User manual BENDIX AH-1B AIR HYD INTENSIFIER

[. . . ] ® Bendix® AH-1BTM Air Hydraulic Intensifier ELECTRICAL FLUID LEVEL INDICATOR CONNECTION RESERVOIR CAP BRAKE FLUID RESERVOIR AIR INLET PORT ACTUATOR BRAKE FLUID DELIVERY PORT MASTER CYLINDER MOUNTING BRACKET NON-PRESS PLATE CLAMP RING AIR INLET PRESSURE PLATE DIAPHRAGM ELECTRICAL CONNECTOR RETURN SPRING BOOT INDICATOR SWITCH FILLER CAP ASSY. DELIVERY PORT RETURN SPRING PISTON ACTUATOR LIP PUSH ROD SEAL O-RING PISTON MOUNTING BRACKET DRAIN HOLE FIGURE 1 DESCRIPTION The AH-1BTM air hydraulic intensifier is a hydraulic brake, power booster which utilizes compressed air for its power assist. Its function is to convert air pressure to hydraulic pressure for use in the brake system. The AH-1BTM intensifier consists of three major component groups; a specially designed type 30 air actuator is bolted to a single piston master cylinder which incorporates an integral brake fluid reservoir. [. . . ] RETAINING NUT RESERVOIR RESERVOIR CAP ASSEMBLY COMPENSATING (TILT) VALVE ASSEMBLY RESERVOIR MTG. PAD ACTUATOR NUT (2) O-RING CLAMP RING SEAL WASHER (2) MASTER CYLINDER BODY LOCKWASHER (2) SPRING O-RING PISTON ASSY. (W/ SEAL) PHILLIPS SCREW (2) MOUNTING BRACKET GASKET FIGURE 5 - EXPLODED VIEW 8. Never attempt to disassemble a component until you have read and understand all recommended procedures. Some components contain powerful springs and injury can result if not properly disassembled. Use only proper tools and observe all precautions pertaining to use of those tools. Use only components, devices and mounting and attaching hardware specifically designed for use in hydraulic brake systems. must be of equivalent size, type and strength as the original equipment. Components with stripped threads or damaged parts should be replaced rather than repaired. Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer. Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition. FIGURE 6 5 REMOVAL FROM VEHICLE 1. Disconnect the hydraulic line from the delivery port of the master cylinder and plug the line. Allow the hydraulic fluid from the master cylinder to drain into a suitable container. Disconnect the air line from the air actuator and cover the end of the air line. Remove the electrical connection from the low level indicator on the reservoir cover. Remove the hardware that secures the mounting bracket of the AH-1BTM intensifier to the vehicle and remove the complete unit. INSTALLING ON VEHICLE 1. Install the hardware which secures the AH-1BTM intensifier mounting bracket to the vehicle. Torque all hardware per the vehicle manufacturer's recommendations. Connect the electrical terminal from the low fluid indicator onto the terminal on the cap of the reservoir. Fill the master cylinder fluid reservoir using the type and grade fluid specified by the vehicle manufacturer. Bleed the hydraulic brakes following the vehicle manufacturer's recommended procedure. Refill the master cylinder fluid reservoir to replace fluid lost during the bleeding procedure. FIGURE 8 1. [. . . ] IMPORTANT: Be sure the beads of the pressure plate and the non-pressure plate are contained by the clamping ring a full 360°. Tap around the circumference of the clamp ring to assure it is seated evenly all around. Install a new gasket on the mounting studs of the nonpressure plate of the assembled actuator and put the assembly aside. Install new o-rings on the master cylinder mounting flange and the master cylinder piston. [. . . ]