Komatsu 830E-AC Shop Manual page 609

Installation
Secure the lining assembly to the caliper housing
using wire ties or safety wire so that it cannot
move away from the caliper housing. Movement
of the lining assembly during installation will
affect the parking piston adjustment which may
cause the brake to drag after installation. The lin-
ing must remain secure to the caliper housing
until the brake is installed on the vehicle. If the
lining does move away from the caliper, the cali-
per will have to be partially disassembled to reset
the adjuster.
NOTE: If installing new calipers, do not cut the band
off the caliper until retaining wire has been installed.
1. Inspect all brake discs (12, Figure 6-2) for wear.
Refer to Brake Disc Inspection, this chapter, for
wear limits. If any disc is worn beyond the wear
limit, replace the disc.
2. If removed, install adapter (2, Figure 6-2) and
secure in place with lubricated cap screws and
flat washers (3). Tighten cap screws to standard
torque.
3. Install two 7/8-9 NC X 14 in. studs in two center
caliper mounting cap screw holes (in place of
cap screws 13).
4. Install inboard disc (12) with four equally
spaced cap screws with flatwashers. Tighten
cap screws, but do not tighten to final torque at
this time.
a. Measure and record distance from caliper
mounting surface to inside face of brake disc
(12). This is Dimension "A", Figure 6-2.
b. If dimension "A" is 126.21 mm (4.97 in.) or
greater, install one 1.016 mm (0.040 in.)
shim at brake mounting surface. Measure
dimension "A" again, measuring from outer
surface of shim to inside face of brake disc.
c. When dimension "A" is less than 126.21 mm
(4.97 in.), then, subtract dimension "A" from
126.49 mm (4.98 in.).
J06025 10/06
5. Remove disc mounting cap screws (11) and
NOTE: The inner and outer caliper halves are
different, and are not interchangeable. The outer half
has countersunk bores for the cap screw head and
flat washers, the inner half has a flat mounting
surface.
NOTE: Each caliper half weighs approximately 45 kg
(100 lbs).
6. With brake linings secured with wire, install
NOTE: Bleed plug (7) may have to be removed
temporarily to obtain clearance around adapter (15,
Figure 6-2) during caliper installation. Cover or plug
hole in caliper to prevent dirt contamination inside
caliper.
7. If brake disc shim pack (7) is required (Step 4d),
Cap Screws (3, 6, 9, 11 & 13) must have the
threads and seats lubricated with simple lithium
base chassis grease (multi-purpose EP NLGI)
prior to installation.
8. Remove the brake lining retaining wire. Do not
Armature Speed Rear Disc Brakes
d. Make a measured shim pack equal to the
result obtained in Step 4c. If not equal, then
within 0.127 mm (0.005 in.) of the result. This
will be brake disc shim pack (7).
inner disc (12).
inner brake caliper half (14) over the two studs.
Ensure brake bleeder plugs (6 & 7, Figure 6-3)
are installed in the locations shown. Bleeder
plug (7) must be installed in the same location
as (4) when viewing from the end.
install shims on adapter (15).
let the lining pull away from the caliper. Install
inner brake disc (12) with bushing (8). Lubricate
then install all cap screws and flat washers (11)
to inner disc. Tighten cap screws (11) to stan-
dard torque.
J6-5