Bendix Commercial Vehicle Systems AH-4 AIR HYD INTENSIFIER 4/04 User Manual

Page 2

OUTER DIAPHRAGM

CLAMP

FIGURE 1

DIAPHRAGM

GUIDE

STROKE WARNING SWITCH

FILTER

3. Observe the stroke warning light. If the master cylinder

piston seal leaks, the master cylinder, under sustained
pressure, will slowly stroke until the stroke warning switch
is activated.

REMOVAL FROM VEHICLE

1. Disconnect the hydraulic line from the delivery port of

the master cylinder and allow the hydraulic fluid to drain
into a suitable receptacle. The drainage may be
expedited by removing the reservoir cover and gasket.

2. Disconnect the air line from the rotochamber, the fluid

supply line from the master cylinder (in the case of
remote mounted reservoirs), and the electrical
connections from the stroke warning switch mounted in
the head of the rotochamber.

3. Remove the nuts from the studs which hold the mounting

brackets and remove the AH-4

™

intensifier from the

vehicle.

INSTALLING ON VEHICLE

1. Remount the AH-4

™

intensifier, reconnect the air delivery

line to the rotochamber and the electrical connections
to the stroke warning switch.

2. In the case of remote mounted reservoir, reconnect the

reservoir to the master cylinder.

3. Before adding hydraulic fluid, cycle the AH-4

™

intensifier

very carefully by making a very light brake application.
The rotochamber should extend to full stroke and operate
the stroke warning switch, causing the warning light to
come on in the cab. This will test the stroke warning
system. Release the application and reset the stroke
warning switch.

4. Remove plugs, reconnect the fluid lines and bleed the

master cylinder. The master cylinder itself may be bled
by gravity by filling the reservoir and opening the bleeder
fitting opposite the discharge port. When clear fluid flows
from the bleeder fitting, it may be closed. If the rest of
the system needs bleeding, it may be done by opening
the appropriate bleed fitting and cycling the AH-4

™

intensifier. Hydraulic brake fluid equivalent to DOT 3
specifications should always be used. Some AH-4

™

intensifier units are designed to be used with mineral
oil, in which case, the reservoir cover will clearly so
designate. Rubber parts for use with mineral oil are color
coded. Reservoir gasket diaphragm is green, seals and
o-rings are brown.

TERMINAL PER SAE

1858 2 - PLACES

PUSH TO RESET

2.45

PUSH PLATE

PUSH ROD

INNER

DIAPHRAGM

CLAMP

DIAPHRAGM