SECTION 10
BRAKES AND REAR WHEEL ASSEMBLY
10-8. MASTER CYLINDER.
clean cylinder components, as they will
attack and deteriorate rubber parts.
10-9. GENERAL.
10-15. Hold cylinder toward a strong light and
10-10. The master cylinder is bolted to the
sight through cylinder bore. Inspect wall for
center of the rear panel of the cockpit in a
pitting and scratches. If any of these or other
horizontal position.
defects are noticed, hone the cylinder wall.
10-11.
REMOVAL.
10-16. Measure if cylinder bore diameter is
1-1/8 inch (28.58 mm). Discard cylinder if
a. Remove the floor plate.
diameter is increased to .005 inch (.127 mm)
over standard. Pressure marks and discolora-
b. Disconnect the hydraulic line from the
tions may be polished out with crocus cloth.
cylinder and plug or tape the opening.
Make sure intake and by-pass ports are open.
The by-pass port may be probed with a soft
c. Disconnect the pedal return spring.
iron wire (see figure 10-1).
d. Remove cotter key and slide the pin out
NOTE: Burrs in the by-pass port are caused by
that mounts the cylinder actuator rod to the
honing the cylinder wall and probing
lever.
t h e by-pass port. These must be
removed. Otherwise, the primary cup
e. Remove the mounting capscrews and
may be damaged during assembly or
remove master cylinder.
brake operation.
10-12.
DISASSEMBLY (see figure 10-1).
1 0 - 1 7 . Check piston bearing surface for
scratches or corrosion and rubber parts for
a. Thoroughly clean the exterior of the
swelling, softening and `tackiness. The spring
cylinder with denatured alcohol.
must be free of corrosion and pits. Make sure
the vent in the filler cap is open.
b. Remove the filler plug and gasket. Empty
the reservoir.
REASSEMBLY (see figure 10-1).
10-18.
c. Place the cylinder in a vise equipped with
a. Always use the repair part kit listed in the
soft jaws. Remove the rod end and push rod as
Hyster parts manual. Installation of "will fit"
an assembly.
parts is not recommended.
d. Remove the cylinder boot and the brake
b . Lubricate all of the master cylinder
line fittings.
internal parts with clean brake fluid prior to
e. Carefully snap the lock ring out of the
reassembly.
groove in the cylinder bore.
c. Make sure that all burrs are removed from
the cylinder housing bore before installing new
WARNING: While removing the look wire, keep
parts. Make sure that the bore is clean.
pressure against the piston. The
internal parts are spring loaded
d. Install the check valve, spring, primary
and when the lock wire is
cup, piston, and piston stop plate.
removed, t h e parts could be
released with considerable force.
e. Keeping pressure on the piston, carefully
install the lock ring into the groove of the
f. Remove the piston stop plate, piston,
cylinder bore.
primary cup, spring, and check valve.
f. Place the cylinder in a vise equipped with
10-13. CLEANING AND INSPECTION.
soft jaws. Install the brake line fitting using
new gaskets. Install the push rod and rod end
10-14. Clean all parts in denatured alcohol
making sure there Is no trace of dirt, sludge,
assembly.
metal particles, or other foreign materials on or
g. Install the filler plug, using a new gasket.
In the cylinder components.
h. After the cylinder has been assembled,
NOTE: Do not use mineral base solvents to
10-2.
