1800119, OPR, HYSTER, Hyster2, SRM

//-->.pos {position:absolute; z-index: 0; left: 0px; top: 0px;}INTRODUCTIONGENERALThis section has the repair instructions for the mastercylinder. The repair instructions for the service andparking brakes are in the sectionTHE BRAKE SYS-TEM, 1800 SRM 80.in the bore. When the pedal is released quickly, thefluid behind the primary cup moves to the pressure sideof the piston. A port between the reservoir and the borepermits fluid to fill the volume in the piston behind theprimary cup. There is a second port between the reser-voir and the bore. This compensator port has a verysmall diameter and is found near the primary cup onpressure side of the piston. The compensator port letsbrake fluid move to or from the pressure side of the sys-tem. The pedal linkage must be adjusted correctly. Ifthe piston does not return to the stop, the primary cupwill close the compensator port. A closed compensatorport can cause the brakes to stay applied after the pedalis released.DESCRIPTION AND OPERATION(See FIGURE 1.)The master cylinder has a housing and a piston assemb-ly. When the brakes are actuated, the brake pedal link-age pushes the piston assembly in the housing. The pri-mary cup pushes the brake fluid through the checkvalve to the wheel cylinders. When the brakes are re-leased, the spring causes the piston to return to the stop4561615987114920623101213111.2.3.4.5.6.7.8.PUSH RODDUST COVERSNAP RINGDOUBLE LIP CUPPISTONCUP PROTECTORPRIMARY CUPCUP RETAINER9.10.11.12.13.14.15.16.SPRINGVALVE BODYCHECK VALVE SPRINGCHECK VALVETUBE FITTINGDIAPHRAGM GASKETRESERVOIR COVERRETAINERFIGURE 1. THE MASTER CYLINDER1REPAIRSREMOVAL AND DISASSEMBLY1. Remove the floor plate. Disconnect the clevis fromthe brake pedal and remove the push rod. Disconnectthe hydraulic line from the master cylinder port. Put aplug in the master cylinder port to control leakage ofthe brake fluid.2. Remove the bolts and the master cylinder from theframe. Drain the fluid from the reservoir.3. Put the master cylinder in a vise with soft jaws asshown in FIGURE 2.4. Hold the piston against the spring with a screwdriver.6. Clean all the parts with alcohol. DO NOT USE SOL-VENT. Solvent will damage the rubber parts.INSPECTIONCheck the bore of the master cylinder for any damage.If any damage is found, replace the master cylinder.ASSEMBLY1. Use a repair kit (Part Number 326931). Install theparts in the order shown in FIGURE 1. Hold the pistonin the cylinder with a screwdriver. Make sure the snapring is in the correct position.2. Install the check valve assembly. Install the dia-phragm gasket and reservoir cover. Install the dust cov-er.3. Fasten the master cylinder to the frame. Install thepush rod and connect the clevis to the pedal.4. Check the clearance between the push rod and thepiston. Adjust the clearance so that there is approxi-mately 6 mm (0.25 inch) pedal movement before thepiston begins to move. Loosen the jam nut and turn thepush rod to adjust the clearance.5. Fill the reservoir with J1703 brake fluid. Operate thebrake pedal to remove air from the master cylinder.Connect the hydraulic line to the master cylinder.6. Remove the air from the system. Loosen the specialfitting at a wheel cylinder. Put one end of a rubber hoseon the special fitting. Put the other end of the hose in aclean container. Loosen the special fitting to permitbrake fluid to flow from the wheel cylinder when thepedal is pushed. Continue this operation until air bub-bles do not come from the hose. Make sure you do notcompletely drain the reservoir. Tighten the special fit-ting and remove the hose. Fill the reservoir. Repeat thisprocedure on the other wheel cylinder.WARNINGThere is a compressed spring behind the piston.Remove the snap ring and carefully remove the pistonassembly and spring.5. Remove the check valve (12) and the spring (11).Use a thin rod as a driver to remove the tube fitting(13).6874FIGURE 2. REMOVING THE PISTON2

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