Bendix Commercial Vehicle Systems AH-1B AIR HYD INTENSIFIER 4/04 - Manual (Page 6)

6
FIGURE 7
FIGURE 8
FIGURE 9
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.
2. Disconnect the air line from the air actuator and cover
the end of the air line.
3. Remove the electrical connection from the low level
indicator on the reservoir cover.
4. Remove the hardware that secures the mounting bracket
of the AH-1B ™ intensifier to the vehicle and remove the
complete unit.
INSTALLING ON VEHICLE
1. Install the hardware which secures the AH-1B ™ intensifier
mounting bracket to the vehicle. Torque all hardware per
the vehicle manufacturer’s recommendations.
2. Reconnect the air line to the actuator. Use a small amount
of thread sealant.
3. Reconnect the hydraulic line to the master cylinder.
4. Connect the electrical terminal from the low fluid indicator
onto the terminal on the cap of the reservoir.
5. Fill the master cylinder fluid reservoir using the type and
grade fluid specified by the vehicle manufacturer.
6. Bleed the hydraulic brakes following the vehicle
manufacturer’s recommended procedure.
7. Refill the master cylinder fluid reservoir to replace fluid
lost during the bleeding procedure.
DISASSEMBLY
General
The following procedure is presented for reference only.
Disassembly of the AH-1B
™ intensifier should not be
attempted without having the appropriate maintenance kits
or replacement parts on hand as some parts may be
damaged during disassembly.
1. Drain the hydraulic fluid from the reservoir.
2. 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.
3. Remove the reservoir cap and retain. DO NOT
DISASSEMBLE CAP. Using a 1-1/4" socket remove the
retaining nut on the inside of the reservoir. Reservoir is
now free of the master cylinder. Remove the seal on the
bottom of the reservoir and discard. (Refer to Figure 6.)
4. Remove the compensating valve assembly from the
master cylinder by placing a crescent wrench across
the flats and turning counterclockwise. If only changing
the reservoir, do not remove the compensating valve
assembly as it cannot be replaced unless the master
cylinder is disassembled. The compensating valve must
be replaced as an assembly (Figure 7).