsforthemaster
cylinder,calipers,hoses,and
tubes,replaceifnecessary

(continued)

Internalmastercylinder
leak

Replacemastercylinder

Airinbrakefluidsystem

Bleedsystem

Brakelinings

Inspectandadjust,orreplace
brakeshoes,ifnecessary

Mastercylinder

Replacemastercylinder

Weakbrakehosesthat
expandunderpressure

Replacehoses

Poorqualitybrakefluid
(lowboilpoint)

Drainthesystem,flushand
refillwiththerecommended
fluid.

Brakeselfadjusting
mechanism
Airinhydraulicbrake
system

Seevehicleservicemanual(if
brakesareadjustable)
Bleedbrakesystem

Poorqualitybrakefluid
(lowboilpoint)

Drainthesystem,flushandrefill
withrecommendedfluid

Weakbrakehosesthat
expandunderpressure

Replacedefectivehoses

Bindingpedallinkage

Contactdealerforservice

Pulsating
brakepedal

Soft,spongy
brakes

Actuatedpedal
doesnotreturn

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TROUBLE SHOOTING
Condition

Cause

Actuatedpedal
doesnotreturn

Fluidcontamination

Seevehicleservicemanualfor
typeoffluidrequired.Drain,
flushandrefillsystem,replace
boosterormastercylinderas
appropriate,andpowersteering
reservoirfilterasnecessary

Mastercylinder

Replacemastercylinder

Bindingbooster

Replacebooster

Selfappliedbooster
(fluidflowtoohigh)

Repairorreplacepower
steeringpump.

ABSoperation

Seeappropriateservicemanual

Wheelbearingslooseor
worn

Seeappropriateservicemanual

Excessiverotorhickness
variation

Seeappropriateservicemanual

Parkingbrakecontrolvalve
(HR1)hasinternalleak

Seeappropriateservicemanual

Selfappliedbooster(fluid
flowtoohigh)

Repairorreplacepowersteering
pump

Constrictedmastercylinder
reservoirvent

Cleanventpassageinreservoir
cap

Selfappliedbooster(fluid
flowtoohigh)

Repairorreplacepowersteering
pump

(continued)

Pulsatingbrake
pedal

Brakeselfapply

Draggingbrake

Remedy

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TROUBLE SHOOTING
Condition
Draggingbrake
(continued)

Noise/Whistle

Backuppump
operates
continuously

Cause

Remedy

Stuckorboundcaliper
pinsorrails

Seeappropriateservicemanual

Bindingbooster

Replacebooster

Bindingpedallinkage

Contactdealerforservice

Mastercylinder

Replacemastercylinder

Softorswollenmaster
cylindersealsduetobrake
fluidcontamination

Flushoutoldbrakefluidthen
replacemastercylinderandadd
newbrakefluid

Tubeandhosepassages
restricted

Replacethepartscontaining
therestriction

Inherentinsomeboosters(whistle)

None-Doesnotaffectoperation

Brakeswitch

Seevehicleservicemanual

Monitormodule

Seevehicleservicemanual

Relay

Seevehicleservicemanual

Flowswitch

Removeswitchcomponents,
clean,inspectfordamageor
contaminationandreplaceif
necessary

Bindingpedallinkage

Contactdealerforservice

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TROUBLE SHOOTING
Condition
Backuppump
doesnot
operate

Leakage

Cause

Remedy

Sameasabove

Repeatasabove

Electricalground

Seeservicemanual

Backuppump

Replacebackuppump

Mastercylinder

Replacemastercylinder

Booster

Replacebooster

Mastercylinderreservoir
ventcaps

Replacediaphragmsandcaps

Fluidcontamination

Seevehicleservicemanualfor
typeoffluidrequired.Drain,
flushandrefillsystem,replace
boosterormastercylinderas
appropriate,andpowersteering
reservoirfilterasnecessary

Backuppumpmountingseals

Replaceseals

Flowswitchseal

Replaceo-ring

Hydraulicfittingsand
connections

Seevehicleservicemanual,
tightenandreplaceifnecessary

Siliconefloating Thismaterialisanassembly
inmastercylinder lubricant

None-Doesnotaffectoperation

Hydro-Max Technical Manual

26
23

TROUBLE SHOOTING
Condition
Fluidlevel
indicatorlight
comeson

Brakeindicator
lightandbuzzer
malfunction

Cause

Remedy

Lowfluidlevel

Inspectbrakepads,replaceas
necessary,addfluidasrequired

Fluidlevelindicatorswitch

Replacemastercylinder

Brakepadswornout

Inspectbrakepads,replaceas
necessary,addfluidasrequired

Vehiclespecific

Seevehicleservicemanual

Hydro-Max Technical Manual

27
24

Correspondence concerning this manual should be

addressed to:
Robert Bosch LLC
Medium Truck Brake Engineering
3737 Red Arrow Highway
St. Joseph, Michigan 49085
Fax: 269-428-6704

PrintedintheUnitedStatesofAmerica
Copyright2002RobertBoschCorporation