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Workman HD SeriesPage 7 − 18Chassis
Brake Master Cylinder Service
Disassembly (Fig. 11)
1. Thoroughly clean outside of master cylinder before
disassembly.
2. Remove reservoir and flange seal. Push in on the
push rod (item 8) so the stop pin (item 3) can be re-
moved.
3. Disconnect lower end of the dust cover from the
housing.
4. Push in on the push rod and remove circlip (item 9)
from cylinder housing, then remove push rod with dust
cover and clevis. Remove retainer washer.
5. Remove primary piston assembly and secondary
piston assembly from cylinder housing.
Inspection
CAUTION
Use eye protection such as goggles when using
compressed air for master cylinder service.
1. Clean all metal parts with isopropyl alcohol, then
clean out and dry grooves and passageways with com-
pressed air. Make sure cylinder bore and component
pieces are thoroughly clean.
2. Check cylinder bore, pistons and springs for damage
or excessive wear. Replace brake cylinder assembly if
signs of pitting, scoring or cracks are evident in cylinder
bore.
Assembly (Fig. 11)
1. Apply a film of clean brake fluid to cylinder bore and
piston assemblies.
2. Install secondary piston assembly and primary pis-
ton assembly into cylinder.
3. Install retainer washer.
4. Install push rod and secure in place with circlip.
Install lower end of dust cover to housing.
5. Push in on push rod so stop pin can be installed to
retain secondary piston assembly, then install flange
seal and reservoir.
1. Reservoir
2. Flange seal
3. Stop pin
4. Secondary piston assy
5. Clevis
6. Jam nut
7. Dust cover
8. Push rod
9. Circlip
10. Retainer washer
11. Primary piston assy
12. Cylinder housing
Figure 11
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