Usage:
Typical Example
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To prevent possible personal injury, make sure all the pressure in the air system in the air system has been released before any air lines are disconnected. |
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1. Drain the oil from the makeup oil tank, and release the air pressure from the system.
2. Disconnect air hoses (7) and (2) from the top of master cylinder and rotochambers (1).
3. Disconnect hoses (4), (5) and (6) from master cylinder and rotochambers (1).
4. Fasten a hoist to either master cylinder and rotochamber (1). Remove the bolts from the base of the master cylinder and rotochamber. The weight of the master cylinder and rotochamber is 25 kg (55 lb).
5. Repeat Step 4 for the remaining master cylinder and rotochamber.
6. Install the master cylinder and rotochambers in the reverse order of removal.
7. Fill the makeup tank with oil to the correct level. Refer to the Operation & Maintenance Manual for further information.
8. Bleed the air from the brake system. See the Systems Operation/Testing & Adjusting Manual and the topic "Remove Air From The Hydraulic Brake System (Bleed The Brakes) for the correct procedure.
Remove & Install Master Cylinder And Rotochamber (Rear Brakes)
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To prevent possible personal injury, make sure all the pressure in the air system has been released before any air lines are disconnected. |
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1. Drain the oil from the makeup oil tank, and release the air pressure from the system.
2. Disconnect air hoses (2) and (3) from the top of each master cylinder and rotochamber (1).
3. Disconnect hoses (5) and (6) from master cylinder and rotochambers (1).
4. Disconnect wire harness (4) from the switch on each master cylinder and rotochamber (1).
5. Fasten a hoist to either master cylinder and rotochamber (1). Remove the bolts from the base of the master cylinder and rotochamber. Remove the master cylinder and rotochamber. The weight of the master cylinder and rotochamber is 25 kg (55 lb).
6. Repeat Step (5) for the remaining master cylinder and rotochamber.
7. Install the master cylinder and rotochambers in the reverse order of removal.
8. Fill the makeup tank with oil to the correct level. Refer to the Operation & Maintenance Manual for further information.
9. Bleed the air from the brake system. See the Systems Operation/Testing & Adjusting Manual and the topic "Remove Air From The Hydraulic Brake System (Bleed The Brakes) for the correct procedure.
Disassemble & Assemble Brake Master Cylinder And Rotochamber
NOTE: Use the same procedures to disassemble and assemble either the front or the rear master cylinder and rotochamber.
Start By:
a. remove front or rear brake master cylinder and rotochamber.
1. Remove bleed screw (1).
2. Use tooling (A) to loosen nut (3).
3. Remove end cap (2).
4. Use tooling (A) to loosen nut (5).
5. Remove cylinder (4). Remove the O-rings and nuts (3) and (5) from cylinder (4).
6. Remove nuts (7) and cylinder (8).
7. Push piston (15) down until power piston (24) clears body (6).
8. Remove snap ring (20) from power piston (24) with tooling (B). Remove power piston (24) and valve (21) from rod (17). Remove the piston and rod assembly and spring (16) from body (6).
9. Remove switch (19) and rod (18) from body (6). Remove the seal from rod (18).
10. Remove seal (23) from power piston (24). Remove seal (22) from valve (21).
11. Remove bolts (13) and ring (12). Remove seal (10).
12. Remove spring (11) from ring (12). Remove O-ring (9) from piston (15).
13. If required remove nut (14) and piston (15) from rod (17). Remove the O-ring from rod (17).
14. Remove the seals from the rod bore in body (6).
NOTE: The following steps are for assembly of the brake master cylinder and rotochamber.
NOTE: Put clean SAE 10W oil on all seals before the cylinder is assembled.
15. Install the seals in the rod bore of body (6).
16. If piston (15) was removed from rod (17), install the O-ring on rod (17). Install piston (15) and nut (14) on rod (17). Tighten nut (14) to a torque of 145 ± 38 N·m (105 ± 28 lb ft).
17. Install O-ring (9) on piston (15). Install spring (11) on ring (12).
18. Install seal (10), ring (12), and bolts (13). Tighten bolts (13) to a torque of 11 ± 1 N·m (8 ± 1 lb ft).
19. Install seal (22) in valve (21). Install seal (23) on power piston (24).
20. Install the seal on rod (18). Install rod (18) and switch (19) in body (6). Tighten switch (19) to a torque of 8 ± 3 N·m (6 ± 2 lb ft).
21. Install the piston and rod assembly and spring (16) in body (6). Push piston (15) down until the end of rod (17) clears body (6).
22. Install valve (21) and power piston (24) on rod (17). Use tooling (B) to install snap ring (20) in power piston (24).
23. Install cylinder (8) and nuts (7). Tighten nuts (7) to a torque of 14 ± 3 N·m (10 ± 2 lb ft).
24. Install nuts (3) and (5) and the O-rings on cylinder (4).
25. Install cylinder (4) in body (6) until it bottoms out. [Tighten cylinder (4) to a maximum torque of 14 N·m (10 lb ft)]. Tighten nut (5) to lock cylinder (4) in place.
26. Install end cap (2) on cylinder (4) until it bottoms out. [Tighten end cap (2) to a maximum torque of 14 N·m (10 lb ft)]. Then back it off up to one turn to line up the bleed screw hole and reservoir port within 10°. Tighten nut (3) to hold end cap (2) in position.
27. Install bleed screw (1). Tighten bleed screw (1) to a torque of 14 ± 3 N·m (10 ± 2 lb ft).
End By:
a. install front or rear brake master cylinder and rotochamber.