UNDERCARRIAGE RT540E SERVICE MANUAL
8-22 Published 4-20-2015, Control # 502-01
3. Measure the diameter of the housing bore. Replace the
housing if the diameter is worn to more than 76.276 mm
(3.003 in) (Figure 8-23).
4. Inspect the linings as described previously.
5. Inspect the threads of the caliper, cylinder caps, and all
fittings. Replace any component that has thread
damage that cannot be repaired.
6. Discard all back-up rings, o-rings, and dust seals. Use
new ones when assembling the caliper.
Cleaning
• Use solvent cleaners to clean all metal parts that
have ground or polished surfaces. Examples of
ground or polished parts are the piston and the
piston bore in the caliper.
• Metal parts with rough surfaces can be cleaned with
solvent cleaners or with alkaline solutions.
• Use a wire brush to clean the threads of fasteners
and fittings.
• Use soap and water to clean parts that are not made
of metal.
• Scrape away build-ups of mud and dirt on the
linings. Replace all linings contaminated with oil or
grease.
• Immediately after cleaning, dry all parts with clean
paper or rags.
Corrosion Protection
Apply brake system fluid to the cleaned and dried parts that
are not damaged and are to be immediately assembled. Do
Not apply fluid to the brake linings or the disc.
If parts are to be stored, apply a special material that
prevents corrosion to all surfaces. Do Not apply the material
to the brake linings or the disc. Store the parts inside special
paper or other material that prevents corrosion.
Assembly
Caliper
NOTE: The o-rings, back-up rings, pistons, and bores
must be lubricated before installing the pistons.
1. Lubricate all pistons, bores, o-rings, and back-up rings
with silicone grease. If silicone grease is not available,
use the same type of fluid that is used in the brake
system.
2. Install new o-ring and a new back-up ring in the groove
in the middle of the bore. The o-ring is installed toward
the outboard end of the bore. The back-up ring is
installed toward the lining side of the bore (Figure 8-16).
3. Install a new dust seal in the top groove of the bore
(Figure 8-24).
DANGER
Use of cleaning solvents, hot solution tanks, or alkaline
solutions incorrectly, can cause serious personal injury. To
prevent serious personal injury, follow the instructions
supplied by the manufacturer of these products. Do not
use gasoline to clean parts. Gasoline can explode and
cause serious personal injury.
CAUTION
Use only solvent cleaners to clean ground or polished
metal parts. Hot solution tanks or water and alkaline
solutions will damage these Parts. Isopropyl alcohol,
kerosene, or diesel fuel can be used for this purpose.
Telescoping
Gauge
Replace Housing if Bore
is Worn to More than
76.276 mm (3.003 in)
FIGURE 8-23
CAUTION
Use only specified components when assembling the
calipers. Do not mix components from other calipers.
Installing the wrong components may cause the caliper
not to operate correctly and may cause damage to
equipment. Use of non manufacturer’s parts can cause
damage, loss of braking, and serious personal injury.
CAUTION
Do not use silicone grease on the dust seal.
Reference Only
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