Usage:
Remove Brakesaver
start by:
a) remove flywheel (BrakeSaver)
1. Disconnect BrakeSaver lubrication oil line (1) from the fitting in the BrakeSaver housing.
2. Disconnect the oil line from fitting (5).
3. Remove two short bolts (2) and two longer bolts (4) that hold manifold (3) to the BrakeSaver housing. Remove manifold (3) from the BrakeSaver control valve.
4. Remove the O-ring seals from the manifold.
NOTE: The two longer bolts (4) from the manifold can be used as forcing screws to remove the BrakeSaver from the flywheel housing.
5. Install a 3/8"-16 NC forged eyebolt in the top of the BrakeSaver housing and fasten a hoist.
6. Install tooling (A) on the BrakeSaver housing and rotor.
NOTE: Tooling (A) holds the BrakeSaver housing and rotor assembly together at removal. This prevents damage to the rotor rings and seals.
7. Remove bolts (6) that hold BrakeSaver housing (7) to the flywheel housing.
8. Use bolts (4) as forcing screws and tighten the bolts evenly to remove BrakeSaver housing (7) from the flywheel housing. The weight is 190 lb. (86 kg).
Install Brakesaver
1. Install tooling (A) on BrakeSaver housing and rotor.
NOTE: Tooling (A) holds the BrakeSaver housing and rotor assembly together at installation. This prevents damage to the rotor rings and seals.
2. Install a 3/8"-16 NC forged eyebolt in the top of the BrakeSaver housing and fasten a hoist.
3. Install two 5/8"-18 guide pins (3) in the crankshaft as shown. Make sure dowel (2) is in alignment with the dowel hole in the rotor assembly and put BrakeSaver housing (1) in position in the flywheel housing.
4. Install the three bolts that hold the BrakeSaver housing to the flywheel housing. Remove tooling (A) and guide pins (3).
5. Connect the oil line to fitting (6).
6. Inspect the O-ring seals for damage and make replacements if needed. Install O-ring seals (4) and (5). Put clean oil on the O-ring seals.
7. Install manifold (7) into the BrakeSaver control valve and install the four bolts that hold the manifold to the BrakeSaver housing.
8. Connect BrakeSaver lubrication oil line (8) to the fitting in the BrakeSaver housing.
end by:
a) install flywheel (BrakeSaver)
Disassemble Brakesaver
start by:
a) remove BrakeSaver
1. Remove tooling (A) from the BrakeSaver housing and rotor.
NOTE: Tooling (A) prevents damage to the rotor seals and rings at removal of the BrakeSaver housing.
2. Remove bolts (1) from gear plate (2). Remove the plate.
3. Make identification as to the location of stator (3) with housing (4). Remove bolts (5) and the stator.
4. Turn the stator over and remove spiral ring (6).
5. Turn the stator over again. Remove sleeve assembly (9). Remove O-ring seal (7) and lip type seal (8) from the sleeve.
6. Remove O-ring seal (11) and the six smaller O-ring seals from the oil holes on the housing.
7. Remove rotor assembly (12).
8. Remove seal ring (10) from both sides of the rotor.
9. Remove carrier (13) and wear sleeve (14) with tooling (B) from both sides of the rotor.
10. Remove spiral ring (15). Turn the housing over and remove sleeve assembly (17). Remove the lip type seal and O-ring seal (16) from the sleeve.
Assemble Brakesaver
1. Inspect the O-ring seals for damage and make replacements if needed. Put clean oil on the O-ring seals.
2. Install O-ring seal (2) on sleeve (1).
3. Install the sleeve in the BrakeSaver housing. Make alignment of the notch in the sleeve with the notch in the housing and install the dowel.
| NOTICE |
|---|
Make certain there is clearance behind the spiral ring when it is correctly installed. |
4. Turn the housing over and install the spiral ring that holds the sleeve in the housing.
5. Heat the carriers and the wear sleeves to a maximum temperature of 300°F (149°C).
NOTE: Make sure the carrier is at bottom on the rotor and the sleeve is against the carrier.
6. Install carrier (5) on each side of rotor (3). Install wear sleeve (4) with the taper edge of sleeve in the "UP" position.
7. Install a seal ring (7) in each of the carriers.
8. Install the rotor assembly in BrakeSaver housing (6).
9. Install O-ring seal (8) on the sleeve. Install sleeve (9) in the stator. Make alignment of the notch in the sleeve with the dowel in the stator.
10. Turn the stator over and install spiral ring (10) that holds the sleeve in the stator.
11. Install O-ring seal (11) and six smaller seals (12) for the oil holes on the housing.
12. Put the stator in the correct location on the housing with respect to the identification put on at removal. Make sure the oil holes in the stator and in the housing are in alignment.
13. Install the bolts that hold the stator to the housing. Tighten the bolts to a torque of 40 ± 5 lb.ft. (55 ± 7 N·m).
14. The following steps are to be used with tooling (A) to install the lip type seals.
a) Put clean engine oil on the lip of the seals.
b) Put the pilot inside the seal. Install pilot and seal with the inside taper of the pilot against the wear sleeve.
NOTE: The lip of the seals must be toward the rotor.
c) Install locator (13) and bolts (14) on the rotor.
d) Put ring (17) over the locator and pusher plate (15) on the ring.
e) Tighten nut (16) on the locator until tooling (A) is at bottom.
15. Install gear plate (18) and the bolts that hold it on the rotor.
16. Carefully turn the housing over and do Step 14 again to install the other lip type seal on the rotor.
17. Install tooling (B) to the rotor and the housing.
NOTE: Tooling (B) will prevent damage to the rotor seals and rings at installation.
end by:
a) install BrakeSaver