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. [. . . ] Use only components, devices and mounting and attaching hardware specifically designed for use in hydraulic brake systems. All replacement hardware, tubing, hose, fittings, etc. 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. Remove reservoir cover to facilitate drainage. 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. Reconnect the hydraulic line to the master cylinder. 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. Drain the hydraulic fluid from the reservoir. Remove the two Phillips screws and lockwashers from the bottom of the reservoir located at the reservoir mounting pad on the master cylinder next to the flange. Using a 1-1/4" socket remove the retaining nut on the inside of the reservoir. [. . . ] Be sure compensating valve is installed between the two larger diameters on the piston. NOTE: The compensating valve assembly should retain the piston assembly in the master cylinder if installed correctly. Install a new seal on the bottom of the reservoir and place both on the master cylinder. Be sure reservoir is oriented so that holes for the Phillips screws line up with the holes on the master cylinder. [. . . ]