atwood Hydraulic Brake Surges - Manual

SAFETY ALERT SYMBOLS
Safety Symbols alerting you to potential personal safety hazards.
Obey all safety messages following these symbols.
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WARNING
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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).
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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.
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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.
DO NOT use a worn
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.
INSTALLATION
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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. (
FIG 3-A).
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. (
FIG 3-A).
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 70-
80 ft. lbs.
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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 ( FIG 2)
WELDING INSTRUCTIONS
• M . I . G . OR STICK - 5/32˝ fillet weld minimum.
• M . I . G . WELDING - Use A.W.S. ER 70S-3 or 6 wire or equivalent with a
diameter of .035 - .045. The recommended shielding gas mixture is
75% - 95% Argon & 25% - 5% CO
2
.
• 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 SAE CLASS 4
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 ( FIG 2-B).
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).
1
ENGLISH, FRANCAIS (et Canada) •Installation •Operation •Maintenance
Effective 11/21/07
LITERATURE NUMBER MPD 85778
HYDRAULIC
SURGE BRAKE SYSTEM 9