3406E On-Highway Engine Caterpillar

Disassembly Procedure

Start By:

1. Remove the compression brake. Refer to Disassembly and Assembly, "Compression Brake - Remove".

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Illustration 1	g00512487
Typical example

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NOTICE
Do not disassemble or tamper with the solenoid valve. Engine damage could result.

1. Remove solenoid valve (1).

2. Remove seals (2) from the solenoid valve. Remove seal (2) from the bottom of the bore for the solenoid valve. Discard the seals.

3. Wash solenoid valve (1) with approved cleaning solvent. Use a brush to clean the oil screen. Dry solenoid valve (1) with 103 to 138 kPa (15 to 20 psi) of compressed air.
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   Illustration 2	g01009776
   Typical example

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   Remove control valve covers carefully. Control valve spring covers are under load from the control valve 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.

4. Compress control valve cover (3) in order to relieve any spring pressure when allen head screw (4) is removed.

5. Remove allen head screw (4).

6. Slowly remove control valve cover (3) in order to relieve spring tension force. Then remove control springs (6).

7. Remove control valve (5).
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   Illustration 3	g01009783
   Typical example

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   NOTICE
   Do not diassemble or tamper with slave piston adjusting screw. Engine damage could result.

8. Loosen slave piston adjustment screw locknut (8) and loosen slave piston adjustment screw (7) until the slave piston is fully retracted. Slave piston adjusting screw (7) should be loose.
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   Illustration 4	g00512594
   Typical example

9. Place Tooling (A) over slave piston adjusting screw (7).
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   Illustration 5	g01009784
   Typical example

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   Remove slave pistons carefully. The slave pistons are under spring pressure. Remove with care to avoid personal injury.

10. Slowly turn the handle on Tooling (A) until retaining washer (13) is compressed approximately 1.00 mm (0.040 inch) in order to relieve the spring pressure from retaining ring (14).

11. Remove retaining ring (14) for the slave piston. Back out the handle on Tooling (A) until the springs are loose. Remove Tooling (A).

12. Remove retaining washer (13), and the inner spring (12), pushrod (11), outer spring (10), and slave piston (9). Ensure that the components are not in a bind. Components must be free of metal burrs.

13. Clean the components with an approved cleaning solvent. Inspect the contact point between slave piston (9) and pushrod (11). Inspect the other components for damage or wear. Components that are pitted, cracked, or galled should be replaced with new parts.
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    Illustration 6	g01009791
    Typical example

14. Remove retaining ring (19) for the master piston. Remove retaining washer (18), master piston spring (17), master piston (15), and pushrod (16). If binding occurs, check for metal burrs or contaminants in the lube oil.

15. Clean the compression brake housing and the components in approved cleaning solvent. Inspect the contact point between master piston (15) and pushrod (16). Inspect the compression brake housing and the other components for damage or wear. Components that are pitted, cracked, or galled should be replaced with new parts.