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Workman HD Series Page 7 − 13 Chassis
Disassembly (Fig. 6)
1. Remove two (2) bolts that secure brake caliper as-
sembly.
2. Remove caliper anvil and then slide brake pads from
pins on caliper bracket.
3. Slide caliper body assembly from caliper bracket.
4. If necessary, remove remaining components from
caliper body:
A. Carefully remove pistons from caliper body mak-
ing sure that outer surface of pistons are not dam-
aged during removal.
B. Carefully, remove and discard O−rings, dust
seals and square seals from caliper body. Make sure
that caliper body is not damaged during removal of
O−rings and seals.
5. Clean caliper components with brake cleaner.
Inspection
1. Check brake pads for uneven wear that would indic-
ate binding in the caliper assembly. Replace the brake
pads if the friction material is worn to less than 1/16” (1.6
mm). Also, if pads are contaminated with grease or oil,
they must be replaced.
2. Inspect brake pistons and piston bores in caliper
body for damage or wear. Replace brake pistons or
complete brake caliper assembly if necessary.
3. Check that pins on caliper bracket are not worn or
damaged. Wear on the pins will prevent smooth brake
operation.
Assembly (Fig. 6)
1. If caliper body was disassembled, install compon-
ents in caliper body:
A. Apply hydraulic brake cylinder assembly lube
(BAF−12 or equivalent) to square seals and pistons
before installation.
B. Fit lubricated square seals into grooves of caliper
body. Make sure that seals are not twisted in groove
after installation.
C. Install lubricated pistons into caliper body bores.
Pistons should slide into bores with light resistance.
D. Install dust seals into caliper body.
E. Lubricate O−rings with white lithium grease and
install into grooves in caliper body.
F. Slide caliper body assembly onto pins on caliper
bracket.
NOTE: If brake pads are being replaced, it will be nec-
essary to push caliper pistons back into the caliper bore
before installing new pads.
2. Slide brake pads onto pins on caliper bracket. Make
sure that friction material on pads is toward brake rotor
position.
3. Fit caliper anvil to assembly and secure caliper com-
ponents with two (2) bolts. Torque bolts from 27 to 33 ft−
lb (37 to 44 N−m).
Chassis