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ZEXEL
105411-2150
1054112150
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105411-2150
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start by:a) remove flywheel 1. Disconnect oil line (1) from the BrakeSaver housing. 2. Remove the bolts and disconnect flanges (2) from the housing. 3. Remove four bolts, manifold (3) and the gasket from the bottom of the BrakeSaver housing. 4. Install tooling (A) on the BrakeSaver housing and rotor. This prevents damage to the rotor and seals when the BrakeSaver is removed. 5. Disconnect two air lines (4) and (5) at the air compressor. 6. Install tooling (B) and fasten a hoist to it. 7. Remove three bolts (6) from the BrakeSaver housing.8. Install two 3/8"-16 NC forcing screws (7) and remove the BrakeSaver. The weight of the BrakeSaver is 168 lb. (76 kg).Install BrakeSaver
1. Install tooling (B) on the BrakeSaver.2. Install two 5/8"-11 NC x 15" guide bolts (1).3. Put BrakeSaver (3) in position with the use of tooling (A) and a hoist.4. Make an alignment of dowel (2) in the crankshaft and the hole in the BrakeSaver. 5. Connect two air lines (4) and (5) to the air compressor. 6. Put O-ring seals (6) and (8) in position on the manifold.7. Put manifold (7) in position and install the bolts. 8. Put the gaskets and manifolds (9) in position and install the bolts. 9. Connect oil line (10) to the BrakeSaver housing.Disassemble BrakeSaver
start by:a) remove BrakeSaver1. Remove tool (A) from the BrakeSaver rotor and housing. Tool (A) prevents damage to the rotor seals and rings at removal of the BrakeSaver. 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 seal (11) from around the housing and the six smaller seals from the oil lines.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. Put clean SAE 30 engine oil on the O-ring seal. Install seal (2) on sleeve (1).2. 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.3. Turn the housing over and install the spiral ring that holds the sleeve in the housing.
Make certain there is clearance behind the spiral ring when it is correctly installed.
4. Heat the carriers and the wear sleeves to a maximum temperature of 300°F (149°C). 5. Install carrier (5) on each side of rotor (3). Install wear sleeve (4) with the taper edge of sleeve in the "UP" position. Make sure the carrier is at bottom on the rotor
1. Install tooling (B) on the BrakeSaver.2. Install two 5/8"-11 NC x 15" guide bolts (1).3. Put BrakeSaver (3) in position with the use of tooling (A) and a hoist.4. Make an alignment of dowel (2) in the crankshaft and the hole in the BrakeSaver. 5. Connect two air lines (4) and (5) to the air compressor. 6. Put O-ring seals (6) and (8) in position on the manifold.7. Put manifold (7) in position and install the bolts. 8. Put the gaskets and manifolds (9) in position and install the bolts. 9. Connect oil line (10) to the BrakeSaver housing.Disassemble BrakeSaver
start by:a) remove BrakeSaver1. Remove tool (A) from the BrakeSaver rotor and housing. Tool (A) prevents damage to the rotor seals and rings at removal of the BrakeSaver. 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 seal (11) from around the housing and the six smaller seals from the oil lines.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. Put clean SAE 30 engine oil on the O-ring seal. Install seal (2) on sleeve (1).2. 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.3. Turn the housing over and install the spiral ring that holds the sleeve in the housing.
Make certain there is clearance behind the spiral ring when it is correctly installed.
4. Heat the carriers and the wear sleeves to a maximum temperature of 300°F (149°C). 5. Install carrier (5) on each side of rotor (3). Install wear sleeve (4) with the taper edge of sleeve in the "UP" position. Make sure the carrier is at bottom on the rotor
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105411-2150