3819408 Volvo.Penta Heat exchanger

Do not disconnect any air lines until the air pressure is zero.
1. Loosen the bleed valves and release the air pressure in the air tanks.2. Drain the oil from the oil pan into a suitable container for storage or disposal. 3. Remove bolt (2) and bolt (3) from manifold (4) and the BrakeSaver housing.4. Remove bolt (5) and bolt (6) from manifold (4) and the BrakeSaver housing.5. Remove manifold (4) and tube assemblies (1). Remove the O-ring seals from the manifold. 6. Remove bolt (7) and retainer (8) that hold the oil lines in the BrakeSaver control valve. 7. Disconnect oil lines (9) and (10) from the oil cooler. Remove oil lines (9) and (10) from the BrakeSaver control valve.
Typical Example8. Remove bolts (12) and BrakeSaver control valve (11) from under the oil pan. The weight is approximately 22 kg (48 lb).9. Remover elbow (13) from the BrakeSaver control valve. Remove the O-ring seals. The following Steps are for installation of the BrakeSaver control valve.10. Inspect the O-ring seals for damage, and make replacements if needed. Put clean engine oil on the O-ring seals.11. Install the O-ring seals and elbow (13) on the BrakeSaver control valve.12. Make sure the O-ring seals are in position on the face of the BrakeSaver control valve. Put BrakeSaver control valve (11) in position under the oil pan. Install bolts (12) that hold the BrakeSaver control valve to the oil pan.13. Install the O-ring seals on manifold (4). Install manifold (4) in the BrakeSaver control valve. Install the four bolts that hold the manifold to the BrakeSaver housing.14. Make sure the O-ring seals are in place on the oil lines, and install oil lines (9) and (10).15. Install retainer (8) to hold the oil lines in the BrakeSaver control valve. If the bottom plug in the oil pan was removed, put the split (seam) of the gasket for the plug against the oil pan. If either plug on the side of the oil pan was removed, put 5P-3413 Pipe Sealant With Teflonon the threads, and tighten the plug to a torque of 80 11 N m (60 8 lb ft).16. Fill the engine with oil to the correct level. See the Operation & Maintenance Manual.Disassemble & Assemble BrakeSaver Control Valve
Start By:a. remove BrakeSaver control valve. Fluid Spillage ContainmentCare must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates. 1. Remove O-ring seals (1) from the valve body.
Covers (3) and (4) hold a spring under compression. To prevent possible personal injury from flying parts, hold covers (3) and (4) when the bolts are removed.
2. Remove four bolts (2) slowly and evenly from cover (4). Remove the cover.3. Remove cover (3) and the seal from the opposite end of the valve body. 4. Remove spool (8) as an assembly.5. Remove spring (7), stop (10), spring (6) and slug (9).6. Remove the O-ring seals and sleeve (5). 7. Remove bolt (11), plate (13) and diaphragm (12) from the spool. Inspect the pin on the spool, and make a replacement of the pin if there is damage or wear. The following Steps are for assembly of the BrakeSaver control valve.
When diaphragm (12) is installed on valve spool (8) make sure the fabric side is pulled down over the valve spool to make contact with it and the smooth (rubber coated) side is next to the valve body.
8. Put diaphragm (12) in position on valve spool (8).9. Align the hole in plate (13) with the pin in valve spool (8) and install the plate.10. Install bolt (11).11. Install sleeves (5) and the O-ring seals.12. Put spring (7), stop (10), spring (6) and slug (9) in position in valve spool (8).13. Install valve spool (8) into the valve body. As the valve is installed, make sure the edge at the diaphragm makes contact all the way around with the groove in the valve body. At this time the valve spool end must extend approximately 38.1 mm (1.50 in)from the valve body. Push the valve spool approximately 6.4 to 12.7 mm (.25 to .50 in)farther into the valve body until a curved depression is caused between the valve spool and valve body. Make sure there are no wrinkles in the diaphragm.14. Install covers (3) and (4) on the valve body.15. Install three O-ring seals (1).End By:a. install BrakeSaver control valve.