Komatsu 830E Shop Manual page 385

Caliper, Disc, And Parking Brake Installation
1. If removed, install adapter (2, Figure 6-3A) and
secure in place with capscrews and flatwashers
(3). Tighten capscrews to standard torque.
2. Install two 7/8 9 UNC - 14 in. studs in two center
caliper mounting capscrew holes (in place of cap-
screws 13). Install spacer (15) and secure in
place with two 0.875 - 9 UNC - 2.5 in. capscrews
and two flat washers.
securely, but not to final torque.
3. Install inboard disc (12) with four equally spaced
capscrews with flatwashers. Tighten capscrews,
but do not tighten to final torque at this time.
4. Measure and record distance from inner caliper
mount surface (on spacer 15) to inside face of
inner brake disc (12), Dimension "A", Figure 6-
3A.
NOTE: All measurements in the following references
are inches, unless otherwise stated.
5. Subtract dimension "A" from 4.375 in. The differ-
ence is shim pack thickness to be placed
between inner disc (12) and one-piece disc
adapter (16).
6. Refer to "Shim Pack Chart" and select shim pack
as follows:
Example: If result found in Step 5 is 0.051", then
0.051 is between 0.045 - 0.055 in Shim Pack
Chart. This range indicates one 0.010 in. shim
and one 0.040 in. shim is required to provide cor-
rect shim pack thickness.
7. Remove disc mounting capscrews (11) and inner
disc (12).
8. Remove the two 0.875 - 9 UNC - 2.5 in. cap-
screws securing spacer (15).
9. Install inner brake caliper half (14) over the two
studs and spacer (15).
10. Install shim pack (7), determined in Step 5, on
inner one-piece disc adapter (16) and install inner
disc (12) with bushing (8).
11. Install all capscrews and flatwashers (11) to inner
disc. Tighten capscrews (11) to standard torque.
12. Install outer brake caliper half (14) and two cap-
screws and flatwashers (13).
13. Remove the two studs in the center and install two
capscrews (13) and
Tighten all capscrews (13) to standard torque.
J06020
Tighten capscrews
hardened flatwashers.
Rockwell Armature Speed Rear Disc Brakes
14. Install outer disc adapter (10). Install capscrews
and flat washers (9). Tighten 12 point head cap-
screws (9) to standard torque.
15. Install two 7/8 UNC-14 in. studs in the two center
caliper mounting capscrew holes for the upper
brake caliper (5).
16. Install park brake bracket (4) over the two studs
and secure in place with two 0.875 - 9 UNC - 2.5
in. capscrews and two flat washers. Tighten cap-
screws securely, but not to standard torque.
17. Install outboard disc (12) with four equally spaced
mounting capscrews (11). Tighten, but do not
tighten to final torque at this time.
18. Measure distance from outer face of park brake
bracket (4) [caliper mounting surface] to inner
face of outboard disc (Dimension "B", Figure 6-
3A).
19. Subtract distance determined in Step 18 from
4.375 in (11.113 cm). This difference is the shim
pack thickness to be placed between adapter (10)
and outer brake disc (12).
20. Make up shim pack from Shim Pack Chart.
21. Remove capscrews (11) and outer disc (12).
22. Install the shim pack (7) determined in Step 19
between outboard disc (12) and adapter (10).
23. Install outboard disc (12) with bushing (8). Install
capscrews and flatwashers (11). Tighten cap-
screws (11) to standard torque.
24. Install outboard caliper half (5) and secure in
place with the outer capscrews and flatwashers
(6). Remove the two studs in the center holes and
install the remaining two capscrews (6) with
washers. Tighten capscrews (6) to standard
torque.
25. Install linings (Refer to "Lining Replacement").
26. Install bleeders in both calipers. Install crossover
tubes and brake lines.
27. Install park brake caliper, refer to "Park Brake Cal-
iper Installation".
28. Brakes must be bled and burnished before truck is
returned to production. Refer to "Bleeding" and
"Service Brake Conditioning" procedure.
J6-5