Taylor-Dunn B0-015-00, Operation, T Roubleshooting And Replacement Parts Manual

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Maintenance, Service, and Repair
Brakes
Page 15
Push Rod
Plunger
Master Cylinder
1/8"
Cutaway of typical master cylinder showing
the push rod clearance
REPLACE THE MASTER CYLINDER
Always use a lifting strap, hoist, and jack
stands, of adequate capacity to lift and
support the vehicle. Failure to use lifting
and support devices of rated load capacity
may result in severe bodily injury.
1. Make sure the key-switch is in the “OFF”
position, then remove the key.
2. Place the forward-reverse switch in the
center “OFF” position.
3. Confirm the electric park brake is set.
4. Place blocks under the front wheels to
prevent vehicle movement.
5. Disconnect the main positive and
negative cables at the batteries.
•
Only use DOT 3 brake fluid from a new
sealed container.
•
DOT 3 brake fluid is corrosive and will
damage paint finishes.
•
Dispose of brake fluid in accordance with
local state and federal regulations.
•
Read and follow all warnings on the
brake fluid container.
Do not ingest brake fluid or allow contact
with skin or eyes. Always wear protective
clothing and a face shield when working
with or around brake fluid.
SKIN CONTACT
Flush area immediately with water for
several minutes. If a rash or skin irritation
develops, get medical attention
immediately.
EYE CONTACT
Immediately flush the eye with water for
15 minutes and call physician.
INGESTION
Get medical attention immediately.
NOTE: Most vehicle configurations do not require
lifting the vehicle to remove the master
cylinder. Lifting the vehicle may not be
required.
6. If required, raise the vehicle and support with jack
stands.
7. Place a drain pan under the master cylinder.
8. Disconnect the brake line(s) to the master cylinder
and pump out the fluid in the master cylinder by
depressing the pedal several times.
9. Remove the master cylinder bolts and remove the
master cylinder from the vehicle.
10. Install in reverse order.
11. Adjust the master cylinder push rod so that it is
approximately 1/8 inch away from the master
cylinder plunger when the brake pedal is up.
12. Fill the master cylinder with brake fluid from a
sealed container.
13. Pump the brake pedal a short distance of one to
two inches until no bubbles are seen coming from
the inlet ports inside of the master cylinder
chamber.
14. If the vehicle was raised, lower it to the ground.
15. Bleed the brakes. refer to Bleed the Brakes
section for information regarding bleeding the
brakes.
16. Reconnect the main positive and negative cables
at the batteries.
17. Remove the blocks from behind the wheels.
18. Release the park brake and test drive the vehicle.