Usage:
D250B (5WD),
D300B (4SD),
D20D (9MG),
D25D (1HK),
D250D (6NG),
D300D (5MG),
D250E (5TN),
D300E (7FN),
D350E (9LR),
D400E (2YR),
D250E Series II (4PS),
D300E Series II (5KS) Articulated Trucks
Dimensions are now available for the re-manufacture of the brake discs and rotors used in the machines listed above.
The procedures that follow are for the re-manufacture of 138-2318 Disc, 9V-6982 Disc and 122-3741 Rotor.
Damaged discs or rotors may be re-manufactured by machining the areas that contact the brake pads. Ensure that machining of the disc or rotor occurs only within the areas shown in Illustrations 1 and 2.
NOTE: If the brake disc or rotor shows signs of heat cracks, or has material missing, this repair procedure must not be performed. The brake disc or rotor must be replaced.
Re-manufacture of 9V-6982 Disc and 138-2318 Disc
NOTE: Reference the relevant Service Manuals of the machines listed above for the Correct Torque Specifications and Procedures to assemble the relevant brake discs to the wheel assemblies.
9V-6982 Disc is used on models D250B, D300B, D20D, D25D, D250D, D300D, D250E (5TN1-1272), D300E (7FN1-479).
138-2318 Disc is used on models D250E (5TN1273-Up), D300E (7FN480-Up), D250E II and D300E II.
Dimensions that will allow the re-manufacture of both brake discs are given in Illustration 1.
(A) Machining area
(B) = 9.43 mm (.37 in) minimum
(C) = 314.5 ± 0.5 mm (12.38 in ± .02 in) diameter
(D) = 2 mm (.08 in) radius max
Illustration 1. Dimensions for Re-manufacture of 9V-6982 Disc and 138-2318 Disc
Machine either side of the disc as required, to remove grooves, warping, etc. Only machine within areas (A).
Ensure both sides are flat, but do not machine thinner than the minimum thickness (B).
Re-manufacture of 122-3741 Rotor
NOTE: Reference the relevant Service Manuals of the machines listed above for the Correct Torque Specifications and Procedures to assemble the brake rotor to the wheel assemblies.
122-3741 Rotor is used on models D350E and D400E. Dimensions that will allow the re-manufacture of 122-3741 Rotor are given in Illustration 2.
(E) Machining area
(F) = 3 mm (.12 in) radius
(G) = 306 mm ± 0.5 mm (12.05 ± .02 in) diameter
(H) = 15.8 mm (.62 in) minimum
(J) Machining area
Illustration 2. Dimensions for Re-manufacture of 122-3741 Rotor
Machine both areas of the rotor as required, to remove grooves, warping, etc. Only machine within areas (E) and (J).
Machine area (J) to dimension (G), and provide a smooth blend into radius (F).
Machine the entire face for area (E).
Ensure both sides are flat, but do not machine thinner than the minimum thickness (H).