Komatsu 830E-AC Shop Manual page 610

NOTE: If the brake lining moves away from the cali-
per while handling during installation, the caliper
must be partially disassembled to re-adjust the park-
ing brake adjuster. The brake caliper must be
installed with the brake linings completely retracted.
9. Install outer brake caliper half (14) over the two
studs. Carefully remove the brake lining retain-
ing wire. Do not let the lining pull away from the
caliper. Lubricate then install four cap screws
and flat washers (13).
10. Remove the two studs in the center holes.
11. Lubricate then install two cap screws (13) and
hardened flat washers. Tighten all cap screws
(13) to standard torque. Ensure brake bleeder
plugs (4 & 5, Figure 6-3) are installed in the
locations shown.
12. Install two 7/8-9 NC X 14 in. studs in the two
center caliper mounting cap screw holes for the
outer brake caliper (5).
13. Install outer disc adapter (10, Figure 6-2) with
six cap screws (9) and tighten securely.
14. Install outboard disc (12) with four equally
spaced mounting cap screws (11). Tighten, 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 "B", Figure 6-2.
b. If dimension "B" is 126.21 mm (4.97 in.) or
greater, install one 1.016 mm (0.040 in.)
shim at brake mounting surface. Measure
dimension "B" again, measuring from outer
surface of shim to inside face of brake disc.
c. When dimension "B" is less than 126.21 mm
(4.97 in.), then, subtract dimension "B" from
126.49 mm (4.98 in.).
d. Make a measured shim pack equal to the
result obtained in Step 14c. If not equal, then
within 0.127 mm (0.005 in.) of the result. This
will be brake disc shim pack (7).
15. Remove cap screws (11) and outer disc (12).
Remove outer disc adapter (10).
J6-6
16. With brake linings secured to caliper with wire,
17. Install outer disc adapter (10, Figure 6-2). Lubri-
18. If brake disc shim pack (7, Figure 6-2) is
19. Install outer brake disc (12) with bushing (8).
20. With brake linings secured to caliper with wire,
21. Remove the two studs in the center holes and
22. Ensure brake bleeder plugs (1 & 2, Figure 6-3)
23. Ensure all brake bleeders in both calipers are in
24. Install crossover tubes and brake lines.
25. Refer to Brake Bleeding Procedure to bleed
26. New brake linings must be burnished before
Armature Speed Rear Disc Brakes
install inner brake caliper half (5) over the two
studs. Ensure brake bleeder plug (3, Figure 6-3)
is installed in the location shown.
cate then install cap screws and flat washers
(9). Tighten 12 point head cap screws (9) to
standard torque.
required (Step 14d), install shims on adapter
(10).
Lubricate then install all cap screws and flat
washers (11) to outer disc. With the brake disc
resting against the brake lining, remove the
wires retaining the brake linings. Tighten cap
screws (11) to standard torque.
install outside caliper half (5). Lubricate then
install the four outer cap screws and flat wash-
ers (6). Remove the wires retaining the brake
linings.
install the remaining two lubricated cap screws
(6) with washers. Tighten all cap screws (6) to
standard torque.
are installed in the locations shown.
the exact locations shown in Figure 6-3.
Remove all extra brake bleed plugs from brake
calipers so they will not be used during the
brake bleeding procedure.
trapped air out of the brake system.
truck is returned to production. Refer to Service
Brake Conditioning Procedure to burnish the
brakes.
10/06 J06025