INTRODUCTION

GENERAL
This section has the repair instructions for the master
cylinder. The repair instructions for the service and
parking brakes are in the section for the BRAKE SYS-
TEM: 1800 SRM 78 for E30–60B, E60–120B; 1800
SRM 80 for H30–60H, H40–50J, H60JS, H60–90C,
J40–50A, J60AS; 1800 SRM 87 for S30–120E,
S40–50F; 1800 SRM 210 for E20–30B, E20–30BC.
DESCRIPTION AND OPERATION (See
FIGURE 1.)
The master cylinder has a housing and a piston assem-
bly. When stopping the brake pedal moves the piston
assembly in the housing. The primary cup pushes the
fluid through the check valve and then to the wheel cy-
linders. A return spring pushes the piston back to the
stop plate. The primary cup slides past the compensator
port in the housing. The reservoir then fills the bore
with fluid. When the pedal is released quickly, the fluid
behind the cup moves to the pressure side of the hous-
ing. The compensator port lets fluid move to and from
the system when the temperature changes. The pres-
sure switch on the electric trucks interrupts the current
flow to the drive motor when the brake pedal is pushed.

6834
1. ROD END
2. JAM NUT
3. PUSH ROD
4. SPRING CUP
5. RETURN SPRING
6. BOOT
7. LOCK WIRE
8. PISTON STOP PLATE
9. PISTON ASSEMBLY
10. PRIMARY CUP
11. RETURN SPRING
12. CHECK VALVE
13. BODY
14. FILLER PLUG
15. GASKET

FIGURE 1. MASTER CYLINDER

REPAIRS

REMOVAL AND DISASSEMBLY (See 2. Remove the capscrews that hold the cylinder to the
FIGURE 2.) frame.

3. Slide the master cylinder from the push rod. Drain

the fluid in the reservoir.
1. Remove the floor plate. Remove the wires to the
pressure switch of the J40–50A, 60AS. Disconnect and 4. Put the master cylinder in a vise with soft jaws. Put
put caps on the hydraulic line and the cylinder port. the end of the housing with the piston away from the

1
vise. Hold the piston against the return spring with a
screw driver. See FIGURE 2.
5. Remove the lock wire and piston stop plate. Slowly
remove the piston from the cylinder.
WARNING
The piston return spring will push the piston from
the cylinder with great force.
Remove the spring and check valve.
F006
FIGURE 2. REMOVING THE PISTON
CHECKS AND ADJUSTMENTS
CHECKS
1. Check the bore of the master cylinder for damage. If
any defect is found replace the master cylinder.
2. Check the clearance between the push rod and the
piston. To adjust the clearance loosen the locknut and
turn the push rod. The clearance must be 3 to l3 mm
(0.12 to 0.5 inch).
3. Check for oil or grease in the system. Remove all the
fluid in the system if oil is found. Fill the master cylin-
der with SAE J1703 brake fluid.
CLEANING
CAUTION
Do not use solvent to clean the parts of the master cy-
linder. Solvent will damage the rubber parts.
Clean all parts with alcohol. Use compressed air to dry
the parts. Do not get oil or grease in the brake fluid.
ASSEMBLY
1. Lubricate all parts with clean brake fluid.
2. Use a repair kit. Install the parts in the order shown
in FIGURE 1. Hold the piston in the cylinder with a
screwdriver. Make sure the lock ring is in position.
3. Remove the air from the master cylinder. Fill the res-
ervoir. Push on the piston with a screwdriver. Repeat
until at least 0.25 pt (0.12 litres) of brake fluid comes
from the fitting.
4. Install the dust cover. Slide the master cylinder to-
ward the push rod. Install and tighten the capscrews.
5. Connect the hydraulic line. Remove the air from the
system. Adjust the brakes.
4. On electric trucks, check that the pressure switch is
activated when the pedal is pushed. The switch is nor-
mally closed.
5. Remove the air from the system. Loosen the special
fitting at a wheel cylinder. Put one end of a rubber hose
on the special fitting. Put the other end in a container of
clean brake fluid. Push down on the pedal and then re-
lease it. Continue until there are no air bubbles in the
container. Tighten the special fitting and remove the
hose. Repeat this procedure on the other wheel cylin-
der.