3406E On-Highway Engine Caterpillar

Assembly Procedure

1. Inspect the O-ring seals. If the O-ring seals are worn or damaged, use new parts for replacement. Put clean engine oil on the O-ring seals.
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   Illustration 1	g01070663

2. Install O-ring seal (16) on sleeve assembly (17).

3. Install the sleeve in the BrakeSaver housing. Align Notch (X) on the sleeve assembly with the notch in the BrakeSaver housing. Install the dowel.
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   Illustration 2	g00523368

   Note: Ensure that there is clearance behind spiral ring (15) when the spiral ring is correctly installed.

4. Rotate the BrakeSaver housing and install spiral ring (15) that holds the sleeve assembly in the BrakeSaver housing.
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   Illustration 3	g01070766

5. Raise the temperature of carrier (13).

   Note: Ensure that the carrier is at the bottom on the rotor.

6. Install carrier (13) and wear sleeve (14) on each side of the rotor.
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   Illustration 4	g00523353

7. Install seal ring (10) on each of the carriers.

8. Install rotor assembly (12) in the BrakeSaver housing.

9. Install O-ring seal (11) and the six smaller O-ring seals for the oil holes on the BrakeSaver housing.
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   Illustration 5	g00523350

10. Install O-ring seal (7) and lip seal (8) on sleeve assembly (9). Install sleeve assembly (9) in the stator. Make an alignment of the notch in the sleeve with the dowel in the stator.
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    Illustration 6	g00523342

11. Rotate the stator and install spiral ring (6) that holds the sleeve in the stator.
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    Illustration 7	g00523331

12. Put stator (3) in the correct location on BrakeSaver housing (4). Ensure that the oil holes in the stator and in the BrakeSaver housing are in alignment.

13. Install bolts (5) that hold the stator to the BrakeSaver housing. Tighten the bolts to a torque of 55 ± 7 N·m (41 ± 5 lb ft).

14. Rotate the BrakeSaver housing. The weight of the BrakeSaver housing is approximately 73 kg (160 lb).

15. Do the following procedure with the appropriate Tooling to install the seals.

    1. Clean the wear sleeve inside diameter and the rotor outside diameter with Tooling (J). Apply Tooling (K) to the outside diameter of the rotor before the wear sleeve is installed on the rotor. Do not allow Tooling (K) to get on the lip of the seal.
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       Illustration 8	g01070733

    2. Install Tooling (E) with Tooling (G).
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       Illustration 9	g01070735

    3. Rotate the BrakeSaver housing and install Tooling (C) and Tooling (D) on the rotor.

    4. The wear sleeve and the seal are installed as a unit on Tooling (C).

       Note: Once the seal and the wear sleeve are separated, these components cannot be used again.

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       NOTICE
       The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the front seal group for the BrakeSaver is different from the rear seal group. If a seal group is installed on the wrong end of the BrakeSaver, oil can actually be taken out of the BrakeSaver instead of moving oil back into the BrakeSaver.

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       Illustration 10	g01070736

    5. Put Tooling (F) in position on the locator.

    6. Put clean engine oil on the face of Tooling (H). Install Tooling (H) on the locator.

    7. Tighten Tooling (H) until Tooling (F) makes contact with the rotor.

    8. The Tooling will install the seal and the wear sleeve to the correct depth.

16. Remove the Tooling from the BrakeSaver.
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    Illustration 11	g01070744

17. Install Tooling (E).

18. Rotate the BrakeSaver. Refer to Steps 15c through 15h in order to install the seal and the wear sleeve.

    Note: It may be necessary to use a wrench to hold the retainer bar in order to prevent the rotor from turning during the installation of the seal and the wear sleeve.

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    Illustration 12	g00523766

19. Install Tooling (A) on the rotor and the BrakeSaver housing.
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    Illustration 13	g00523236

20. Rotate the BrakeSaver housing and install gear plate (2) and bolts (1) on the rotor.

End By:

1. Install the BrakeSaver. Refer to Disassembly and Assembly, "BrakeSaver - Install".