TecBrake T346A User manual

TecBrake
P.O.Box 27822
Houston, Texas 77227
Installation
Manual
ModelT346A Engine Brakes
For Caterpillar 3406, 3406B
And 3406C Series Engines
Engine Brakes

INSTALLATION MANUAL
TECBRAKE MODEL T346A ENGINE BRAKE
FOR CATERPILLAR 3406, 3406B AND 3406C
SERIES ENGINE
SECTION 1-INTRODUCTION
The TecBrake T346A engine brake may be installed on
Caterpillarmodel3406,3406B and3406C seriesengine.
These engines although similar, were produced with
variations that affect the components required and the
installation procedure.
NOTICE
The TecBrake Engine Brake is designed as a device
for slowing a vehicle, not stopping it. It is to be used
in conjunction with, but not a substitute for the
vehicle’s service brakes. The service brakes must
be in good operating condition and used to bring
the vehicle to a complete stop.
Material Required
The TecBrake kit includes all of the parts required to
make an installation on the most common engine
configurations. An optional shim & washer kit (Part No.
TJ013677)is requiredon allengines witha serialnumber
lower than 7FB39279, or with a 92U prefix. This is not
included with the engine brake kit and must be ordered
separately.Refertotheidentificationplateonvalvecover
for required data.
The TecBrake kit does not contain a control group. Five
different control groups are available to cover all
applications. These groups must be ordered separately
in addition to the basic kit.
Refer to the TecBrake Parts Manual for additional
information.
Special Tools
The following special tools are required for installation:
TecBrake Tools TecBrake P/N.
1. Feeler gage-0.080” TB900005
2. Feeler gage-0.067” TB900006
3. Feeler gage-0.060” TB900004
4. Feeler gage-0.090” TJ018488
Caterpillar Tools Caterpillar P/N.
1. Fuel Line Socket-Flank Drive 3/4” 5P144
2. Fuel Line Wrench-7/8” 5P5195
3. Timing Pin-Fuel Pump (3406) 8S2291
4. Timing Pin-Fuel Pump (3406B) 6V4186
5. Turning Tool 9S9082
Recommended Torque Values
Bridge Adj. Screw lock nuts- 24 lbft (32 N*m)
Cylinder Head Bolts- 330 lbft (450 N*m)
Engine Brake Hold-down nuts- 100lbft (135 N*m)
Engine Brake 7/16” cap screws- 60lbft (82 N*m)
Rocker Arm Adj. Screw nuts- 22 lbft (30 N*m)
Slave Piston Adj. Screw nuts- 16 lbft (22 N*m)
Fuel Lines- 30lbft (41 N*m)
SECTION 2 - ENGINE PREPARATION
1
Figure 2-1
1. Thoroughly clean engine before beginning installation.
Removeallengine componentsnecessary topermitaccess
to cylinder heads.
Figure 2-2
2. Remove the upper valve covers.
Figure 2-3
3. Remove the valve cover base.

NOTICE
Follow procedure specified below to set engine to
cylinder No.1 T.D.C. compression. This procedure
will allow three cylinders to be adjusted for both
valves and engine brakes without rotating the
engine. One additional rotation to cylinder No 6
T.D.C. compression will be required to adjust the
other three cylinders.
Timing Bolt Method to obtain T.D.C.
2
Figure 2-4
4. From just above the starter, remove the timing bolt
from its storage location and the access plate to the
flywheel.
Figure 2-5
5. Insert the Caterpillar Turning Tool P/N 9S9082 as
shown.
Figure 2-6
6. Insert timing bolt in location shown and rotate engine
usingthe CaterpillarTurningTool counterclockwise (looking
from the flywheel side of the engine) until the timing bolt is
aligned with the threaded hole in the flywheel. When the
timing bolt can be threaded into the tapped hole in the
flywheel, the engine is at T.D.C. cylinder No. 1. Look at
bothvalveson cylinderNo.1 toseeif theyare both closed.
If closed, cylinder No. 1 is on the compression stroke. If
not, remove the timing bolt and rotate the engine 360
degrees until the timing bolt is aligned with the thread in
the tapped hole.
Figure 2-7
7. Check both rocker arms on cylinder No. 1 to make sure
there is clearance by moving the rocker arms up and down.
This insures cylinder No.1 is on the compression stroke.
NOTICE
If the access to the flywheel is not available, then an
optional method that is described below can be used.
Fuel Pump Method to obtain T.D.C.
1. Remove the plug from the fuel injection pump as shown
in Figure 2-8
Figure 2-8
2. Selectcorrecttimingpinidentifiedinsectionone-special
tools.
3. Insert timing pin in hole in fuel pump and slowly rotate
crankshaft counterclockwise until pin drops into slot.

3
The engine is now at cylinder No. 1 top dead center
compression stroke.
CAUTION
Do not bar engine with timing pin inserted in fuel
pump. Pin may be sheared off and cause engine
damage.
Figure 2-9
4. Mark crankshaft vibration damper to locate cylinder
#1 T.D.C. This mark will be required after engine brake
assembly for engine valve and engine brake adjustment.
5. Remove timing pin from fuel pump and install seal
plug back in pump.
Removal Of Fuel Tube
CAUTION
Avoid any contamination of fuel lines or nozzle
assemblies. Fuel contamination after fuel filters can
cause engine damages.
Figure 2-10
1. Removefuellines usingCaterpillar’sfuel linewrench.
2. Install protective caps on nozzle assemblies and put
fuel lines in clean plastic bags.
3. Install plastic plugs in open fuel lines.
Figure 2-11
Rocker Arm Removal
CAUTION
Install only one brake housing at a time to avoid
removing all six engine head bolts at once. Removing
six head bolts can cause head seating problems.
Figure 2-12
1. Loosen rocker arm adjusting screw locknuts.
2. Remove rocker arm hold-down bolts. Save washers for
reassembly.
Figure 2-13
3. Remove the rocker arm assembly from the engine.

4
Figure 2-14
4. Remove the exhaust valve bridges from the engine.
Figure 2-15
5. Back out the bridge adjusting screw. Leave loose; do
not tighten until placed on engine for leveling.
Bridge Leveling Procedure
Figure 2-16
1. Lubricate bore of exhaust valve bridge with clean
engine lubrication oil prior to installation on engine. Install
TecBrake exhaust bridges on the engine.
2. Level the TecBrake exhaust valve bridges :
a) Press on center of bridge with finger.
b) Loosen adjusting screw a couple of turns to insure
screw is not contacting valve stem.
c) Turn adjusting screw clockwise until contact with the
valve stem.
d) Turn adjusting screw an additional 30 degrees
(approximately ½ flat of screw).
e) Hold adjusting screw in position and torque jam nut to
24 lbft (32N*M).
f) Applycleanenginelubricationoiltotopofbridgewhere
rocker arm contacts.
g) Adjust (3) intake valve bridges using same procedure
as above.
Figure 2-17
3. Verifythereisatleast0.020”minimumclearancebetween
the bridge body and valve spring retainers on both sides of
bridge.
Changing Exhaust Rocker Adjusting Screws
Figure 2-18
1. Remove the slotted Caterpillar exhaust rocker adjusting
screws from the rocker arm.
2. Remove jam nuts from rocker adjusting screws.

3. Place jam nuts on TecBrake exhaust rocker adjusting
screws.
Figure 2-19
4. Install the TecBrake exhaust rocker screw in the
exhaust rocker arm.
5. Discard the Caterpillar slotted adjusting screws.
Removal of Dowel Pin
5
Figure 2-20
1. Place Dowel Pin Removal Tool in position to remove
the dowel pin that is located on the front end (fan side) of
the rocker shaft assembly.
2. Clamp dowel pin in dowel pin removal tool.
3. Removedowelpinbytighteningthetwo jackingscrew
in small equal increments (approximately ¼ turn each).
This process must be repeated on the other rocker shaft
assembly, also on the front end (fan side).
NOTE
The dowel pins that are being removed are located
at cylinder # 1 and cylinder # 4.
Figure 2-21
4. Apply clean engine lube oil to the end of the TecBrake
Oil Supply Adapter.
5. Insert adapter in removed dowel pin hole, making sure
pedestal and rocker shafts holes aline.
6. Completeadapterinstallationbyusing aplastic hammer
totapadapterdownuntillarge O.D.contactsrockerpedestal.
Do not install “O” ring on adapter at this time.
Rocker Arm Assembly Installation
Figure 2-22
1. Blow out oil that has gotten into cylinder head bolt holes
usingcompressed airwithasuitablelength ofhoseattached
to a nozzle. Use a clean rag to cover area to avoid oil from
spraying.
CAUTION
Eyeprotectionmust beworn. Personalinjuty canresult
if safety glasses are not used. Oil Must be blown out
of cylinder head bolt holes to prevent the engine block
from cracking when torquing of TecBrake hold-down
stud.
2. Apply clean engine oil to threads of the TecBrake studs
and contact area on top of pedestal, washer and stud hex.

3. Install two TecBrake studs on each end of the rocker
assemblyusing thewashermarked“A”betweenthehead
of the stud and the rocker support bracket.
4. Insert the rocker adjusting screws into the push tube
ends.
Figure 2-23
CAUTION
Prevent damaging lead wires on engines equipped
with glow plugs when installing rocker assemblies.
Figure 2-24
5. Center rocker assembly about TecBrake studs when
tighteningstuds. Boltrockerassemblyfirmlyinplacewhen
centered. Torquing procedure: Start with center bolt then
change to ends. Begin torquing sequence at 200 lbft
(270 N*M) and continue to increase toque at 50 lbft (70
N*M) increments until specification of 330 lbft (450 N*M)
is obtained.
Support Bracket Installation
6
Figure 2-25
1. Remove the two cylinder head bolts as shown on Figure
2-25 to install TecBrake outer support bracket.
Figure 2-26
2. Blowoutoilthat hasgottenintocylinderheadboltsusing
same procedure described before.
3. Apply clean engine oil to head bolt threads and to under
side of bolt hex and washer. Install support bases as
illustrated above. The boss on the bottom of the support
basewill fitintocylinderheadexpansionholeto locatebase.
4. Torque the head bolts to 200 lbft (270 N*M). Torque the
head bolts to 330 lbft (450N*M).
SECTION 3 - BRAKE HOUSING INSTALLATION
Engines with serial numbers lower than 7FB39279 and all
92U prefix engine require a procedure that is described in
“Leveling Procedure” on page #15 of this manual. Each
engine brake kit has a front and rear housing that is
identified by the plate attached to the top of the housing.
The front housing must be installed on the front three
cylinders (fan end) of the engine and the rear housing on
the rear three cylinders of the engine.
1. Install the spacer marked “B” on the brake hold down
stud as illustrated below.
Figure 3-1

Fuel Tube Installation
CAUTION
Do not bend or modify fuel lines as fuel leakage may
result. When installing new fule lines, use new
O’rings lubricated with clean engine oil.
2. Remove protective plug and cap from the fuel lines
and nozzles.
3. Hand tighten all fuel lines.
7
Figure 3-2
4. Torque to 30 lbft (41N*M) using the Caterpillar fuel
line socket wrench.
NOTE
Adequate clearance must be maintained between
the fuel line and the TecBrake hold down stud. After
torquing, a clearance of 0.125 in. (3.175mm) min. to
0.375 in. (9.525mm) max. is required. Repositioning
or interchanging of fuel lines may be required to
maintain the required clearance.
Figure 3-3
5. Apply a small amount of grease on O-ring and oil
supply adapter and carefully slid O-ring into groove in oil
supply adapter.
Figure 3-4
6. Prior to placing engine brake housing on engine, loosen
slave piston adjusting screws until slave pistons are seated
in bores. Locate brake housing on the two studs and lower
brake slowly to locate oil supply adapter into brake housing.
Figure 3-5
7. Place the spacer tubes between the housing and the
installed lower support bases. Install the two 7/16” bolts
with washers, taking care to align the tubes with the tapped
holes in the support bracket.
Figure 3-6
8. Installthe3/4”washersandnutson theholddownstuds.
Hand-tightenthenutsintothe stud. Torque theenginebrake
fasteners to the following specifications:

Torque hold down nuts to 60 lbft 882 N*M). Torque the
7/16” capscrews to 60 lbft (82 N*M). Torque again the
hold down nuts to 100 lbft (135 N*M).
NOTE:
Check to make sure fuel lines have clearance
between brake and engine components. Reposition
fuel lines if necessary.
9. Use same procedure on the other engine brake
housing installation.
10. Both engine brake housings should now be installed.
The next step is to adjust the exhaust and intake valves
on the engine and the slave pistons of the engine brake.
The engine position should be on cylinder #1 TDC
compression stroke to start the adjustment procedure.
Valve Adjustment Procedure
Figure 3-7
Engine Set Int. Set Exh. Set Lash.
Position Valve Cyl. Valve Cyl. Slave Cyl.
Cyl. 1 TDC 1,2,4 1,3,5 1,3,5
Cyl. 6 TDC 3,5,6 2,4,6 2,4,6
Table 3.1
1. Using the table above, set the exhaust and intake
valves that can be set when cylinder #1 is at TDC. Set
intake valves to 0.015” (0.38mm) and exhaust valves to
0.030”(0.76mm). Reviewenginemanualtoconfirmvalve
setting values. After setting the valves, the slave piston
lash can be set on the cylinders specified. When setting
slave lash, the exhaust bridge and exhaust rocker must
be loose and have clearance.
2. Torque rocker adjusting screw jam nut to 22 lbft (30
N*M).
Slave Piston Adjusting Procedure
1. Select correct slave lash (Table 3.2) and cylinders to
be adjusted from table 3.1
CAUTION
For optimum performance and to prevent engine
damage make sure that correct lash is selected and
care is taken in adjustment procedure. Slave piston
adjustment must be done when engine temperature is
stabilized and cold and not running. A cold engine is
defined when engine coolant temperature is below 140
degrees F (60 degrees C).
Engine Model Engine Slave
Yr./Prefix Rating (HP) Lash
3406 92U All 0.060” (1.52 mm)
3406B Pre-91 4MG, All 0.080 in. (2.03mm)
5YG, 7FB, 8TC
3406B 3ZJ16181 & All except 400 0.080 in. (2.03mm)
below
3406B 3ZJ16181 & 400 0.067 in. (1.70mm)
below
3406C 3ZJ16182 & 310-350 0.080 in. (2.03mm)
greater
3406C 3ZJ16182 & 365-460 0.090 in. (2.28mm)
greater
3406B 5KJ All except 400 0.080 in. (2.03mm)
3406B 5KJ 400 0.067 in. (1.70mm)
3406C 5KJ 310-350 0.080 in. (2.03mm)
3406C 5KJ 365-460 0.090 in. (2.28mm)
3406C 8PN All 0.080 in. (2.03mm)
Table 3.2
Figure 3-8
2. Insertcorrectfeelergaugebetweenbothfeet oftheslave
piston and the crosshead bridge. Lossen slave piston jam
nutandscrewdownslavepistonadjustingscrewuntil aslight
drag is felt when the feeler gauge is moved. Torque jam nut
to16lbft (22 N*M). Finishadjustingthe twoengineposition.
3. Remove timing bolt and rotate engine one revolution
(360 degrees) and reinstall timing bolt. Now engine is at
cylinder#TDC. Finish adjustingexhaust,intake andslave
piston settings for the remaining three cylinders.
4. Remove timing bolt and install timing bolt and access
cover to proper location.
8

Lower Base/ Spacer Installation
Figure 3-9
1. Install both lower cover bases on engine and check
for possible interference between cover internal bosses
and exhaust bridges on cylinder #3 and cylinder #6. If
there is any interference, remove base and grind lower
cover base to provide clearance.
CAUTION
Do not grind exhaust valve bridge to provide
clearance. Grinding bridge will reduce strength and
may cause severe engine damage.
Figure 3-10
2. Attach the lower cover base with the four supplier
mounting studs and washers. Install the short-threaded
end of the stud into the cylinder head. The figure above
shows the location of the studs.
Figure 3-11
3. Install Caterpillar screws on remaining locations.
4. Torque spacer studs and the other two bolts securing
the spacer to 10 lbft (13.5 N*M).
Figure 3-12
5. Installelectricalterminallead-outassemblyinspacerwith
a six point socket. Tighten until terminal assembly hex
contacts spacer.
Figure 3-13
6. Install the TecBrake gasket in spacer. Gasket length will
have to be trimmed after assembly.
Figure 3-14
7. Install valve cover spacer on lower base using vibration
resistant nuts supplied in the kit on the four mounting studs.
Torque both studs and nuts to 13 lbft (18 N*M).
9