| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 1P-1858 | Retaining Ring Pliers | 1 |
| B | 1P-1854 | Retaining Ring Pliers | 1 |
| C | 134-2837 | Piston Compressor | 1 |
Start By:
- Remove the compression brake. Refer to Disassembly and Assembly, "Compression Brake - Remove".
| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
- Apply downward pressure to accumulator cover (2) with a punch of suitable size. Remove retaining ring (1) with Tooling (A).
- Slowly release the pressure from accumulator cover (2) until the spring pressure ceases. Remove accumulator cover (2) and spring (3).
- Use a magnet or needle nose pliers to remove accumulator piston (4) from the bore in compression brake housing (5).
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Illustration 3 g00523476 Show/hide table
Illustration 4 g00524780 Show/hide table
Remove control valve covers carefully. Control valve spring covers are under load from the control valve springs. Remove with care to avoid personal injury.
Show/hide tablePersonal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are loosened.
- Apply downward pressure to control valve cover (6) with a punch of suitable size. Remove retaining ring (7) with Tooling (B).
- Slowly release the pressure from control valve cover (6) until the spring pressure ceases. Remove control valve cover (6) and control valve springs (8).
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Illustration 5 g00524781 - Use a magnet or needle nose pliers in order to reach into the bore and remove control valve (9) from compression brake housing (5).
Note: Repeat Steps 1 through 6 for the remaining control valve.
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Illustration 6 g00523481 Show/hide tableNOTICE Do not disassemble or tamper with the solenoid valve. Engine damage could result.
- Unscrew solenoid valve (10) from the compression brake housing.
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Illustration 7 g00523482 - Remove O-ring seals (11) from solenoid valve (10). Discard the O-ring seals.
Note: The lower O-ring may stay in the bore in the compression brake housing. If this is the case, use a seal pick in order to remove the O-ring from the compression brake housing.
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Illustration 8 g00523483 Show/hide tableNOTICE Do not diassemble or tamper with slave piston adjusting screw. Engine damage could result.
- Remove slave piston adjustment screw locknut (12).
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Illustration 9 g00523484 - Loosen slave piston adjustment screw (13) until the slave piston is fully retracted.
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Illustration 10 g00524785 Show/hide table
Illustration 11 g00523486 Show/hide table
Illustration 12 g00524782 Show/hide tableRemove slave pistons carefully. The slave pistons are under spring pressure. Remove with care to avoid personal injury.
Show/hide tablePersonal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are loosened.
- Place Tooling (C) over slave piston adjustment screw (13). Turn the handle on Tooling (C) until spring retainer (14) is depressed approximately
1.0 mm (0.04 inch) in order to relieve the pressure from retaining ring (15). - Remove retaining ring (15) with Tooling (A). Slowly back out the handle on Tooling (C) until the spring pressure ceases. Remove Tooling (C).
- Remove spring retainer (14), springs (16), and slave piston (17).
Note: Repeat Steps 9 through 13 for the remaining slave piston.
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Illustration 13 g00524783 Show/hide table
Illustration 14 g00524784 Show/hide tableRemove master pistons carefully. The master piston is under spring pressure. Remove with care to avoid personal injury.
Show/hide tablePersonal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are loosened.
- Apply downward pressure to retaining washer (19) with a punch of suitable size. Remove retaining ring (18) with Tooling (B).
- Slowly release the pressure from retaining washer (19) until the spring pressure ceases. Remove retaining washer (19), springs (20), and master piston (21).
Note: Repeat Steps 14 and 15 for the remaining master piston.
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| Illustration 1 | g00523471 |
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| Illustration 2 | g00523472 |
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Remove accumulator covers carefully. The accumulator covers are under load from the accumulator springs. Remove with care to avoid personal injury. |
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Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. |
