atwood Hydraulic Brake Surges User Manual

LITERATURE NUMBER

MPD 85778

HYDRAULIC

SURGE BRAKE SYSTEM

ENGLISH, FRANCAIS (et Canada) •Installation •Operation •Maintenance

SAFETY ALERT SYMBOLS

Safety Symbols alerting you to potential personal safety hazards. Obey all safety messages following these symbols.

 WARNING  CAUTION

avoid possible avoid possible injury or death injury and/or property damage

FOR YOUR SAFETY

READ ALL INSTRUCTIONS BEFORE OPERATING BRAKE SYSTEM Installer: Provide this instruction to consumer. Consumer: Keep documents for future reference.

INDEX

HYDRAULIC SURGE BRAKE SYSTEM

Installation ............................................................................................1-3

Straight Tongue ....................................................................................1-2

A-Frame Weld-Between ............................................................................2

Painting the Brake Actuator ......................................................................2

Foundation Brakes....................................................................................2

Installation - Disc Brake Actuator/Solenoid Back-up Valve ....................2-3

Bleed Brake System..................................................................................3

OPERATION

Towing......................................................................................................3

Backing-up ............................................................................................3-4

MAINTENANCE ..................................................................................................4

Extended Storage Instructions..................................................................5

WARRANTY ......................................................................................................4

Troubleshooting........................................................................................5

Figures 1-15 ............................................................................................6

Replacement Kits....................................................................................12

The installation instructions must be followed to insure safe operation of Atwood brake actuators and foundation brakes. Failure to install according to installation instructions nullifies warranty.

DRUM BRAKE APPLICATIONS:

• For best performance use Atwood Foundation Brakes with an Atwood Brake

Actuator. These components are system matched.

DISK BRAKE APPLICATIONS:

• Use only Atwood 80360, 80366, 88740, 88730 Disc Brake Actuators for disc

brake applications.

• Atwood Disc Brake Actuators have been tested for compatibility with Kodiak

brand and Reliable brand Disc Brake Systems.

• To be used with a maximum of 4 2-1/4˝ diameter calipers.

• For more information call Atwood Mobile Products (866-869-3118), Kodiak

Trailer Components (817-284-2324), or Reliable Tool & Machine (219-347-4000).

 WARNING

PERSONAL INJURY & PRODUCT DAMAGE

• Observe maximum trailer weight for Atwood brake actuator Gross Vehicle

Weight Rating (GVWR) and tongue load.

• Do not exceed these capacities. Gross Vehicle Weight Rating is total weight

of trailer fully loaded included personal belongings. Know your trailer GVWR.

 CAUTION

PRODUCT DAMAGE / BRAKE FAILURE

• Use only a 2˝ machined or forged ball with Atwood brake actuator. Ball

capacity must be equal to or greater than trailer GVWR. hitch ball-it is unsafe and must be replaced.

• DO NOT submerge actuator in water. Water may enter and corrode master

cylinder, contaminating Brake System, causing brake failure.

DO NOT use a worn

INSTALLATION

 WARNING

BRAKE FAILURE

• Brake actuator MUST BE installed with frame stops in contact with trailer tongue.

STRAIGHT TONGUE - BOLT ON APPLICATION (FIG 1)

8000 LB. BRAKE ACTUATORS SAE CLASS 4- DISC AND DRUM APPLICATIONS

8000 LB. GVWR, MAX. TONGUE LOAD 1000 LB. - DO NOT EXCEED THESE RATINGS PART NO. 83005, 83010 - DRUM APPLICATION / PART NO. 80366 - DISC APPLICATION

1. Determine proper location of brake actuator on trailer tongue. Set actuator on trailer tongue, push down and back until frame stops (FIG 1-A), making contact with tongue.

2. Drill 17/32˝ holes in trailer tongue where bolt holes are positioned.

3. Reinforcement of trailer tongue spacer must be 1/2˝ ID pipe or equiv. (

4. Attach brake actuator to trailer tongue with 1/2˝ diameter bolts (3) S.A.E. grade 8 lockwasher (3) and nuts (3) (FIG 1-B). Torque nuts to 110-120 ft/ lbs.

6000 LB. BRAKE ACTUATORS SAE CLASS 4 - DISC AND DRUM APPLICATIONS

6000 LB. GVWR, MAX. TONGUE LOAD 900 LB. - DO NOT EXCEED THESE RATINGS PART NO. 82543, 83153, 83154, 84132, 88730, 88740

1. Determine proper location of brake actuator on trailer tongue. Set actuator on trailer tongue, push down and back until the frame stops (FIG 1-A), making contact with tongue.

2. Drill 17/32˝ holes in trailer tongue where bolt holes are positioned.

3. Reinforcement of trailer tongue spacer must be 1/2˝ ID pipe or equiv. (

4. Attach brake actuator to trailer tongue with 1/2˝ diameter bolts (2) S.A.E. grade 5 or greater lockwasher (2) and nuts (2) (FIG 1-B). Torque nuts to 7080 ft. lbs.

 WARNING

BRAKE FAILURE

• Trailer tongue must have adequate strength to support attachment of brake

actuator without mounting nuts losing torque during life of trailer.

• Trailer tongue must be properly reinforced to prevent any potential

loosening of brake actuator during service.

STRAIGHT TONGUE - WELD ON APPLICATION (

WELDING INSTRUCTIONS

• M.I.G. OR STICK - 5/32˝ fillet weld minimum.

.I.G. WELDING

• M

diameter of .035 - .045. The recommended shielding gas mixture is 75% - 95% Argon & 25% - 5% CO

• STICK WELDING - Use E6011 A.W.S. welding rod or equivalent.

Recommended machine settings for specific electrode diameter are as follows: 1/8” electrode set power between 115-130 Amps DC or 5/32” electrode set power between 140-160 Amps DC.

8000 LB. BRAKE ACTUATORS

8000 LB. GVWR, MAX. TONGUE LOAD 1000 LB. - DO NOT EXCEED THESE RATINGS PART NO. 83000 - DRUM APPLICATION / PART NO. 80360 - DISC APPLICATION

1. Determine proper location of brake actuator on trailer tongue. Set actuator on trailer tongue, push down and back until frame stops (FIG 2-A), making contact with tongue.

2. Using WELDING INSTRUCTIONS weld actuator to trailer with a minimum of 9˝ weld per side. Make a 5/32˝ fillet weld (

3. Make sure to return weld on front end of frame of trailer up inside actuator frame to forward frame stop (see FIG 2-C).

- Use A.W.S. ER 70S-3 or 6 wire or equivalent with a

SAE CLASS 4

FIG 2-B).

Effective 11/21/07

FIG 3-A).

FIG 2)

6000 LB. BRAKE ACTUATORS SAE CLASS 4 - DISC AND DRUM APPLICATIONS

6000 LB. GVWR, MAX. TONGUE LOAD 900 LB. - DO NOT EXCEED THESE RATINGS PART NO. 82543, 83153, 83154 - DRUM APPLICATION ONLY PART NO. 88740 - DISC APPLICATION ONLY

1. Determine proper location of brake actuator on trailer tongue. Set actuator on trailer tongue, push down and back until frame stops (FIG 2-A), making contact with tongue.

2. Using WELDING INSTRUCTIONS weld actuator to trailer with a minimum of 7˝ weld

per side. Make a 5/32˝ fillet weld (see FIG 2-B).

3. Make sure to return weld on front end of frame of trailer up inside actuator frame to forward frame stop.

 CAUTION

DAMAGE TO CABLE

• Breakaway cable and hook must not touch ground during welding operation.

A-FRAME - WELD-BETWEEN APPLICATION (

8000 LB. BRAKE ACTUATORS SAE CLASS 4- DISC AND DRUM APPLICATIONS

8000 LB. GVWR, MAX. TONGUE LOAD 1000 LB. - DO NOT EXCEED THESE RATINGS PART NO. 83000 - DRUM APPLICATION / PART NO. 80360 - DISC APPLICATION

1. Position actuator between A-Frame members with leading edge of A-Frame located 8˝ from back of actuator (FIG 4).

WELDING INSTRUCTIONS weld actuator to trailer tongue by welding along

2. Using entire length where trailer frame contacts actuator. Weld must be a minimum of 9˝ along each side (

6000 LB. BRAKE ACTUATORS SAE CLASS 4 - DISC AND DRUM APPLICATIONS

6000 LB. GVWR, MAX. TONGUE LOAD 900 LB. - DO NOT EXCEED THESE RATINGS PART NO. 82543, 83153, 83154 - DRUM APPLICATION ONLY PART NO. 88740 - DISC APPLICATION ONLY

1. Position actuator between A-Frame members with leading edge of A-Frame

located 5˝ from back of actuator (FIG 4).

WELDING INSTRUCTIONS weld actuator to trailer tongue by welding along

2. Using entire length where trailer frame contacts actuator. Weld must be a minimum of 7˝ along each side (FIG 4).

FIG 4).

FIG 4)

 CAUTION

PRODUCT DAMAGE

• Breakaway cable and hook must not touch ground during welding operation.

• Weld trailer A-frame members together with additional bracing (i.e. cross mem-

bers or jack mounting plates (FIG 4). Brake actuator alone is not designed to withstand torsional twist of trailer.

• Cross member(s) should be comparable in strength to trailer frame, and located

as close to brake actuator as possible.

NOTE: If Atwood top and bottom jack mounting plates are used (MPD 82570 or

MPD 80255) ( as possible and weld along entire area where plates and trailer frame contact.

WELDING INSTRUCTIONS.

Use

PAINTING THE BRAKE ACTUATOR

DIP PAINTING PROCEDURE

NOTE: Carefully perform procedure in order given.

1. Plug vent hole in master cylinder boot.

2. Fully apply brake actuator.

3. Plug master cylinder outlet port (1/8˝ NPTF thread).

4. Plug master cylinder reservoir port to prevent paint from entering master cylinder.

5. Paint brake actuator.

6. Remove all plugs and fully release brake actuator.

7. Inspect for paint contamination of master cylinder and shock absorber shaft after painting. Replace parts if contaminated with paint.

8. Continue with

SPRAY PAINTING PROCEDURES

1. Fully apply brake actuator.

2. Plug master cylinder outlet port (1/8˝ NPTF thread).

3. Plug master cylinder reservoir port preventing paint from entering master cylinder.

4. Paint brake actuator.

5. Fully release brake actuator & paint unpainted portions of socket assembly.

6. Remove all plugs.

7. Inspect for paint contamination of master cylinder and shock absorber shaft after painting. Replace parts if contaminated with paint.

FIG 4-A), move jack mounting plates as close to brake actuator

MANDATORY FUNCTIONAL CHECK AFTER PAINTING.

MANDATORY FUNCTIONAL CHECK AFTER PAINTING

1. Check function of ball socket and latching mechanism by inserting, locking and removing a 2˝ diameter hitch ball. Once hitch ball is fully inserted in socket, release handle must close completely and freely when released.

2. If ball socket and latching mechanism does not close completely and freely as described above.

a. Check for paint build-up in ball socket and clean if necessary. b. Lubricate ball socket and latching mechanism with SAE 30 oil and work

mechanism by inserting, locking and removing a 2˝ diameter hitch ball until latching mechanism does work freely.

3. Move back-up lever to indicated back-up position and lock. Operate brake actuator back-up lever, return to towing position freely using only return spring force. Clean off excess paint and lubricate as necessary to ensure lever assembly operates freely.

 CAUTION

TRAILER COULD DISCONNECT

• DO NOT use actuator if latching mechanism does not operate freely. Contact

Atwood Service Department at 866-869-3118.

FOUNDATION BRAKES (FIG 5-8)

SIZE RATED AXLE CAPACITY LBS.

7”x1-3/4” 1800 lbs. (2500 lb. axle capacity when used with an inte-

gral cast hub and drum) 10”x2-1/4” 3500 lbs. 12”x2-1/4” 6000 lbs.

1. Check if axle has brake flanges (FIG 5-A) if so, skip step No. 2.

2. If axle does not have brake flanges, install flanges as follows: a. Secure flange to back of brake assembly (

FIG 5-B) with 4 bolts (FIG 5-C).

b. Insert brake assembly into hub and drum assembly (FIG 5-D). Drum must

completely cover surface of brake shoes (FIG 6). Be certain brake assembly back plate does not contact drum edge (

FIG 6-A), and inside edges of

shoes are not in contact with hub or drum.

c. Adjust brake shoes snugly against drum by inserting brake adjusting tool

(

FIG 7-A & B) through adjusting slot (FIG 7-C). Back plate must be centered

within drum diameter after adjustment. Visually check for equal space between edge of back plate and edge of drum.

d. Mount brake/drum/flange assembly on spindle and secure with spindle

nut. Be sure brake/drum/flange assembly is fully mounted on spindle.

e. With trailer level, locate top of brake flange parallel with bottom of trailer

FIG 8).

frame (

f. Tack weld flange to axle (a tack weld is a small semipermanent weld used

for securing). g. Remove brake/drum assembly. h. Finish welding flange securely to axle, using

WELDING INSTRUCTIONS.

3. Mount brake and shoe assembly to flange. Wheel cylinder must be at top of brake with rubber boot toward the front of trailer. For 7˝ brakes use nuts and lockwashers provided (torque to 50 ft. lbs.).

4. Mount drum and bearings on axle spindle, secure with washer and spindle nut.

5. Tighten spindle nut securely and then loosen or untighten) nut one quarter (1/4) turn 90°.

6. Consult installation instructions to connect brake piping MPD 85869.

NOTE: Consult Atwood Engineering Dept. when using non-Atwood brake piping or

other components or when questions arise concerning installation or application.

7. Raise one trailer wheel at a time, remove dust clip from adjusting slot at lower part of back side of brake assembly and insert brake adjusting tool (FIG 7). Adjust brake shoes out by moving end of adjusting tool as illustrated, only until adjustment wheel (

FIG 7-D) will not turn. When this condition is felt by

rotating wheel, back-off (loosen) adjustment until wheel will just turn freely.

INSTALLATION - DISC BRAKE ACTUATOR SOLENOID BACK-UP VALVE

 WARNING

DEATH OR PERSONAL INJURY

• This system requires the solenoid wire leads be connected ONLY into the tow

vehicle back-up light circuit.

8,000 LB. ACTUATORS are equipped with a solenoid back-up valve.

1. Connect the solenoid valve wire leads to the tow vehicle back-up light circuit.

2. Connect trailer brake line to actuator.

3. Bleed brake system.

6,000 LB. ACTUATORS are not equipped with a solenoid back-up valve. When a solenoid back-up valve is desired please contact Atwood for the solenoid backup valve kit. Atwood Mobile Products 866-869-3118. To install Atwood solenoid back-up valve -

1. Remove the plug in return port of master cylinder (this is the upper port in the master cylinder).

2. Install straight barbed fitting (torque to 16-20 in/lb).

3. Install assembly in supply port of master cylinder (this is the lower port in the master cylinder).

4. Connect the solenoid wire leads only into the reverse back-up light circuit.

5. Connect trailer brake line to actuator.

6. Bleed brake system

FOR DISC BRAKE SYSTEMS

 CAUTION

DAMAGE TO BRAKE ACTUATOR OR VEHICLE

• If brass orifice fitting is not installed (FIG 10B), trailer-braking action may

cause vehicle(s) to shake during brake applications.

The brass orifice fitting installed in master cylinder ( assembly must remain in hydraulic circuit to brakes (FIG 10C) of trailer.

If brass orifice fitting must be moved to accommodate plumbing (FIG 10E) for a back up solenoid valve (

FIG 10D), it must be replaced in hydraulic circuit in line to brakes.

FIG 10A) of brake actuator

 WARNING

DEATH OR PERSONAL INJURY

• Contaminated brake fluid in system could plug brass orifice fitting. This

could render brakes inoperative.

Be especially careful to clean all fittings, tubing and threads between master cylinder and brass orifice fitting. A very small particle of dirt or thread sealant can plug hole in orifice.

Do not use Teflon

•

If a liquid or paste thread sealant is used, keep it back two threads from end

•

of male fitting.

• Do not apply sealant to female threads. Clean female threads thoroughly.

tape on fittings.

BLEED BRAKE SYSTEM

 CAUTION

BRAKE FAILURE

• DO NOT use brake fluid drained from brake system in refilling master cylinder.

Brake fluid can be contaminated from the system.

1. Remove master cylinder filler cap and fill reservoir with DOT type 3 or 4 automotive brake fluid.

2. Check all hydraulic line fittings & connections to make sure they are leak free.

3. At brake assembly, connect a bleeder hose to bleeder fitting on wheel cylinder and submerge free end in a container with brake fluid.

NOTE: Use power bleeder or bar with 2˝ diameter hitch ball attached (FIG 9).

Do not use breakaway cable for purpose of bleeding brake system. If a power bleeder is used air pressure 35 PSI is most effective.

NOTE: Bleed brakes on rear most axle furthest from the actuator first.

4. Loosen bleeder fitting at top of brake assembly.

5. Apply actuator (see ward position. Again, loosen bleeder valve one turn and apply actuator. Repeat this procedure until fluid expelled from bleeder hose is free of air bubbles. It is helpful to lower the trailer tongue to promote air bubble movement in the brake tubing. It is also helpful to tap gently along the brake tubing during brake bleeding to keep air bubbles from sticking to the inside of the brake tubing. During this procedure, master cylinder reservoir fluid level must be maintained at no less than 1/2 full and no more than 1/2˝ from top of reservoir.

6. When no air bubbles are visible, close bleeder valve securely and remove bleeder hose.

7. Repeat

8. If installation is tandem axle with brakes on both axle, repeat bleeding proce-

9. After bleeding has been completed, re-check fluid level in master cylinder.

STEP 1-6 for remaining brake, then brakes on forward axle.

dure on rear axle brakes for second time to assure positive purging of all air in system.

FIG 9) and tighten bleeder fitting. Return actuator to for-

DO NOT reuse brake fluid.

OPERATION - TOWING

 CAUTION

TRAILER MAY DISCONNECT

• Release handle (FIG 12A) must be fully closed before towing.

• Do not force release handle into closed position.

1. Position actuator ball socket above 2˝ ball.

NOTE: Do not damage actuator when backing up towing vehicle for hook-up.

2. Hold release handle in open position ( in fully open position to remove from or place on ball.

3. Lower trailer tongue until ball rests in ball socket.

4. Close release handle (FIG 12A). Release handle will close freely with finger pressure when ball is properly inserted into ball socket.

5. To make sure actuator is securely latched onto ball, extend trailer tongue jack to ground and lift car and trailer combination 2˝ to 4˝. If ball does not disengage, actuator is securely attached.

6. Insert padlock or bolt through lock hole for theft protection.

7. Connect breakaway cable solidly to bumper or frame of tow vehicle as near to center as possible. Cable must hang clear of trailer tongue and long enough to permit short radius turns without pulling breakaway cable forward.

8. Make sure breakaway cable (

FIG 13B) touching or resting against cable spring stop (FIG 13A).

bead (

FIG 11A). Release handle must be held

FIG 13C) is in released position with indicator

 CAUTION

PRODUCT DAMAGE

• DO NOT use breakaway cable as a parking brake.

NOTE: Check location of breakaway cable periodically during each trip, indicator

should rest against spring stop. Accidental application will cause brakes to drag

and heat up, causing failure.

9. Cross safety chains under tongue & securely attach to bumper or frame of tow vehicle.

 CAUTION

TRAILER DAMAGE

Safety chains must be used.

•

10. Retract jack fully. Remove and store caster, if applicable.

11. Check for proper car-trailer hook-up: tow vehicle and trailer should be level

with positive tongue load. For further information, consult a dealer or Atwood Service Department.

12. Back-up lever knob must be positioned in

13. If actuator is used with equalizing hitch, be sure hanger chains (FIG 14D)

hang between straight down and forward up to 34° (FIG 14C). DO NOT use less than 6-1/2˝ hanger chain length (FIG 14x). For optimum brake performance, hang chains forward 34° (

14. DO NOT use Atwood brake actuator with a sway controller, unless prior

Atwood Engineering approval of sway control system has been received.

15. You are now ready to tow your vehicle.

FIG 14).

TOWING POSITION (FIG 15-A).

 CAUTION

PRODUCT & TRAILER DAMAGE

• Avoid sharp turns. This could bend, create extreme stress or fracture either

actuator or trailer tongue.

BACKING UP

1. Follow step 1 through 15 for TOWING.

2. If equipped with solenoid valves skip to

3. Before backing up a slope or through soft ground, pull trailer forward slightly to assure actuator socket is in fully forward position.

4 Move lever knob on side of actuator downward from TOWING POSITION (FIG 15A)

along curved slot in actuator frame to notch at bottom of its travel. Push lever knob down to engage locking notch.

5. Back trailer up.

STEP 5.

BACK-UP POSITION (FIG 15B). Slot has a

 CAUTION

PRODUCT & TRAILER DAMAGE

• Avoid sharp turns. This could bend, create extreme stress or fracture either

actuator or trailer tongue.

6. If trailer is to be uncoupled from tow vehicle after backing with lever knob engaged, block all trailer wheels and pull forward slightly to take strain off actuator. Uncouple actuator by lifting release handle and raising trailer tongue. Make sure lever knob is in pling from trailer.

TOWING POSITION (FIG 15A) when uncou-

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