Matco MCMC-4 Series Reference manual
MATCO mfg
Wheels & Brakes
MCMC-4 SERIES
MASTER CYLINDERS
MC-4, MC-4A, MC-4D, MC-4E,
MC-4F(L), MC-4F(R), MC-4F(S),
MC-4G, MC-4GH, MC-4HV,
MC-4NGA, MC-4R, and MC-4X
Technical Service Bulletin
REV 3 2010 SRT
SECTION SUBJECT PAGE
A. MC-4 Series Master Cylinder------------------------------3
B. MC-4 Assembly Drawing-----------------------------------4
C. MC-4A Assembly Drawing---------------------------------5
D. MC-4 Parts List # 1-------------------------------------------6
E. MC-4 Parts List # 2-------------------------------------------7
F. MC-4 F Left, Right, & Slotted Identification------------8
G. MC-4 Series Master Cylinder Assembly-----------------9
H. Hydraulic pressure Testing--------------------------------11
I. Clevis Attachment-------------------------------------------11
J. Optional Intensifier Kit-------------------------------------11
K. MC-4 Rebuild Kits-------------------------------------------12
L. Hydraulic Installation Drawing---------------------------13
M. Pedal Geometry-----------------------------------------------14
a. Diagram # 1 Poor & Min Geometry---------------17
b. Diagram # 2 Poor & Min Geometry---------------17
c. Diagram # 3 Good Mechanical Advantage-------18
d. Diagram # 4 Pivot Connect--------------------------18
e. Diagram # 5 Heel Brakes-----------------------------19
N. Technical Assistance-----------------------------------------19
2
Table of Contents
The MC-4 Series Master Cylinder is a "series connected" type
cylinder. It is gravity fed by a remote reservoir like the MATCO
mfg R-100. The MC-4 is used primarily on toe and heel brake
applications for single as well as dual brake systems. When placed
under the copilot pedals and connected in series, no shuttle valve is
needed in the system. MATCO mfg master cylinders feature Buna-
N O-Rings to provide a leak proof seal. The MC-4 series use 1/8
NPT standard fittings and utilize long lasting industrial springs.
Each shaft is ground and polished to provide smooth operating
efficiency. The MC-4 master cylinder has evolved to include a
series of high quality products that meet the needs of the sport
aircraft community. Following is a list of available models and
their specifications. in the MC-4 series of master cylinders.
MATCO
PART # PART DESCRIPTION BORE (in) /
DISPLACE (cu in) INSTALL
LENGTH OVERALL
LENGTH STROKE
A
NODIZE
FINISH
MC-4 MASTER CYLINDER 0.625 / 0.43 7.7 8.25 1.388 GOLD
MC-4A MASTER CYLINDER 0.625 / 0.37 7.2 7.7 1.19 GOLD
MC-4D MASTER CYLINDER 0.625 / 0.37 6.5 7 1.19 GOLD
MC-4E MC EXTRA 0.625 / 0.37 7 8 1.19 GOLD
MC-4F(L) MC.62 (LEFT) 0.625 / 0.43 7 8 1.19 GOLD
MC-4F(R) MC.62 (RIGHT) 0.625 / 0.43 7.875 8.05 1.388 GOLD
MC-4F(S) MC.62 (SLOTTED) 0.625 / 0.43 7.875 8.05 1.388 GOLD
MC-4G MASTER CYLINDER 0.625 / 0.37 7.875 8.05 1.388 GOLD
MC-4GH MASTER CYLINDER 0.625 / 0.18 5 5.4 0.6 SILVER
MC-4HV MC HIGH VOLUME 0.688 / 0.52 11.66 11.91 1.388 GREEN
MC-4NGA MC NEW GLASSAIR 0.625 / 0.43 8.2 8.75 1.388 GOLD
MC-4R MC REDLINE 0.688 / 0.52 11.66 11.91 1.388 BLACK
MC-4X MASTER CYLINDER 0.625 / 0.18 5 5.4 0.6 SILVER
MASTER CYLINDER SPECIFICATIONS (IN)
3
A. MC-4 SERIES MASTER CYLINDERS
4
B. MC-4
ASSEMBLY DRAWNG
5
C. MC-4A ASSEMBLY DRAWNG
PART NUMBER
DESCRIPTION
4 4A 4D 4E 4F(L) 4F(R) 4F(S)
2
MCMC4H(A) HOUSING MC-4 111
2
MCMC4H(E) HOUSING, EXTRA 1
2
MCMC4H(F)L HOUSING, LEFT 1
2
MCMC4H(F)R HOUSING, RIGHT 1
2
MCMC4H(F)S HSING, SLOTTED 1
11
MCMC-16 SPRING GUIDE 1111 1 1 1
3
MCMC-17 CLEVIS 11
3
MCMC-17S CLEVIS, SHORT 1
16
MCMC-18 PEDESTAL 111
14
MCMC4-2 END GLAND 1111 1 1 1
7
MCMC4-1 SHAFT MC-4 1
7
MCMC4A-1 SHAFT MC-4A 11
7
MCMC4D-1 SHAFT MC-4D 1
7
MCMC4E-1 SHAFT, MC4E 1
7
MCMC4F-1 SHAFT, MC-4F 111
5
MCMCP.625(B) PISTON .625 1111 1 1 1
6
MSC.31-24JAMNUT JAM NUT 11
8
MSC2-012 O-RING 1111 1 1 1
15
MSC2-111 O-RING 1111 1 1 1
9
MSC2-112 O-RING 1111 1 1 1
4
MSC3000-X68 SNAP RING 1111 1 1 1
13
MSC600-0101-10 STAT-0 SEAL 1111 1 1 1
12
MSCC0300-026-0440M SPRING, VALVE 1111 1 1 1
10
MSCC0480-055-2500M SPRING 11
10
MSCC0480-055-3000M SPRING 11111
N/A MSCLABELMATCO-4 LABEL, MC-4 1
N/A MSCLABELMATCO-4A LABEL, MC-4A 1
N/A MSCLABELMATCO-5 LABEL, SILVER 11 1 1 1
1
MSCP-18 THREADED PLUG 222 2 2 2
MCMC-4 PARTS LIST # 1
MODEL NUMBER / MC-MATCO mfg
DWG
#
6
D. MC-4 SERIES PARTS LIST # 1
E. INSTALL CLEVIS / SHCS
PART NUMBER
DESCRIPTION
4G 4GH 4HV 4NGA 4R 4X
2
MCMC4H(A) HOUSING MC-4 11
2
MCMC4H(GH) HOUSING, EXTRA 11
2
MCMC4H(Ŕ) HOUSING, REDLINE 1
11
MCMC-16 SPRING GUIDE 11 1 1 11
3
MCMC-17 CLEVIS 11
3
MCMC-17S CLEVIS, SHORT 1
3
MCMC-17L CLEVIS, LONG 1
3
MCMC-17M CLEVIS, METRIC 1
16
MCMC-18 PEDESTAL 1
14
MCMC4-2 END GLAND 111 1 11
7
MCMC4-1 SHAFT MC-4 11
7
MCMC4G-1 SHAFT MC-4G 1
7
MCMC4-1GH SHAFT MC-4GH 11
7
MCMC4R-1 SHAFT MC-4® 1
5
MCMCP.625(B) PISTON .625 11 1 1
5
MCMCP.688(B) PISTON, REDLINE 1
6
MSC.31-24JAMNUT JAM NUT 11 1 1
8
MSC2-012 O-RING 111 1 11
15
MSC2-111 O-RING 11 1 1
9
MSC2-112 O-RING 112 1 11
4
MSC3000-X68 SNAP RING 11 2 1 11
13
MSC600-0101-10 STAT-0 SEAL 11 1 1 11
12
MSCC0300-026-0440M SPRING, VALVE 11 1 1 11
10
MSCC0480-055-2250M SPRING MC-4GH 11
10
MSCC0480-055-2500M SPRING 1
10
MSCC0480-055-3000M SPRING 111
MCMC-4 PARTS LIST # 2
DWG
#MATCO mfg MODEL NUMBER / MC-
7
E. MC-4 SERIES PARTS LIST # 2
8
F. MC-4F LEFT, RIGHT, AND SLOTTED
NOTE: The following assembly instructions are intended as a general
guideline for the assembly of all MC-4 master cylinder models. The
parts list will vary slightly with each model, but the sequence for
assembly is the same. SHAFT ASSEMBLY
1.Place the stat o-seal, part number ( 13 ), onto the o-ring groove of
the MC4-1 shaft, PN ( 7 ), making sure that the o-ring is not
damaged and is fully seated in the groove.
2.Using Buna o-ring, PN ( 15 ), install it on to the o-ring groove of
the piston, PN ( 5 ). Make sure that the o-ring is not damaged and
is fully seated in the groove.
3.Place the Piston, PN ( 5 ), on the shaft with the flat side of the
piston resting against the stat-o-seal and the beveled side up
PN ( 13 ),
4. Install the valve spring PN ( 12 ), over the threaded end of the shaft
and into the beveled side of the piston, PN ( 5 ).
5 Thread the spring guide, PN ( 12 ), on to the shaft until it is firmly
seated.
END GLAND ASSEMBLY
1. Install 0-ring 2-012, PN ( 8 ), into the interior o-ring groove of the
end gland, PN ( 14 ), making sure that it is seated properly.
2. Install o-ring 2-112, PN ( 9 ), onto the outer o-ring groove of the
end gland, PN ( 14 ), making sure that it is seated properly.
3. Using caution, slide the end gland assembly over the threaded
portion of the shaft, slotted end first. Continue to slide the end
gland on to the shaft until it is seated firmly against the piston.
9
G. MC-4 SERIES MASTER CYLINDER ASSEMBLY
FINAL ASSEMBLY
1. Inspect the housing bore, PN ( 2 ), using adequate lighting to
insure that no burrs, chips or foreign materials are present, and
that no damage has occurred to the bore. Housing bore may be
polished with a Scotch Brite pad (green # 96).
NOTE: Master Cylinders MC-4A, MC-4D, MC-4E & MC-4G
Require a Pedestal PN ( 16 ) on the MC-4A drawing. The pedestal is
inserted into the bore of the housing at this point in the assembly.
The machined end of the pedestal facing up, and the flat end resting
against the bottom of the bore.
2. Place spring, PN (10 ), into the bore of the housing and make
sure that the spring is fully seated.
3. Generously lubricate the piston o-ring, PN ( 15 ), and the end
gland exterior o-ring, PN ( 9 ), with petroleum jelly. Insert
shaft assembly, (piston end first), into the bore of the housing,
PN ( 2 ), making sure that the piston o-ring is not damaged as it
passes over the snap ring groove.
4. With the shaft assembly securely seated in the bore, firmly
press the end gland, PN ( 14 ), below the snap ring groove, and
using a pair of snap ring pliers, install the snap ring, PN ( 4 ),
into place. Make sure that the flat side of the snap ring faces
away from the end gland assembly.
5. Fill assembly with MIL-H-5606 brake fluid. Do Not use
automotive glycol based brake fluids such as DOT 3, DOT
4, and DOT 5.1
MATCO mfg. strongly recommends MIL-H-5606.
10
1. Plug outlet hole with a 1/8 in NPT plug.
2. Fill bore of assembly with Mil-H-5606 red aircraft fluid and make
sure that no air bubbles remain in the assembly.
3. Using a hydraulic press, or suitable tool, pressurize the assembly to
between 800 and 1000 PSI. The assembly should start to pressurize
after a stroke of no more than .25 inches (1/4 of an inch).
4. Apply a minimum side load pressure of 20 pounds to ensure that
the assembly maintains its pressure.
1. Thread the jamnut, PN ( 6 ), on to the shaft of the master cylinder.
2. Thread the clevis, PN ( 3 ), onto the shaft of the master cylinder
until it is flush with the ¼ inch milled cut out. Tighten the jamnut
firmly against the bottom of the clevis.
MATCO mfg. offers an intensifier kit, part number MC-4I, that
will provide a 50 percent increase in pressure through the use of a
(1/2’’) .50 inch piston. This kit can be installed at the factory or in
the field.
11
H. HYDRAULIC PRESSURE TEST
I. CLEVIS ATTATCHMENT
J. OPTIONAL INTENSIFIER
NOTE All o-rings in the brake and master cylinder, are Buna
Nitrile and are NOT compatible with automotive glycol based
brake fluids such as DOT 3, DOT 4, and DOT 5.1.
MATCO mfg. strongly recommends MIL-H-5606.
MATCO mfg rebuild kits are available for all models of.
master cylinders. By following the general MC-4 assembly
instructions in this manual, your master cylinder can be rebuilt
in a short period time. A pair of snap ring pliers is
recommended for the job, and can be purchased through one of
several aviation catalog suppliers.
PART # DESCRIPTION REBUILD KIT PART #
MC-4 MASTER CYLINDER MCMCRBD4
MC-4A MASTER CYLINDER MCMCRBD4A
MC-4D MASTER CYLINDER MCMCRBD4A
MC-4E MC EXTRA MCMCRBD4A
MC-4F(L) MC.62-LEFT MCMCRBD4
MC-4F® MC.62-RIGHT MCMCRBD4
MC-4F(S) MC.62-SLOTTED MCMCRBD4
MC-4G MASTER CYLINDER MCMCRBD4A
MC-4GH MASTER CYLINDER MCMCRBD4X
MC-4HV MC HIGH VOLUME MCMCRBD4R
MC-4NGA MASTER CYLINDER MCMCRBD4
MC-4R MC REDLINE MCMCRBD4R
MC-4X MASTER CYLINDER MCMCRBD4X
MC-4 REBUILD KITS
12
K. MC-4 REBUILD KITS
13
L. HYDRAULIC INSTALLATION
The importance of good pedal geometry can make the difference
between a marginal performing brake system, and one that gives
maximum braking performance to the wheels.
It is important that the calipers are properly mounted so that the
pads make contact on both sides of the disc (both new and worn)
and are maintained so that the calipers float freely.
With that said, the most common reason for under performance in
a brake system, is low pressure. MATCO mfg. brakes require
450 pounds per square inch of hydraulic pressure to achieve
their rated torque. Additional calipers can be added to get higher
torque at lower pressures, but is often more weight efficient to
modify the hydraulic system pedal geometry to generate higher
pressures. As a minimum, systems using hand or foot operated
master cylinders such as the MC-4, MC-5 or MC-7 series, require
a 2.5 to 1 mechanical advantage. The MC-4 & MC-5 have a.625
inch diameter pistons. (Systems using MC-4 or MC-5 with
intensifiers have .500-inch pistons and require a 1.6 to 1
mechanical advantage). Mechanical advantage, MA, is the ratio of
the force applied to the master cylinder shaft divided by the force
applied by the hand or foot. Dia.1 shows two examples of pedal
geometry. The first has an MA of 1 to 1 since the distance from the
applied load to the pivot point is the same as the distance to the
MC and is undesirable. The second shows a more favorable
configuration that will easily provide the required pressure to the
brakes with moderate toe force. It is often necessary to keep the
foot pedal shorter than that shown in Dia.1. An alternate geometry
is shown in Dia.2. This design would utilize a fork arrangement on
the MC connection to allow clearance of the MC body and then a
short linkage to the MC connect point. A design common to many
aircraft uses linkage as shown in Dia.3. This design also allows for
a shorter brake pedal but has a major disadvantage.
14
M. PEDAL GEOMETRY
This linkage can be configured to have a proper MA in the start
position (with the master cylinder fully extended). The MA varies with
rotation however, as shown in Fig.2 of Dia.3, a 15 degree rotation of
the linkage reduces the MA at the start position from 1.5 to 1 down to
only 1.12 to 1. In actual operation, this has the effect of causing a
nearly constant brake torque even though increasing force is applied.
For example, if the geometry is set for an initial MA 2.5 to 1. In the
start position and the pilot applies pedal force, the MC will begin to
stroke as pressure builds. As the rotation occurs, the MA decreases. If
there is any air in the brake lines or if there are long brake line runs,
hydraulic system expansion will occur as pressure increases requiring
more MC stroke. If the pilot applies more pedal force, more MC stroke
occurs, and the MA decreases further. Even though the pilot has now
increased his pedal force, the force applied to the MC will be only
marginally increased because more rotation will result and cause a
further decrease in MA. A geometry like that in Dia.2 will provide the
same reduced pedal height and is not prone to the effect of rotation
since the MC is essentially connected to the brake pedal pivot. Dia.4
illustrates the benefit of pivot connect geometry during rotation. The
MA remains virtually unchanged for expected rotation angles and
results in a linear pressure increase with applied pedal force.
HEEL BRAKES
A common means of providing pilots with differential braking ability
without resorting to a more complicated geometry of toe brakes is to
use heel brakes. The same design requirements exist for the MA of a
system using heel brakes as for toe brakes. It is not uncommon to see
MC’s configured to allow the pilot to apply heel force directly to the
MC by means of a pad or button connected on the end of the shaft.
This configuration is shown in Fig.1 of Dia.5. The MA of this system
is 1 to 1 and produces very low pressure for reasonable heel force.
Perhaps a larger concern however is the potential for causing damage
to the MC. The MC is designed to accept loads applied along the
length of the shaft.
15
Loads applied off axis or perpendicular to the shaft cause bending
moments in the MC shaft that it is not designed for. Damage to the
MC end gland, or bending of the MC shaft may result if the off
axis loads are high enough. A more desirable configuration for
heel brakes is shown in Fig.2 of Dia.5. This system uses a short
linkage connected to the MC that provides the 2.5 to 1 MA while
insuring that loads will be applied along the length on the MC and
prevent any damage during actuation.
CONCLUSION
Like any system on an aircraft, the hydraulic system has many
engineering options for providing the necessary requirements. The
systems common on light aircraft must be engineered to provide
adequate pressure to the brakes to achieve the rated torque.
The pedal geometry whether hand, toe, or heel operated,
requires a mechanical advantage of at least 2.5 to 1. This allows
the pilot to easily generate the required 450-psi with moderate
applied force. Pivot connected geometry provides the best means
of accomplishing this requirement without the problem of
rotational effect that reduces mechanical advantage.
16
NOTE MATCO mfg. Brakes require 450 psi to achieve
Their rated torque.
PEDAL GEOMETRY / POOR & MINIMUM
Dia. 1 Figures 1 & 2
PEDAL GEOMETRY / POOR & MINIMUM
Dia. 2 Figures 1 & 2
17
PEDAL GEOMETRY / MECHANICAL ADVANTAGE
Dia. 3 Figures 1 & 2
PEDAL GEOMETRY / PIVOT CONNECT
Dia. 4 Figures 1 & 2
18
PEDAL GEOMETRY / HEEL BRAKES
Dia. 5 Figures 1 & 2
For technical Information, Product Matching, and Helpful Hints, see
our website at:
www.matcomfg.com
E-mail our technical service manager for specific information at:
To speak with someone in person about specific products or
receive answers to technical questions, please contact us at
our
OR FAX US AT 801-335-0581
TECHNICAL HOTLINE
80
1-
335
-
058
2
N. TECHNICAL ASSISTANCE
MASTER CYLINDER INFORMATION PAGE
MODEL NUMBER_______________________________________
BORE / DISPLACEMENT (pg. 3)____________________________
INSTALL LENGTH (pg. 3)_________________________________
STROKE (pg. 3)__________________________________________
CLEVIS (pg 7 or 8) MC-17S______MC-17_____MC-17L_____
HYDRAULIC FLUID_____MIL-H-5606__________________
This manual suits for next models
14
Table of contents
