atwood Hydraulic Brake Surges - Manual (Page 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.
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CAUTION
DAMAGE TO CABLE
• Breakaway cable and hook must not touch ground during welding operation.
A-FRAME - WELD-BETWEEN APPLICATION ( FIG 4)
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).
2. Using WELDING INSTRUCTIONS weld actuator to trailer tongue by welding along
entire length where trailer frame contacts actuator. Weld must be a mini-
mum of 9˝ along each side (
FIG 4).
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).
2. Using WELDING INSTRUCTIONS weld actuator to trailer tongue by welding along
entire length where trailer frame contacts actuator. Weld must be a mini-
mum of 7˝ along each side (
FIG 4).
ƽ
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) ( FIG 4-A), move jack mounting plates as close to brake actuator
as possible and weld along entire area where plates and trailer frame contact.
Use
WELDING INSTRUCTIONS .
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 MANDATORY FUNCTIONAL CHECK AFTER PAINTING .
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.
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 actua-
tor 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.
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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
frame ( FIG 8).
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
ƽ
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.
2