CHAPTER 7 AIR-HYDRAULIC CYLINDER ASSEMBLY MODEL N-4105-H Section |, DESCRIPTION AND OPERATION 158. Description Note. The Key letters noved in parentheses are in figure 11, except where otherwise indicated a. The air-hydraulie cylinder assembly is com- prised of a compressed air actuated air eylinder as- sembly (C) and a hydraulically actuated slave cylinder assembly (D) assembled together in such ‘ manner that any movement of the internal parts of one assembly is transmitted to the internal parts of the other assembly. }. When installed in a vehicle, the assembly is mounted in some convenient location near the service brake system master cylinder. ‘The as- sembly is secured in position by means of the mounting holes (F and A, fig. 111). The line leading from the compressed air source is con- nected to the slave cylinder assembly at the com- pressed air inlet opening (A). ‘The air line (B) carries the supply of compressed air from tho inlet of the slave cylinder assembly to the air eylinder A— INLET OPENING (COMPRESSED AIR FROM VEHICLE COMPRESSED AIR SYSTEM) BAIR LINE — AIR CYLINDER ASSY D— SLAVE CYLINDER ASSY E— BREATHER OPENING (AIR CYLINDER PISTON) F— MOUNTING HOLES G— OUTLET OPENING (HYDRAULIC FLUID TO STOP LIGHT SWITCH) H— OUTLET OPENING (COMPRESSED AIR TO TRAILER SERVICE BRAKE SYSTEM) RA PD 215562 Figure 110, Airshydraulie eylinder assembly —bollom front three-quarter view. 130A— MOUNTING HOLE B — DRAIN OPENING PLUG. —AIR CYLINDER SHELL D— SLAVE CYLINDER ASSY E — OUTLET OPENING (HYDRAULIC FLUID TO BRAKE SYSTEM WHEEL CYLINDERS) Figure 111 assembly when the brake system is operated The breather opening (E) serves as the outlet through which the compressed air is exhausted from the air eylinder shell when the vehicle service Drakes are released. Tt also serves as the inlet and exhaust opening for the air at atmospheric pressure which occupies the space in the shell be- hind the piston. The tapped hydraulic fluid out lot opening (@) provides the means for connecting the hydraulic fluid line leading to the stop light switch. ‘The compressed air outlet opening (H) normally used for connecting the compressed air line leading to the trailer brake system. When not used for this purpose, it is closed with a pipe plug. ¢, The hydraulic fluid line leading from the ve- hiele service brake system master cylinder con- nects to the inlet opening (G, fig. 111). Hydraulic fluid from the slave cylinder is admitted to the service brake system hydraulic line through the outlet opening (B, fig. 111). ‘The slave cylinder bleeder serew (F, fig. 111) provides the means for F — SLAVE CYLINDER BLEEDER SCREW G— INLET OPENING [HYDRAULIC FLUID FROM BRAKE SYSTEM MASTER CYLINDER) RA PD 215563 Air-hydraulie eylinder assembly—top rear three-quarter view. ridding the slave cylinder of trapped air. ‘The drain opening plug (B, fig. 111) closes an opening provided in the end of the air cylinder assembly for draining any accumulations of condensed moisture 159. Operation (Bg. 112) a, When the operator of the vehiele begins to depress the foot brake pedal to apply the service brakes, hydraulie fluid is forced from the service brake ‘system master cylinder into the slave cylinder assembly through the slave cylinder inlet opening (C) », Inside the slave eylinder assembly, the fluid is forced into the hydraulic fluid eavity (B) above the control valve piston (A) and into the hy- draulic fluid cavity (R) surrounding the ported end of the slave eylinder piston (N). The fluid flows into the center of the slave cylinder piston through the ports and along the flat sides of the check valve (Q) installed in the center of the slave 131TOP SECTIONAL VIEW OF AIR-YDRAULIC CYLINDER ASSEMBLY ‘ontrol valve piston Solipetoufe mid any Stave evlinder init pent Do Air evlinder shell ond saver B—Compressed air inlet and exhaust opening to ait lider F—Aireyider platon push rod G—Blve evlinder piston spring retainer HAtpteale fal "oul "opening fo sevion brake mo dine uid outlet opening to vahicle stop light gave Srlinger ston inner ring piston outer spring der piston ep N—Slave eplindsr piston Figure 112. cylinder piston. ‘The hydraulic fluid flows out of the slave cylinder piston and into the piston bore through the holes in the end of the piston, the slave cylinder piston eup (M), and the slave cylinder piston spring retainer (G). ‘The slight pressure being exerted at this time is sufficient to force hydraulic fluid out of the hydraulic fluid ‘outlet opening (J) to operate the stop light switch of the vehicle, and out of the hydraulic fluid outlet opening (H) to commence application of the service brakes It also moves the control valve RAPD 715564 W Slave oylinder exhaust valve x de et Fae ace elinder —Compressed air inlet opening to slave erlin Zeman exh valve cag AT Inlet and exhaust valve spring A‘r-hydraulicenlinder assembly—crose sectional view. with piston (A) into firm contact the slave eylinder compensator piston (EE). ¢. As the foot brake pedal is further depressed, the higher pressure in the hydranlie fluid cavity (B) overcomes the pressure of the slave eylinder compensator piston spring (CC) and tho ox- tended hollow stem of the compensator piston is forced against the rubber seat of the slave cylinder exhaust valve (W). A further inereaso of pres- sure in hydraulic fluid cavity (B) overcomes the combined pressure of the inlet and exhaust valvespring (AA) and the compressed air entering the slave cylinder through the compressed air inlet opening (¥), and forces the slave cylinder inlet valve (X) off its seat in the inlet and exhaust valve cage (Z). d, With the inlet valve (X) off its seat, com- pressed air is admitted to the air line (V). Note, If the assembly does not include a pipe plug in compressed air outet opening (BB), but instead, a traler Drake compressed air line is connected to the’ opening, ‘compressed air will alo be admitted to the trailer brake Tines. Under these conditions, the trailer brakes and ‘elite brakes are applied simultaneously ‘The compressed air admitted to the air line (V) is conducted to the end of the air eylinder shel, entering the shell through the compressed ait inlet and exhaust opening (E) in the air cylinder shell end cover (D). The compressed air, acting against the end of the sir eylinder piston assembly (U), forees the piston assembly forward in the shell, As the piston assembly starts to move, the air cylinder piston push rod (F) forces the check valve (Q) forward against the end of the slave cylinder piston (N) to close the opening in the end of the piston. When the check valve is soated against the end of the piston, any further movement of the push rod forces the slave eyl- inder piston (N) farther forward in the slave cylinder body. ‘Thus, the hydraulic fluid in the space ahead of the piston is put under pressure ‘and foreed into the service brake system hydraulic lines connected to opening (H). ¢. When the foot brake pedal is released, the hydraulic fluid pressure exerted against the con- trol valve piston (A) is relieved. ‘The compen- sator piston spring (CC) returns the compensator piston to the released position and out of contact with the exhaust valve (W). ‘This action permits the inlet and exhaust valve spring (AA) to expand and pull the inlet valve (X) against its seat, closing off the supply of compressed air to the air cylinder. With the air supply cut off, the com- pressed air in the cylinder backs up into the slave cylinder through the air line (V), passes through the hollow center of the compensator piston (EW), and out of the slave cylinder through the air breather opening (DD). J. With pressure on the head of the piston assembly (U) relieved, the air eylinder piston ro- turn spring (T) forces the piston assembly (and the piston push rod) to the released position. At the same time, the slave cylinder piston inner spring (K) and outer spring (L) force the slave cylinder piston (N) into released position. When the push rod moves out of contact with the check valve (Q), in the center of the slave cylinder piston, the slave cylinder check valve spring (P) forces the check valve away from its seat against, the end of the slave cylinder piston. With the check valve in released position, the hydraulic fluid that was forced into the service brake system flows backwards through, and out of, the slave cylinder following the path it followed upon enter- ing (a and 6 above). ¢. To operate in its intended manner, the air- hydraulic cylinder assembly requires a supply of ‘compressed air. However, should the air supply fail, the vehicle still ean be brought to a halt. or operated under emergency conditions. For, there is no compressed air available to move the air eylinder piston (and push rod) forward, the check valve in the slave eylinder piston will not close. And if the valvo does not closo, the mo: mum pressure developed in the service brake system master cylinder will be exerted on the service brake system (2 and 6 above). 133Section Il. IDENTIFICATION DATA AND REPAIR KIT INFORMATION 160. Model Number Location (ig. 113) ‘The air-hydraulie eylinder assembly model num- ber (C) is stamped in the surface of the air cylinder shell (A) about 2 inches from the end of the shell, 161. Repair Kit Information All of the parts which must be replaced in the course of rebuilding an air-hydraulic cylinder are furnished as a repair kit. The individual parts included in the kit are illustrated in figure 114. Figure 118. Location of air-hyarouliceplinder arsembly model number. 1349A PO 218866 Figure 114. Air-hydeaulic cylinder assembly repair kit -ylinder piston inner B-Ab cylinder piaton cup C—Blave body gas Slave évlinder piston outer spring Sitve cylinder inlet and exaust valve gage packet PAin"ylinder pinto push od seal G—Slave"eytinder body and ng ecko naive Mevnder inet and “exhaust valve spring J-Slave eyinder contra valve ston Outer cup K—#lave einer compensator ton ‘el, 1A cylinder shell end cover ME Sinder shel gasket — Air eylnder shell gaske nd piston push rod ea ‘TSiave olinder compensator Piston UA Sindee piston fet ing V—Slave oyinigr compensator ston apr weAitve eylinder control valve fend pg gasket X—Slave'eylinder inlet valve 135Section Ill. DISASSEMBLY OF AIR-HYDRAULIC CYLINDER ASSEMBLY INTO SUBASSEMBLIES 162. Remove Air Cylinder Piston Assembly a, Preliminary Instructions. The first step in the disassembly of the air-hydraulie cylinder as- sembly is the separation of the air cylinder assembly from the slave eylinder assembly after which, the slave eylinder is disassembled into its subassemblies. Figure 115 shows the complete air-hydraulie cylinder assembly separated into its two major subassemblies with the air eylinder assembly shown disassembled. Refer to figure 121 for disassembled view of slave cylinder assembly. 4. Remove Slave Cylinder Body and Plug (fg. 116). Clamp the air eylinder shell (G) in a bench vise equipped with soft copper or lead jaws. Remove the plug (D) and the gasket (E). Pull the slave cylinder piston inner spring (C) and outer spring (B) out of the slave cylinder body (A). Unserew and remove the slave cylinder bleeder serew (F) Note. When the asiembly i being assembled after being rebuilt, certain parts must be installed in the same positions from which they were removed. To iasure the proper positioning of the parts, refer to figure 117 and fstablish matching marks either by prick punching oF by plating or serbing a line aaross the parting lines of the following parts: the slave eylinder compensator body. (N) and the slave cylinder body (G); the air eylinder shell (A) and the slave eylinder body (G); the air eylinder shell end cover (C) and the alr cylinder shell (A). e. Remove Air Cylinder Shell End Cover and Gasket (fig. 117). Unscrew the fittings at each end of the airline (B) and remove the airline. Remove the nuts (B) and lockwashers (F) secur- ing the cover (C) to the air cylinder shell (A) Remove the cover (C) and gasket (D). Pull the piston assembly (C, fig. 118) and piston retum spring (B, fig. 118) out of the air cylinder shell, 163. Remove Air Cylinder Shell From Slave Cylinder Assembly (ig. 119) Remove the air cylinder piston return spring retainer (D) from its position in the end of the air eylinder shell (B). Shift the assembly in the bench vise so that the vise jaws are clamped around the body of the slave cylinder. Remove four cap screws (B) and lockwashers (A) and pull the air cylinder shell (I) forward over the end of 136 the air cylinder piston push rod bushing assembly. (©). Remove air cylinder shell (B, fig. 120) and air cylinder shell gasket (A, fig. 120). Pull air cylinder piston push rod bushing assembly (C, fig. 120) forward out of the slave eylinder body (D, fig. 120). 164. Remove Slave Cylinder Piston Assembly (Gig. 121) Insert a stick of wood into the threaded end of the bore of the slave cylinder body (X) and force the piston spring retainer (L), the piston cup (M), the piston assembly (N), and the air eylinder piston push rod seal (P) out of the bore. 165. Remove Slave Cylinder Compensator Body Assembly (fig. 122) Remove the nut (D), lockwasher (EB), bolt (F), two cap screws (H), and lockwashers (G) seeur- ing the compensator body assembly (A) to the slave cylinder body (B). Lift the body assembly straight up until clear of the compensator piston spring (A, fig. 123) Note. The compensator piston assembly and compen sator piston spring may sik in the compensator body. Te they do, remove the body assembly and jar it on the palin of the hand eausing the piston and spring to. drop out of the body. 166. Remove Slave Cylinder Compensator Piston and Control Valve Piston As- sem (fig. 123) Remove the compensator piston spring (A) and the compensator piston assembly (B). Lift the control valve piston assembly (D) out of the slave cylinder body (C), 167. Remove Slave Cylinder Inlet and Ex- haust Valve Cage Assembly (fig. 124) Clamp the slave cylinder compensator body assembly (C) in « bench vise and remove four cap serews (F) and lockwashers (E), Remove the ‘age cover (A), the ease assembly (D), and the two eage gaskets (B)iota poqquaeoesp Myosind—Ayqucnsn sopusyho onmosphy-aiy -g4y 2undsy issstt 04 Vi GEER) 137G— AIR CYLINDER SHELL “.he B— SLAVE CYLINDER PISTON (OUTER SPRING 2 'C— SLAVE CYLINDER PISTON. INNER SPRING, ine KG) Figuré 110. Removing slave cylinder body end plug. H— SLAVE CYLINDER COMPENSATOR BOD’ (C—AIR CYLINDER SHELL END COVER Figure 117. Air-hydraulic cylinder assembly. 138RAPD 215570 Figure 118. Removing air cylinder piston assemblyA LOCK WASHER ‘CAP SCREW E— AIR CYLINDER SHELL: DER PISTON Pat Figure 120. Air cylinder shell removed.‘Slave cylinder assombly—partilly disassembled view. Figure 121. 141RA PD 215574 ‘A COMPENSATOR PISTON SPRING Figure 128. Removing slave cylinder compensator piston and control valve piston assemblies, 142Figure 124 Removing slave cylinder inlet and exhaust valve cage assembly. Section |V. REBUILD OF SLAVE CYLINDER BODY AND SLAVE CYLINDER COMPENSA- TOR BODY ASSEMBLIES 168. Disassembly and Cleaning Remove the control valve end plug (V, fig. 121) and gasket (W, fig. 121) from the slave inder body (X, fig. 121). Clean the slave eylinder body, the slave cylinder compensator body (A, fig. 125), and the slave cylinder inlet and exhaust valve cage cover (B, fig. 125) in dry-cleaning solvent or volatile mineral spirits 169. Inspection Make sure all internal bores and small holes in the slave eylinder body are clean and free of foreign material. The slave cylinder piston bore in the slave cylinder must be smooth throughout its length. Polish out any minor imperfections with crocus cloth, but replace the body if the bore is scored or gouged. Inspect all finished surfaces on the slave eylinder body, the slave cylinder compensator body, and the slave eylinder inlet and exhaust valve cage cover for scratches or gouges. Replace any parts with imperfections that cannot be removed with a light cut of a honing stone. Inspect all tapped openings for rough or damaged threads. Clean up any rough or damaged threads with a tap; replace any of the parts, however, in which the threads are stripped. Do not remove either the air cylinder air line connector (B, fig. 125) or the pipe plug (G, fig, 125) from the slave cylinder compensator body (A, fig. 125) unless either or both are dam- aged. After completing the cleaning and inspec- tion operations, lubricate the parts with pre- servative oil (PL-MED). 143ie EB —AIR CYLINDER AIR LINE CONNECTOR H—PIPE PLUG (3/8 IN) lncles 4 Figure 125. ‘© — SLAVE CYTINDER INLET AND EXHAUST VALVE CAGE GASKET D— SLAVE CYLINDER INLET AND EXHAUST VALVE CAGE ASSY (FIG 127) E— SLAVE CYLINDER INLET AND EXHAUST VALVE CAGE COVER 6-10 msi Dory ee RA PD 215577 ‘Slave cylinder compensator body assembly —disastembled view. Section V. REBUILD OF SLAVE CYLINDER INLET AND EXHAUST VALVE CAGE ASSEMBLY 170. Disassembly (Gg. 126) Remove the self-locking nut (C) from the end of the exhaust valve (B). Remove and discard the exhaust valve (B, fig. 127), the inlet and ex- hhaust valve spring (D, fig. 127), and the inlet valve (D). 171. Assembly (fig. 127) 4. Clean the inlet and exhaust valve cage (C) in dry-cleaning solvent or volatile mineral spirits Replace the part if it is damaged in any manner. Install a new inlet and exhaust valve spring (D) on the stem of a new exhaust valve (E) with the small coil end of the spring against the head of the valve, Insert the spring and the valve into 144 the valve cage (C) and install a new inlet valve (B) over the end of the exhaust valve stem so that the rubber face of the inlet valve faces the cage. Install the self-locking nut (A) on the stem of exhaust valve, turning the nut down until one full thread extends beyond the end of the nut. Lubricate the assembly with preservative oil (PL-MED) 9, To avoid damage by rough handling, install the assembly in the slave cylinder compensator body immediately upon completion of the final assembly operation. Use a new slave cylinder inlet and exhaust valve cage gasket (C, fig. 125) on each side of the assembly. Install ‘the slave cylinder inlet and exhaust. valve cage cover (B, fig. 125), securing it in place with four cap screws @, fig. 125), and lockwashers (G, fig. 125).Figure 128. Dieasgombling slave cylinder inlet and ezhauet valve cage assembly. = EXHAUST VALVE: B— INLET VALVE A SELF-LOCKING NUT coy Figure 127. Slave cylinder inlet and exhaust wave cage assembly —eaplodd vi. usSection VI, REBUILD OF SLAVE CYLINDER CONTROL VALVE PISTON ASSEMBLY 172. Disassembly (Gig. 128) Remove the slave cylinder control valve piston ‘outer eup (A) and inner eup (C) from the ends of the slave cylinder control valve piston (B). 173, Assembly (fig. 128) 4a, Clean and inspect the piston and replace it if it is scored or seratched. Lubricate the slave cylinder control valve piston (B) and the piston inner cup (C) and outer cup (A) -with hydraulic brake fluid. ‘Note. Te twa piston eups are very similar in appear- ance; however, the outer cup has a smaller eenter hole ‘han the ner cup Force the outer cup over the end of the smaller of tho two stems projecting from the ends of the piston, Install the cup so that the flat face seats against the end of the piston, '. Install the inner cup on the opposite end of the piston in the same manner. Se 0 a0 exploded view Section Vil. REBUILD OF SLAVE CYLINDER COMPENSATOR PISTON ASSEMBLY 174. Disassembly. (ig. 120) Remove the felt ring (B) and the piston cup (©) from the grooves in the slave cylinder com- pensator piston (A). Discard ring and cup. 175. Assembly (fig. 129) Clean the compensator piston in dry-cleaning solvent or volatile mineral spirits, making sure that the center hole and the cross holes are com: pletely open and clean. Replace the piston if the edges of the felt ring or piston cup grooves are chipped or broken. Lubricate the piston (A) ‘and a new piston cup (C) with hydraulic brake fluid and install the cup in the groove nearest the center of the piston, Install the eup so that the lip of the cup faces away from the end of the piston through which the cross hole is drilled Install a new felt ring (B) in the groove above the cup. heel Ea Figure 129. Slave cylinder compensator piston assembly — ‘exploded view. Section Vill. REBUILD OF AIR CYLINDER PISTON ASSEMBLY 176. Disassembly a, Remove Air Cylinder Piston Follower (fig. 130). Clamp the piston push rod (C) in a bench vise equipped with soft copper or lead jaws Secure push rod as close behind the piston as- sembly as possible. Remove the self-locking nut (D) from the end of the push rod (C) and pull the follower (B) off the end of the push rod. b. Remove Air Cylinder Piston Pressure Plate ig. 131), Remove the push rod O ring seal (F) 146 and the piston cup (B), and pull the pressure plate (A) forward and off the piston push rod (G). Slide the snap ring collar (H, fig. 132) off the push rod. Do not remove the snap ring (J, fig, 132) unless it is damaged or loose. Remove the push rod from the vise. 177. Cleaning and Inspe Remove the piston cup expander (D, fig. 131) and the piston felt ring (EB, fig. 131) from the pistonFigure 130. follower (C, fig. 131). Discard the felt ring and the piston cup (B, fig. 131). Clean the air eylinder shell and end cover and all remaining parts of the ston assembly in dry-cleaning solvent or volatile mineral spirits. Check the piston push rod, pres- sure plate, and the follower for smoothness of all surfaces. Inspect the internal surface of the air Linder shell and the end cover. Each piece must be smooth and free from gouges, nicks, or scratches. Slight imperfections may be removed with crocus cloth, Replace any part that is deeply gouged or damaged in any other manner. Replace the cup expander if damaged or broken. Lubricate all metal parts with preservative oil (PL-MED) after completing the inspection operations. 178, Assembly fig. 132) a, Clampthe piston push rod (K) inabench vise equipped with soft copper or lead jaws, with the threaded end of the push rod projecting approxi- Air eylinder piston assembly mately 5 inches beyond the vise jaws. Force the snap ring (I) onto the rod and into the groove pro- vided. Slide the snap ring collar (H) onto the push rod with the recessed side of the collar facing. the snap ring. 8. Slide tho piston pressure plate (@) onto the push rod with the cupped side of the piston facing the snap ring collar. Install a new push rod O. ing seal (F) seating it in the recess provided in the face of the pressure plate. ¢, Install a new piston felt ring (C) and the piston cup expander (D) on the piston follower (B). Refer to figure 131 for the proper position of the parts. 4. Install a new piston cup (B), centering the cup on the shoulder projecting from the face of the pressure plate (G). Hold the eup in this posi- ion and slide the follower (B) onto the push rod and against the pressure plate. Install and tighten the self-locking nut (A), 147c—Fonomen Figure 181. Disassembling air eplinder piaton asvembly. G — PRESSURE PLATE F—PUSH ROD “0” RING SEAL Rea NS coe )J-— SNAP RING E— cur D— CUP EXPANDER c-FE11 RING: B-Fowower \ \) inehdat \ 4g —SfF-AOCKING NUT Figure 188, Air eylinder piston asoembly-—ezploded view. RAPD 215584 148Section IX, REBUILD OF AIR CYLINDER PISTON PUSH ROD BUSHING ASSEMBLY 179. Disassembly (fig. 133) Reach into the bore of the piston push rod bushing (B) with e pair of needle nose pliers; grasp the lip of the piston push rod bushing seal (A) and pull the seal from its seat in the push rod bushing. Discard seal. 180. Assembly (ig. 133) Chock the bore of the piston push rod bushing (B) for seoring or abrasion, replacing the bushing A—SEAL if such defects are present or if the pushing is defective or damaged in any other manner. Lubrieate the bushing preservative oil (PL-MED) and install a new piston push rod bushing seal (A) in the bushing, ‘To install the seal, reduce the overall diameter by folding the seal in upon itself. Insert. the seal into the bore of the bushing.so that the lip faces the same end of the bushing through which installation is made. Maneuver the seal so that it expands to normal shape and seats in the slot provided inside the bushing. Refer to cross-sectioned inset of figure 133 for installed view of seal. B BUSHING: (RA PD 215585 Figure 188. Air eylinder piston push rod bushing assembly-—erploded view. See yn X. ASSEMBLY OF AIR-HYDRAULIC CYLINDER ASSEMBLY FROM ‘SUBASSEMBLIES 181. Install Slave Cylinder Control Valve Piston Ascembly (fig. 123) Clamp the slave cylinder body (C) in a bench vise as shown in figure 123. Carefully insert the control valve piston assembly (D) into the boro in the body with the piston stem having the smallest diameter facing down. Make sure that the flared lip of the piston outer cup enters the bore without folding back. 149182. Install Slave Cylinder Compensator Install the compensator piston spring (A) in the cylinder in compensator body (B) with the large diameter end of the spring seated against the closed end of the cylinder. Install the eom- pensator piston assembly (E) in the body with the stem projecting from the end of the piston centered in the coils of the eompensator piston spring. ‘Nole. When installing the compensator piston sssem- bly, carefully guide the Mared lip of the piston eup (D) into the cylinder in the compensator body. Push the piston into the cylinder as far as possible. ‘The pressure ‘of the cup against the eylinder walls will hold the piston in place while the compensator body assembly is being Installed (par, 183) arm 75586 Figure 184. Installing slave cylinder compencator piston aascembly. 183. Install Slave Cylinder Compensator Body Assembly (ig. 122) Use a new compensator body gasket (C) and, lining the match marks that wore made when the parts were disassembled, install the compensator body assembly (A) on the slave cylinder body (B). Secure the body in place with two cap screws 150 (H) and lockwashers (G), and one bolt (F), Jockwasher (E) and nut (D). 184, Assemble Air Cy! Cylinder Assembly (fig. 120) 4, Insert the air cylinder piston push rod bush- ing assembly (C) into the nonthreaded end of the slave cylinder body (D). 8, Using.a new air cylinder shell gasket (A) and, alining the match marks made when the paris were separated, assemble the air cylinder shell (B) to the slave cylinder body and secure in place with four lockwashers and cap screws (A. and B, fig. 119). Slide the air cylinder piston return spring retainer (D, fig. 119) over the end of the air cylinder piston push rod bushing assembly (G, fig. 119) so that the flat side of the retainer seats against the cap serew heads. 185. Install Air Cylinder Piston Assembly (Gg. 118) a, Insert the air cylinder piston return spring (B) into the air cylinder shell (A) centering the small coil end on the air cylinder piston return spring retainer (D, fig. 119) Note. To avoid any possibilty of folding back the lip ‘of the piston push rod Bushing seal (A, fig. 38) when in serting the push rod of the piston assembly into the bush ing, use a rod with the same diameter as the push rod ‘tapered at ono end, and 12 to 15 inches long to guide the push rod through the seal. Lubrieate the rod with y= raul oil and inser the tapered end into the push rod bushing vhrough the air eslinder shell, eaving approx imately inches of tho rod extending into the shel. 6, Butt the end of the piston push rod (D) against the end of the guide rod and push the piston assembly (C) into the air cylinder shell against the compression of the piston return spring (B). Hold the piston in position and, alin- ing the match marks that wore made when the parts were disassembled, install the air eylinder shell end cover (C, fig. 117) using a new air eylinder shell end cover gasket (D, fig. 117) between the cover and the shell. Secure the cover in place with six nuts (B, fig. 117) and lockwashers (F, fig. 117). ¢. Check the air line (B, fig. 117) for eracks, flattened areas, or distortion. Replace the line if such defects are noted. Install the air line, connecting it to the air eylinder shell end cover (C, fig. 117) and the slave cylinder compensator body GH, fig. 117) der Shell to Slave186, Install Slave Cylinder Piston Assembly (ig. 121) 4a, Insert the air eylinder piston push rod seal (P) into the threaded end of the bore of the slave cylinder body (X) with the lip of the seal facing the same end of the body through which installa- tion is made. Note. Avold interchanging the push rod seal and the Slave eylinder piston up (Mf), They are very similar in fppearance; however, the push rod seal as s larger center ‘opening than the piston cup. 6. Insert a new slave cylinder piston assembly (SN) into the bore with the open end of the piston facing the push rod seal already installed Note. ‘The complete slave cylinder piston assombiy rust be replaced when rebuilding the air-hydraulic cxlinder assembly. ‘The disassembled view of the slave exlinder piston (fig. 188) is ineluded here for its informa~ tional valuo only. ‘The individual parte are not furnished 1s service replacement parts © — CHECK VALVE SPRING Boe A= SNAP RING ¢. Insert the piston cup (M) with the lip of the cup facing the end of the body through which installation is made. d. Insert the slave cylinder piston spring retainer (1), small diameter end first, into the slave cylinder bore ¢. Slide the slave cylinder piston inner spring (G, fig. 116) into the center of the slave cylinder piston outer spring (B, fig. 116) and insert, both springs into the bore. Install the slave cylinder body end plug (D, fig. 116) using & new slave cylinder body end plug gasket (B, fig. 116). Install the slave cylinder bleeder screw (F, fig. 116) in the slave eylinder body, turning the screw by hand until it bottoms on its seat, Use a wrench to make an additional one-eighth of a turn of the screw 187. Painting Exterior surfaces of the air-hydraulic cylinder will be painted in accordance with TM 9-2851 = PISTON sony RAPD 215507 Figure 185. Slave eplinder piston ansembly—exploded view. 151