AR42.10-B-0021B | Disassemble/assemble combination cylinder | 12.02.16 |
Vehicle 688 with Cumbustion engine 904.919, 904.918, 904.924, 904.957, 374.977, 904.908
B42.10-0385-09
1 Pin
2 Hex. nut
3 Metal sealing ring
4 Sealing ring
5 Neck
6 Accumulator spring cylinder
7 Hex. nut
8 Protection cap
9 Spring
10 Guide ring
11 Complete piston
12 Gasket
13 Screw
14 Sealing ring
15 Sealing ring
16 Intermediate flange
17 Hexagonal screw
18 Guide ring
19 Sealing ring
20 Thrust piston
21 Diaphragm
22 Piston
23 Spring seat
24 Tapered spring
25 Hexagonal screw
26 Belt
27 Hex. nut
28 Ring
29 Cover
30 Ring
31 Neck
32 Cylinder cover
33 Ring
34 Sleeve
35 Washers
36 Ball joint
| Disassemble | ||
Danger! | Risk of injuries by crushing when working with springs or components under tension | ||
1 | Lightly compress the cylinder cover (32) and unscrew the nut (27) on bolt (25) of the fastening strap (26) | Use a press with appropriate base. | |
2 | Relieve the press pressure and separate from the part of the spring accumulator, the membrane cylinder part, remove the diaphragm and the diaphragm vent (21) | It is recommended to mark beforehand the-accumulator spring cylinder (6), the flange (16), the cylinder cover (32) and the fastening strap (26) in relation to the assembly. | |
3 | Remove the piston (22) together with the spring seat (23), the ring (28), the sleeve (34), the washer (35), the joint ball (36) and the taper spring (24) | ||
4 | Remove the cylinder cover (32), the rings (30), the boot (29) and the neck (31) | ||
4 | Fasten the combined cylinder by the intermediate flange (16) and unfasten the relief bolt (13) until approximately half of its total travel | Mechanical relief bolt | |
5 | Remove the thrust piston (20) | Secure the cylinder by its flange in a vise, with the jaws protected, and remove the thrust piston with the help of two screwdrivers. | |
6 | Remove the lock pin (1) and unfasten the nut (2) from the relief bolt (13). | ||
7 | Completely unscrew the relief bolt (13) and remove it from inside the rod of piston (11) | ||
8 | Disassemble the portion of the piston's of the accumulator spring (6), compress slightly and loosen the nuts (7) of the fastening bolts (17) on the intermediate flange (16) | Support the cylinder on a wooden base, leaving a retraction stroke on the press spindle to permit the spring expansion. | |
9 | Slowly relieve the press pressure until complete spring expansion | ||
10 | Remove the cylinder (6), the spring (9) and the protection boot (8). | ||
11 | Remove from the flange (16) the complete piston (11) | ||
12 | Remove from the piston (11), the package (12) and the guide-ring (10) | ||
| Clean | ||
13 | Clean the parts and check them for wear or damages, and if necessary, replace them. | Utilize an adequate product in order not to damage the rubber and plastic parts of the component. | |
| Assembling | ||
The repair kit components must be replaced whenever the valve is disassembled. | |||
14 | Install the guide-ring (18), in the flange (16), together with the sealing ring (19). | Observe the correct mounting position of the guide-ring (18). | |
15 | Assemble the sealing ring (15) on the intermediate flange (16) | ||
16 | Assemble the guide-ring (10) and the package (12) in the piston | Observe the correct mounting position of the guide-ring (10). | |
17 | Install the complete piston (11) in the flange (16) | ||
18 | Assemble the protection boot (8) in the spring (9) and insert it in the piston (11) | Perfectly accommodate the spring (9) in the piston (11). | |
19 | Assemble the cylinder (6) on the spring (9) and install it on the flange (16) | Lubricate the inside cylinder walls. | |
Take the whole assembly to the workshop press on a wooden block and compress until the cylinder edge touches the flange, coinciding the markings made at disassembly. | |||
20 | Install the bolts (17) and the nuts (7) | Intermediate flange fastening bolt | |
21 | Install the relief bolt (13). | Lubricate it and screw it in to approximately half its total stroke. Having compressed air available, pressurize the cylinder and manually screw in the bolt. | |
Mechanical relief bolt | |||
22 | Assemble the sealing ring (4) and the metal ring (3) on the relief's bolt end | Observe the assembly position of the metal ring. | |
23 | Assemble the nut (2) and place the pin (1) | Screw the nut on the relief bolt, until the holes coincide perfectly, and insert the pin. | |
24 | Install the thrust piston (20) in the complete piston (11) | Install the sealing ring (19) on the thrust piston (20) | |
25 | Assemble the cylinder cover (32) the neck (31) and the ring (33) | ||
26 | Assemble in the spring (24), the ring (30) and insert the piston (22) with the spring seat (23) | ||
27 | Assemble on the piston (22) the diaphragm (21) and install it in the cylinder cover (32) and over this, the spring accumulator assembly | Adequately support the cylinder cover (32) in the press on a wooden base and compress the parts until obtaining their assembly, observe the markings made at disassembly. | |
28 | Install the strap (26) and insert the bolt (25) with the nut (27) | | |
29 | Connect the vent tube in the openings (2, 31) | Remove the combination cylinder from the press. | |
30 | Assemble the ring (28), and the boot (29), the sleeve (34), the washer (35) and the ball joint (36) | Check the ball joint (36) for condition. | |
31 | Install the combined cylinder on the bench and test it |
Brake cylinder