Usage:
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 to it.
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 86 kg (190 lb.)
Install BrakeSaver
1. Install tooling (A) on the 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 to it.
3. Install two 5/8" - 18 NC guide bolts (9) in the crankshaft as shown. Make sure dowel (8) is in alignment with the dowel hole in the rear assembly, and put BrakeSaver housing (7) 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 (9).
5. Connect the oil line to fitting (5).
6. Inspect the O-ring seals for damage, and make replacements if needed. Install O-ring seals (10) and (11). Put clean engine oil on the O-ring seals.
7. Install manifold (12) into the BrakeSaver control valve, and install the four bolts that hold the manifold to the BrakeSaver housing.
8. Connect BrakeSaver lubrication oil line (1) 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 BrakeSaver housing and rotor.
NOTE: Tooling (A) prevents damage to the rotor seals and rings during removal of the BrakeSaver housing.
2. Remove bolts (1) from gear plate (2). Remove the plate.
3. Put alignment marks on stator (3) and housing (4) for assembly purposes. 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 engine oil on the O-ring seals.
2. Install O-ring seal (16) on sleeve (17).
3. Install the sleeve in the BrakeSaver housing. Make an alignment of the notch (18) on 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 to a maximum temperature of 149° C (300° F).
NOTE: Make sure the carrier is at bottom on the rotor.
6. Install carrier (13) on each side of rotor (12).
7. Install a seal ring (10) in each of the carriers.
8. Install the rotor assembly in BrakeSaver housing (4).
9. Install O-ring seal (7) on the sleeve. Install sleeve (9) in the stator. Make and alignment on the notch in the sleeve with the dowel in the stator.
10. Turn the stator over, and install spiral ring (6) that holds the sleeve in the stator.
11. Install O-ring seal (19) and six smaller seals (20) for the oil holes on the housing.
12. Put the stator in the correct location on the housing with respect to the alignment marks put on at removal. Make sure 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 55 ± 7 N*m (41 ± 5 lb.ft.).
14. Turn the housing over. The weight is 73 kg (160 lb.).
15. The following steps are to be used with tooling (C) to install the spiral groove type seals.
a. Clean and make preparation of the wear sleeve inside diameter and rotor outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to the rotor outside diameter before the wear sleeve is installed on the rotor. Do not let any Quick Cure Primer Retaining Compound get on the lip of the seal.
b. Install the 8T2856 Bar (21) with four S1594 Bolts.
c. Turn the housing over, and install the 5P3594 locator (22) and the bolts on the rotor.
d. Put the wear sleeve and seal as a unit in position on the locator.
| NOTICE |
|---|
The BrakeSaver seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read special Instruction Form SMHS8508 that is included with each seal and wear sleeve before any handling of the seal group is made. |
NOTE: Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.
| NOTICE |
|---|
The later design seal and wear sleeve have different spiral grooves in the seal. Because of this type of design, the rear seal group for an engine is different from the front seal group. If a seal group is installed on the wrong end of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine. |
e. Put the 8T2855 Installer (23) in position on the locator.
f. Put clean engine oil on the face of the 9S8858 nut (24) and its contact area on installer (23). Install nut (24) on the locator.
g. Tighten nut (24) until installer (23) makes contact with the rotor.
h. Remove tooling (C) from the BrakeSaver. Tooling (C) will install the seal and wear sleeve to the correct depth.
16. Remove tooling (C) from the BrakeSaver.
17. Install bar (21) on the rotor as shown.
18. Turn the BrakeSaver over and follow steps 15c through 15h to install the seal and wear sleeve.
NOTE: It may be necessary to use a wrench (25) to hold bar (21) to prevent the rotor from turning while installing the seal and wear sleeve.
19. Install tooling (A) to the rotor and housing.
NOTE: Tooling (A) will prevent damage to the rotor seals as rings at installation.
20. Turn the housing over, and install gear plate (2) and the bolts that hold it on the rotor.
End By:
a. install BrakeSaver