OPTION AR-HYDRAULIC 3658092 - Caterpillar

Assembly Procedure
Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     134-2837     Piston Compressor     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01009791
Typical example
Improper assembly of parts that are spring loaded can cause bodily injury.To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Note: Never use rags to clean the compression brake housing or any of the components. Rags may leave lint or residue that can obstruct oil passages.
Thoroughly clean the compression brake housing and all of the components with an approved solvent. Dry the compression brake housing and the solenoid valve with 103 to 138 kPa (15 to 20 psi) of compressed air.
Install master piston (15), pushrod (16), master piston spring (17), retaining washer (18), and retaining ring (19) .
Illustration 2 g01009784
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Illustration 3 g00512594
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Install slave piston (9), outer spring (10), pushrod (11), inner spring (12), and retaining washer (13) .
Use Tooling (A) to compress the assembly until retaining washer (13) is approximately 1.00 mm (0.039 inch) below the retaining ring groove. Install retaining ring (14). Ensure that retaining ring (14) is properly seated in the groove.
Remove Tooling (A) .
Illustration 4 g01009783
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Inspect slave piston adjustment screw (7). The plunger should protrude from the bottom of slave piston adjusting screw (7). Approximately 53 N (12 lb) of force is required to move the plunger. Ensure that the spring retaining pin for the plunger is seated.
Install slave piston adjusting screw (7) and slave piston adjustment screw locknut (8). Do not tighten the assembly at this time.Note: Refer to Testing and Adjusting, "Slave Piston Lash - Adjust" for more information on the adjustment of the slave piston lash.
Illustration 5 g01009776
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Push a wire through the hole in the base of control valve (5) in order to ensure that the check ball is free. The check ball should unseat with slight pressure on the wire. If the check ball is stuck, replace the control valve.
Put clean engine oil on control valve (5) and install the control valve in the compression brake housing. If binding occurs, replace the control valve. Install control valve springs (6) .
Put control valve cover (3) in position and install allen head screw (4) .
Illustration 6 g00512487
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Use new seals (2). Coat the seals with clean engine oil. Install the upper seal and the center seal on the solenoid body. Install the lower seal in the bottom of the bore for the solenoid valve in the compression brake housing.
Ensure that seals (2) are seated properly. Carefully install solenoid valve (1) in the compression brake housing. Tighten the solenoid valve to a torque of 12.4 N m (110 lb in). Be careful not to twist the seals during installation.End By: Install the compression brake. Refer to Disassembly and Assembly, "Compression Brake - Install".