Bendix Commercial Vehicle Systems AH-1B AIR HYD INTENSIFIER 4/04 - Manual (Page 8)

8
FIGURE 11
2. Place the push rod and diaphragm assembly into the
pressure plate and place non-pressure plate onto the
push rod. Check to assure that the spring is in proper
position (each end contained and centered in the spring
guides).
3. Orient the pressure and non-pressure plates as marked
and compress the spring by pushing down on the
non-pressure plate. Retain with a clamp or light pressure
from a press. Be sure the ferrule on the pressure plate
is properly oriented and the edges of the non-pressure
plate, diaphragm, and pressure plate are equally
distributed around the entire circumference.
4. Install clamping ring and retain with the two bolts and
nuts. Torque to 130-150 inch pounds. 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.
5. Install a new gasket on the mounting studs of the
nonpressure plate of the assembled actuator and put
the assembly aside.
Master Cylinder Assembly
6. Install new o-rings on the master cylinder mounting flange
and the master cylinder piston.
7. Carefully insert the spring and piston into the master
cylinder body. Making certain not to damage the seal
and o-ring. The lip seal and o-ring must enter the body
last. Depress and hold the piston by inserting a dull
object into the recess in the end of the piston. Piston
actuator lip should be completely past the compensating
TRT valve assembly port to allow for proper installation
of the compensating valve assembly. Install the
compensating valve assembly into the threaded port of
the top of the master cylinder. Be sure compensating
valve is installed between the two larger diameters on
the piston. Torque to 30-40 foot pounds. NOTE: The
compensating valve assembly should retain the piston
assembly in the master cylinder if installed correctly.
(See Figure 10.)
8. 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. Install the two
Phillips screws and lockwashers and tighten snugly.
9. Install the reservoir retaining nut onto the compensating
valve through the reservoir cover opening. Use a 1-1/4"
socket and torque to 13-16 foot pounds.
10. Install the reservoir filler cap assembly on the reservoir.
11. Clamp the mounting bracket securely in a vise, making
sure it is oriented so that the unit may be assembled,
and lining up the marks made prior to disassembly.
12. Install the new gasket(6) over the mounting studs of the
brake chamber. Make sure the gasket is flat against the
top of the brake chamber.
13. Place the brake chamber onto the mounting bracket with
the push rod extending through the center hole and the
mounting bolts extending through the outer holes.
14. Install the master cylinder/reservoir assembly onto the
brake chamber mounting studs and retain with nuts(4)
and washers(5). Torque to 100-115 foot pounds. NOTE:
The end of the push rod must enter the recess of the
master cylinder piston.
Bench Bleeding
Before installing the AH-1B ™ intensifier assembly on the
vehicle the master cylinder should be bench bled. Follow
the vehicle manufacturer’s recommendations in lieu of the
following.
1. Plug outlet port and secure cylinder in a vise with front
end tilted slightly downward. NOTE: Bleeder tubes or
Bendix bleeding kit #74013 may also be used following
the kit instructions enclosed. (Refer to Figure 11.)
2. Fill reservoir with brake fluid. Refer to vehicle
manufacturer’s manual for fluid requirements.
3. Apply and release air pressure to the actuator several
times.
4. Re-position the master cylinder in the vise with the front
end tilted slightly up. Again, apply and release air
pressure several times. NOTE: When using this method
of bench bleeding, the master cylinder will not be capable
of being stroked once all the air is removed.
5. Install the AH-1B ™ intensifier on the vehicle and perform
the “Operating and Leakage Tests” prior to placing the
vehicle in service.
BW1599 © 2004 Bendix Commercial Vehicle Systems LLC All rights reserved. 4/2004 Printed in U.S.A.