Bendix Commercial Vehicle Systems AH-1B AIR HYD INTENSIFIER 4/04 - Manual (Page 4)

4
TECHNICAL SPECIFICATIONS
AH-1B ™ Air Hydraulic Intensifier Assembly
Power ratio - 20.2 to 1
Weight - approximately 2-1/2 pounds
Air Actuator
Effective area of diaphragm at 2-1/8 inches of push rod stroke
- approximately 28 sq.in.
Volume at 2-1/8 inches of push rod stroke - approximately
75 cubic inches.
Master Cylinder
Bore diameter - 1.38 inches
Maximum piston stroke - 2-1/8 inches
Maximum fluid displacement - 3.17 cubic inches
Fluid Reservoir
Volume - 33.5 cubic inch to “MAXIMUM” level mark with
cap removed.
PREVENTIVE MAINTENANCE
Every month, after 8,000 miles, or 300 operating hours;
1. Remove accumulated dirt and grime from the area
around the reservoir cover. With the ignition switch in
the on position, remove the cover and hold in an upright
position and allow brake fluid in the tube of the cap to
drain back into the reservoir. Check to see if the low
fluid indicator bulb is operating (in cab of vehicle).
2. If the fluid level is low, fill to proper level indicated on the
side of the reservoir. CAUTION: Fill the reservoir with
type and grade of fluid recommended by the vehicle
manufacturer.
3. Check tightness of the mounting nuts, air and hydraulic
fittings.
4. Make a visual inspection of air and hydraulic lines for
kinking, bending or fraying. Replace as necessary.
Every 12 months; 100,000 miles; or 3,600 operating hours;
1. Perform the operating and leakage tests. Replace or
repair components or assemblies as indicated using
only genuine Bendix parts.
OPERATING AND LEAKAGE TESTS
1. With vehicle air system pressure built to governor cut-out,
make and hold a full brake application. Hold for at least
5 minutes. Using a soap solution, check for air leaks at
fittings and air lines. Tighten and/or replace as necessary.
Apply a soap solution around the actuator clamp ring.
No leakage is permitted. Tighten or replace as necessary.
Apply a soap solution to the actuator non-pressure plate
drain holes. Replace the actuator diaphragm if leakage
is detected.
2. While holding the brake valve in the fully applied position,
check for hydraulic fluid leaks at all fitting connections
and at the hydraulic cylinders in the foundation brake.
Check for fluid leakage at the drain holes of the actuator
non-pressure plate. Repair or replace components as
necessary.
3. With the reservoir filter cap removed apply and fully
release the brakes several times while observing the fluid
in the reservoir. CAUTION: WEAR SAFETY GLASSES
AS FLUID MAY EXIT THE RESERVOIR.
A slight fluid turbulence should be noted at the beginning
of the application and should immediately cease. If
prolonged turbulence is noted, the master cylinder must
be repaired or replaced.
WARNING! PLEASE READ AND FOLLOW
THESE INSTRUCTIONS TO
AVOID
PERSONAL INJURY OR DEATH:
When working on or around brake systems and
components, the following precautions should be
observed at all times:
1. Park the vehicle on a level surface, apply the
parking brakes, and always block the wheels.
When working around or under the vehicle, stop
the engine and remove the key from the ignition.
Always keep hands away from chambers as they
may apply as system pressure drops. Always wear
safety glasses.
2. When working in the engine compartment, the
engine should be shut off and the ignition key
should be removed. Where circumstances require
that the engine be in operation, extreme caution
should be used to prevent personal injury resulting
from contact with moving, rotating, leaking, heated
or electrically charged components.
3. Do not attempt to install, remove, disassemble or
assemble a component until you have read and
thoroughly understand the recommended
procedures. Use only the proper tools and observe
all precautions pertaining to the use of those tools.
4. Following the vehicle manufacturer’s
recommended procedures, deactivate the electrical
system in a manner that safely removes all
electrical power from the vehicle.
5. If the vehicle is equipped with an air over hydraulic
brake system or any auxiliary pressurized air
system, make certain to drain the air pressure from
all reservoirs before beginning ANY work on the
vehicle. If the vehicle is equipped with an AD-IS
™
air dryer system or a dryer reservoir module, be
sure to drain the purge reservoir.
6. Never connect or disconnect a hose or line
containing pressure; it may whip. Never remove a
component or pipe plug unless you are certain all
system pressure has been depleted.
7. Never exceed manufacturer’s recommended
pressure.