- Joined
- Mar 1, 2000
- RO Number
- 6
- Messages
- 231
NOTE: Atwood brake actuators and foundation brakes must be installed in accordance with the instructions provided within.
SAFETY INFORMATION
NOTE:
Installer: Provide these instructions to the consumer.
Consumer: Read these instructions and keep them for future reference.
CAUTION: The maximum trailer weight for the Atwood brake actuator is 6,000 lbs. Gross Vehicle Weight Rating, with a maximum tongue load of 900 lbs. Do not exceed this capacity.
Gross Vehicle Weight Rating (GVWR) is the total weight of the trailer fully loaded including personal belongings. Know your trailer GVWR.
CAUTION: Use only a 2" machined or forged ball with the Atwood brake actuator. Do not use a fabricated or multi-piece ball.
CAUTION: Do not submerge actuator. Water may enter and corrode master cylinder causing brake failure.
INSTALLATION
( STRAIGHT TONGUE )
WARNING: The brake actuator must be installed with the frame stops in contact with the trailer tongue.
Bolt-on Application
1. Determine proper location of brake actuator on trailer tongue.
2. Drill 17/32" holes in trailer tongue where bolt holes are positioned.
3. Attach brake actuator to trailer tongue with 1/2" diameter bolts (2) S.A.E. grade 5 or greater, lock-washers (2) and nuts (2). Torque nuts to 60 70 ft. lbs.
WARNING: The trailer-tongue must have adequate strength to support the attachment of the brake actuator without the mounting nuts losing torque during the life of the trailer. If there is any potential for trailer tongue deformation or loss of installation torque, the trailer tongue must be properly reinforced to prevent any potential loosening of the brake actuator in service. See Figure 2 for view of recommended trailer tongue reinforcement.
Weld-on Application
1. Determine proper location of brake actuator on trailer tongue.
2. Weld actuator to trailer tongue with a minimum of 7" weld per side. Make a 5/32" fillet weld (see Figure 1)No. E6011 A.W.S. Welding rod (AC or DCRP). Use a 5/32" diameter rod, machine amps at 140-150 with 50 volts.
CAUTION: Breakaway cable and hook must not touch ground during welding operation.
"A" FRAME WELD-BETWEEN
1. Position actuator between A-Frame members with the leading edge of the A-Frame located a maximum of 5" from the back of the actuator (Figure 3, below).
2. Weld actuator to trailer tongue by welding along the entire length where trailer frame contacts actuator. Weld must be a minimum of 7" along each side. Make a 5/32" fillet weld (see Figure 3) No. E6011 A.W.S. welding rod (AC or DCRP). Use a 5/32" diameter rod, machine amps at 1 40 150 with 50 volts.
CAUTION: Breakaway cable and hook must not touch ground during welding operation.
WARNING: The brake actuator is not designed to withstand the torsional twist of the trailer "A" frame in service. Additional means, must be used to tie the trailer "A" frame members together (i.e. cross members, etc.).The cross member(s) should be comparable in strength to the trailer frame, and should be located as close to the brake actuator as possible.
NOTE: If Atwood top and bottom jack mounting plates are used, move the jack mounting plates as close to the brake actuator as possible and weld along the entire area where the plates and trailer frame contact. Use welding instructions given in Step No. 2 above.
PAINTING THE BRAKE ACTUATOR
Dip Painting Procedure
NOTE: Carefully perform instructions in the 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 any paint from entering master cylinder.
5. Paint brake actuator.
6. Remove all plugs and fully release brake actuator.
7. Inspect for paint contamination of the master cylinder and the shock absorber shaft after painting. Replace parts if contamination with paint.
8. Continue with "Mandatory Functional Check"
Spray Painting Procedure
1. Fully apply brake actuator.
2. Plug master cylinder outlet port (1/8" NPTF Thread).
3. Plug master cylinder reservoir port to prevent paint from entering the master cylinder.
4. Paint brake actuator.
5. Fully release brake actuator and 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 the function of the ball socket and latching mechanism by inserting, locking, and removing a 2" diameter hitch ball. Once the hitch ball is fully inserted in the socket, the release handle must close completely and freely when released.
2. If the 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 the back-up lever to the indicated back-up position and lock. Operate brake actuator, back-up lever must return to the towing position freely using only the return spring force. Clean off excess paint and lubricate as necessary to ensure lever assembly operates freely.
CAUTION: If locking mechanism does not operate freely, do not use actuator, contact Atwood Service Department.
FOUNDATION BRAKES
1. Check to see if axle has brake flanges (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 with 4 bolts (Figure 5).
b. Insert brake assembly into hub and drum assembly (Figure 5). Drum must completely cover surface of brake shoes (Figure 6). Be certain that brake assembly back plate does not contact drum edge, and that inside edges of shoes are not in contact with hub or drum.
c. Adjust brake shoes snugly against drum by inserting brake adjusting tool through adjusting slot (Figure 7). 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 the spindle.
e. With trailer in a level attitude, locate top of brake flange parallel with bottom of trailer frame (Figure 8).
f. Tack weld flange to axle (a tack weld is a small semi-permanent weld used for securing).
g. Remove brake/drum assembly: first back off (loosen) brake adjustment, remove drum, then remove brake.
h. Finish welding flange securely to axle, using 5/32" fillet weld, No. E6011 A.W.S. welding rod (AC or DCRP). Use a 5/32" diameter rod, machine amps at 140-150 with 50 volts.
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 lock-washers provided (torque to 50 ft. lbs.).
4. Mount drum and bearings on axle spindle and secure with washer and spindle nut.
5. Tighten spindle nut securely and then loosen (or un-tighten) nut one quarter (1/4) turn (900).
6. Consult the installation instructions to connect the brake piping.
NOTE: Consult the Atwood Engineering Department when using non-Atwood brake piping or other components or when questions arise concerning installation or application.
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 (Figure 7). Adjust brake shoes out by moving end of adjusting tool as illustrated., only until wheel will not turn. When this condition is felt by rotating wheel, back-off (loosen) adjustment 5 notches. If wheel still does not rotate freely, apply pressure to brakes to expand shoes against drum and center shoes. Release pressure and check to see if wheel rotates freely. If not, repeat procedure from above.
8. Check that all hydraulic fittings are secure.
9. Remove master cylinder filler cap and fill the reservoir with DOT 3 automotive brake fluid.
10. At brake assembly, connect a bleeder hose to bleeder fitting on wheel cylinder and submerge free end in a container with brake fluid. DO NOT REUSE BRAKE FLUID.
NOTE: On tandem axle trailers, bleed brakes on rear most axle first.
11. Loosen bleeder fitting at top of brake assembly one turn.
12. Apply actuator (see Figure 9) and then tighten bleeder fitting. Return actuator to released position. Again, loosen bleeder valve one turn and apply actuator. Repeat this procedure until the fluid expelled from the bleeder hose is free of air bubbles. During this procedure, the 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.
NOTE: Use power bleeder or bar with 2" diameter hitch ball attached (Figure 9). Do not use breakaway cable for purpose of bleeding brake system.
13.When no air bubbles are visible, close bleeder valve securely and remove the bleeder hose.
14. Repeat steps 9. 10, 11 and 12 for remaining brake, and then brakes on forward axle.
15. If installation is tandem axle with brakes on both axles, repeat bleeding procedure on rear axle brakes for second time to assure positive purging of all air in system.
16. After bleeding has been completed, re-check fluid level in master cylinder.
CAUTION: DO NOT use brake fluid drained from brake system in refilling master cylinder as such fluid may have contaminants from system.
OPERATION ( TOWING )
CAUTION: Ball capacity must be greater than or equal to the trailer GVWR. Do not use a worn hitch ball, it is unsafe and must be replaced.
NOTE: Take care not to damage actuator when backing up towing vehicle for hook-up.
1. Position actuator ball socket above 2" ball.
2. Hold release handle in open position (Figure 10).
3. Lower trailer tongue until ball rests in ball-socket.
4. Close release handle.
CAUTION: The release handle will close freely with finger pressure when ball is properly inserted into ball socket. If the release handle does not close freely, do not tow the trailer. Do not force release handle into closed position.
5. To make sure that the actuator is securely latched onto the ball, extend the trailer tongue jack to the ground and lift the car and trailer combination 2" to 4". If the ball does not disengage, the 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. The cable must hang clear of trailer tongue and be long enough to permit short radius turns without pulling breakaway cable forward.
8. Make sure breakaway cable is in released position with indicator bead touching or resting against cable spring stop (Figure 11).
CAUTION: 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 and securely attach to bumper or frame of tow vehicle.
CAUTION: Safety chains must be used.
10. Retract jack fully. Remove and store caster, if applicable.
11.Check for proper car-trailer hook-up: the tow vehicle and trailer should be level with a positive tongue load. For further information, consult a dealer or Atwood Service Department.
12. The back-up lever knob must be positioned in the "Towing Position" (Figure 13).
13. If actuator is used with equalizing hitch, be sure hanger chains hang between straight down and forward up to 34". Do not use less than 6-1/2" hanger chain length. For optimum brake performance, hang chains forward 340 (Figure 12).
14. Do not use the Atwood brake actuator with a sway controller, unless prior Atwood Engineering approval of the sway control system has been received.
15. You are now ready to tow your trailer.
CAUTION: Avoid sharp turns. This could bend, create extreme stress or fracture either the actuator or trailer tongue.
BACKING UP
1. Follow step 1 through 15 for Towing.
2. Before backing up a slope or through soft ground, pull trailer forward slightly to assure that the actuator socket is in the fully forward position.
3. Move the lever knob on the side of the actuator downward from the "Towing Position" along the curved slot in the actuator frame to the "Back-up Position" (Figure 13). The slot has a notch at the bottom of its travel. Push the lever knob down to engage the locking notch.
4. Back trailer up.
CAUTION: Avoid sharp turns. This could bend,create extreme stress or fracture either the actuator or trailer tongue.
5. If trailer is to be uncoupled from tow vehicle after backing with the lever knob engaged, block all trailer wheels and pull forward slightly to take strain off of the actuator. Uncouple the actuator by lifting the release handle and raising the trailer tongue. Make sure the lever knob is in the "Towing Position" when uncoupling from the trailer.
CAUTION : Before towing trailer, always ensure the lever knob has disengaged and is in the "Towing Position".
MAINTENANCE
1. Keep all links and pivots lubricated to prevent rusting and ensure ease of operation. Use SAE 30 oil, lubricate inside release handle and inside actuator body reached from underside of actuator.
NOTE: Lubricate hitch ball with conventional automotive grease or a lubricant made for hitch balls.
2. Check for any leaks in the brake system. Periodic checks should be made on all hoses to guard against cuts and worn hoses which may cause failure (leaks, rupturing under pressure, and collapsing). Replace defective hoses.
3. Check brake fluid level in the master cylinder reservoir. Keep filled to within 1/2" from top of reservoir.
CAUTION: Do not fill master cylinder reservoir with used brake fluid. Do not fill reservoir beyond 1/2" from top. Do not overfill, brake fluid will damage paint.
4. At the beginning of each year inspect brakes for excessive wear, replace linings if necessary. Adjust brakes referring to Step #7 page 5.
NOTE: Wheel bearing and seals should be inspected and packed at this time.
Extended Storage Instructions
The following preventative maintenance is recommended for extended periods of storage.
1. Check brake system for proper fluid level in master cylinder and bleed all lines.
2. lubricate all links and pivots to prevent any rusting.
3. Remove wheel and drum assemblies and spray a good anti-corrosion compound (CRC formula 5-56) under rubber boot on forward end of brake wheel cylinder. Avoid spraying drum and brake lining.
4. Grease all bearings and reinstall wheel and drum assemblies.
5. Make sure breakaway cable is fully released.
6. After extended storage refer to Maintenance Steps 1 through 4 on page 9, to insure trailer readiness for towing.
TROUBLE SHOOTING
WARNING: If any of the following problems develop, the trailer must be immediately stopped and the proper corrective action taken before the trailer is put back into service.
PROBLEM: Squeaking, Clatter or Chucking
Cause is in the next group below.
1) This could be caused by the hitch ball requiring a bit of lubrication.
2) The linkage and pivots on the brake actuator.
3) Loose hitch ball.
4) Loose hitch.
5) Loose brake actuator.
6) Hitch ball worn or too small.
7) Overheated brakes.
8) Broken brake drum(s).
9) Low brake fluid level.
10) Worn out shock absorber.
11) Partial application of breakaway cable.
12) Brakes improperly adjusted.
13) Broken return spring.
14) Seized actuator master cylinder.
15) Worn out brake shoes.
16) Leaky wheel cylinder.
17) Leaky wheel bearing grease seal. Remedy
Cause
1) Lubricate with conventional automotive grease or commercial lubricant made for hitch balls.
2) Oil linkage and pivots on brake actuator.
3) Inspect hitch ball and tighten.
4) Inspect hitch and tighten.
5) Inspect brake actuator and tighten.
6) Replace.
7) Replace wheel bearing.
8) Replace brake drum(s) and check brake shoes.
9) Fill and bleed brakes (see step 9-16, page
6).
10) Replace.
11) Fully release breakaway cable.
12) Check brakes for adjustments (see step 7, page 6).
13) Replace return spring.
14) Replace/rebuild actuator master cylinder.
15) Replace brake shoes and check brake drums.
16) Replace/rebuild wheel cylinders and replace brake shoes. Clean drums and other hardware.
17) Pack wheel bearings and replace wheel bearing grease seal and wheel bearings. Clean drums and other hardware.
PROBLEM: Release Handle Does Not Close Easily
Probable Cause
1) Oversize ball.
2) Ball not fully inserted into socket.
3) Foreign material in actuator.
Remedy
1) Check ball size.
2) Check for proper ball size. Check to see if tongue jack is fully retracted. Hold release handle open when inserting ball.
3) Clean and lubricate.
PROBLEM: Brake Overheating, Side-pull, Brakes Do Not Operate, Poor Brake Performance
Probable Cause
1) Only one brake is applying.
2) Leaking wheel cylinder.
3) Seized wheel cylinder piston.
4) Foreign material in brake unit.
5) Low hydraulic fluid level.
6) A bent shoulder bolt.
7) A bent push rod in the shock absorber.
8) A damaged socket assembly.
9) Broken or pinched brake lines.
10) Brake actuator frame damaged.
Remedy
1) Check brake adjustment.
2) Check and replace wheel cylinder and bleed brakes
3) Check and rebuild or replace wheel cylinder and bleed system.
4) Clean thoroughly.
5) Fill and bleed brakes.
6)Replace.
7) Replace.
8) Replace.
9) Replace.
10) Replace actuator.
SAFETY INFORMATION
NOTE:
Installer: Provide these instructions to the consumer.
Consumer: Read these instructions and keep them for future reference.
CAUTION: The maximum trailer weight for the Atwood brake actuator is 6,000 lbs. Gross Vehicle Weight Rating, with a maximum tongue load of 900 lbs. Do not exceed this capacity.
Gross Vehicle Weight Rating (GVWR) is the total weight of the trailer fully loaded including personal belongings. Know your trailer GVWR.
CAUTION: Use only a 2" machined or forged ball with the Atwood brake actuator. Do not use a fabricated or multi-piece ball.
CAUTION: Do not submerge actuator. Water may enter and corrode master cylinder causing brake failure.
INSTALLATION
( STRAIGHT TONGUE )
WARNING: The brake actuator must be installed with the frame stops in contact with the trailer tongue.
Bolt-on Application
1. Determine proper location of brake actuator on trailer tongue.
2. Drill 17/32" holes in trailer tongue where bolt holes are positioned.
3. Attach brake actuator to trailer tongue with 1/2" diameter bolts (2) S.A.E. grade 5 or greater, lock-washers (2) and nuts (2). Torque nuts to 60 70 ft. lbs.
WARNING: The trailer-tongue must have adequate strength to support the attachment of the brake actuator without the mounting nuts losing torque during the life of the trailer. If there is any potential for trailer tongue deformation or loss of installation torque, the trailer tongue must be properly reinforced to prevent any potential loosening of the brake actuator in service. See Figure 2 for view of recommended trailer tongue reinforcement.
Weld-on Application
1. Determine proper location of brake actuator on trailer tongue.
2. Weld actuator to trailer tongue with a minimum of 7" weld per side. Make a 5/32" fillet weld (see Figure 1)No. E6011 A.W.S. Welding rod (AC or DCRP). Use a 5/32" diameter rod, machine amps at 140-150 with 50 volts.
CAUTION: Breakaway cable and hook must not touch ground during welding operation.
"A" FRAME WELD-BETWEEN
1. Position actuator between A-Frame members with the leading edge of the A-Frame located a maximum of 5" from the back of the actuator (Figure 3, below).
2. Weld actuator to trailer tongue by welding along the entire length where trailer frame contacts actuator. Weld must be a minimum of 7" along each side. Make a 5/32" fillet weld (see Figure 3) No. E6011 A.W.S. welding rod (AC or DCRP). Use a 5/32" diameter rod, machine amps at 1 40 150 with 50 volts.
CAUTION: Breakaway cable and hook must not touch ground during welding operation.
WARNING: The brake actuator is not designed to withstand the torsional twist of the trailer "A" frame in service. Additional means, must be used to tie the trailer "A" frame members together (i.e. cross members, etc.).The cross member(s) should be comparable in strength to the trailer frame, and should be located as close to the brake actuator as possible.
NOTE: If Atwood top and bottom jack mounting plates are used, move the jack mounting plates as close to the brake actuator as possible and weld along the entire area where the plates and trailer frame contact. Use welding instructions given in Step No. 2 above.
PAINTING THE BRAKE ACTUATOR
Dip Painting Procedure
NOTE: Carefully perform instructions in the 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 any paint from entering master cylinder.
5. Paint brake actuator.
6. Remove all plugs and fully release brake actuator.
7. Inspect for paint contamination of the master cylinder and the shock absorber shaft after painting. Replace parts if contamination with paint.
8. Continue with "Mandatory Functional Check"
Spray Painting Procedure
1. Fully apply brake actuator.
2. Plug master cylinder outlet port (1/8" NPTF Thread).
3. Plug master cylinder reservoir port to prevent paint from entering the master cylinder.
4. Paint brake actuator.
5. Fully release brake actuator and 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 the function of the ball socket and latching mechanism by inserting, locking, and removing a 2" diameter hitch ball. Once the hitch ball is fully inserted in the socket, the release handle must close completely and freely when released.
2. If the 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 the back-up lever to the indicated back-up position and lock. Operate brake actuator, back-up lever must return to the towing position freely using only the return spring force. Clean off excess paint and lubricate as necessary to ensure lever assembly operates freely.
CAUTION: If locking mechanism does not operate freely, do not use actuator, contact Atwood Service Department.
FOUNDATION BRAKES
1. Check to see if axle has brake flanges (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 with 4 bolts (Figure 5).
b. Insert brake assembly into hub and drum assembly (Figure 5). Drum must completely cover surface of brake shoes (Figure 6). Be certain that brake assembly back plate does not contact drum edge, and that inside edges of shoes are not in contact with hub or drum.
c. Adjust brake shoes snugly against drum by inserting brake adjusting tool through adjusting slot (Figure 7). 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 the spindle.
e. With trailer in a level attitude, locate top of brake flange parallel with bottom of trailer frame (Figure 8).
f. Tack weld flange to axle (a tack weld is a small semi-permanent weld used for securing).
g. Remove brake/drum assembly: first back off (loosen) brake adjustment, remove drum, then remove brake.
h. Finish welding flange securely to axle, using 5/32" fillet weld, No. E6011 A.W.S. welding rod (AC or DCRP). Use a 5/32" diameter rod, machine amps at 140-150 with 50 volts.
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 lock-washers provided (torque to 50 ft. lbs.).
4. Mount drum and bearings on axle spindle and secure with washer and spindle nut.
5. Tighten spindle nut securely and then loosen (or un-tighten) nut one quarter (1/4) turn (900).
6. Consult the installation instructions to connect the brake piping.
NOTE: Consult the Atwood Engineering Department when using non-Atwood brake piping or other components or when questions arise concerning installation or application.
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 (Figure 7). Adjust brake shoes out by moving end of adjusting tool as illustrated., only until wheel will not turn. When this condition is felt by rotating wheel, back-off (loosen) adjustment 5 notches. If wheel still does not rotate freely, apply pressure to brakes to expand shoes against drum and center shoes. Release pressure and check to see if wheel rotates freely. If not, repeat procedure from above.
8. Check that all hydraulic fittings are secure.
9. Remove master cylinder filler cap and fill the reservoir with DOT 3 automotive brake fluid.
10. At brake assembly, connect a bleeder hose to bleeder fitting on wheel cylinder and submerge free end in a container with brake fluid. DO NOT REUSE BRAKE FLUID.
NOTE: On tandem axle trailers, bleed brakes on rear most axle first.
11. Loosen bleeder fitting at top of brake assembly one turn.
12. Apply actuator (see Figure 9) and then tighten bleeder fitting. Return actuator to released position. Again, loosen bleeder valve one turn and apply actuator. Repeat this procedure until the fluid expelled from the bleeder hose is free of air bubbles. During this procedure, the 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.
NOTE: Use power bleeder or bar with 2" diameter hitch ball attached (Figure 9). Do not use breakaway cable for purpose of bleeding brake system.
13.When no air bubbles are visible, close bleeder valve securely and remove the bleeder hose.
14. Repeat steps 9. 10, 11 and 12 for remaining brake, and then brakes on forward axle.
15. If installation is tandem axle with brakes on both axles, repeat bleeding procedure on rear axle brakes for second time to assure positive purging of all air in system.
16. After bleeding has been completed, re-check fluid level in master cylinder.
CAUTION: DO NOT use brake fluid drained from brake system in refilling master cylinder as such fluid may have contaminants from system.
OPERATION ( TOWING )
CAUTION: Ball capacity must be greater than or equal to the trailer GVWR. Do not use a worn hitch ball, it is unsafe and must be replaced.
NOTE: Take care not to damage actuator when backing up towing vehicle for hook-up.
1. Position actuator ball socket above 2" ball.
2. Hold release handle in open position (Figure 10).
3. Lower trailer tongue until ball rests in ball-socket.
4. Close release handle.
CAUTION: The release handle will close freely with finger pressure when ball is properly inserted into ball socket. If the release handle does not close freely, do not tow the trailer. Do not force release handle into closed position.
5. To make sure that the actuator is securely latched onto the ball, extend the trailer tongue jack to the ground and lift the car and trailer combination 2" to 4". If the ball does not disengage, the 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. The cable must hang clear of trailer tongue and be long enough to permit short radius turns without pulling breakaway cable forward.
8. Make sure breakaway cable is in released position with indicator bead touching or resting against cable spring stop (Figure 11).
CAUTION: 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 and securely attach to bumper or frame of tow vehicle.
CAUTION: Safety chains must be used.
10. Retract jack fully. Remove and store caster, if applicable.
11.Check for proper car-trailer hook-up: the tow vehicle and trailer should be level with a positive tongue load. For further information, consult a dealer or Atwood Service Department.
12. The back-up lever knob must be positioned in the "Towing Position" (Figure 13).
13. If actuator is used with equalizing hitch, be sure hanger chains hang between straight down and forward up to 34". Do not use less than 6-1/2" hanger chain length. For optimum brake performance, hang chains forward 340 (Figure 12).
14. Do not use the Atwood brake actuator with a sway controller, unless prior Atwood Engineering approval of the sway control system has been received.
15. You are now ready to tow your trailer.
CAUTION: Avoid sharp turns. This could bend, create extreme stress or fracture either the actuator or trailer tongue.
BACKING UP
1. Follow step 1 through 15 for Towing.
2. Before backing up a slope or through soft ground, pull trailer forward slightly to assure that the actuator socket is in the fully forward position.
3. Move the lever knob on the side of the actuator downward from the "Towing Position" along the curved slot in the actuator frame to the "Back-up Position" (Figure 13). The slot has a notch at the bottom of its travel. Push the lever knob down to engage the locking notch.
4. Back trailer up.
CAUTION: Avoid sharp turns. This could bend,create extreme stress or fracture either the actuator or trailer tongue.
5. If trailer is to be uncoupled from tow vehicle after backing with the lever knob engaged, block all trailer wheels and pull forward slightly to take strain off of the actuator. Uncouple the actuator by lifting the release handle and raising the trailer tongue. Make sure the lever knob is in the "Towing Position" when uncoupling from the trailer.
CAUTION : Before towing trailer, always ensure the lever knob has disengaged and is in the "Towing Position".
MAINTENANCE
1. Keep all links and pivots lubricated to prevent rusting and ensure ease of operation. Use SAE 30 oil, lubricate inside release handle and inside actuator body reached from underside of actuator.
NOTE: Lubricate hitch ball with conventional automotive grease or a lubricant made for hitch balls.
2. Check for any leaks in the brake system. Periodic checks should be made on all hoses to guard against cuts and worn hoses which may cause failure (leaks, rupturing under pressure, and collapsing). Replace defective hoses.
3. Check brake fluid level in the master cylinder reservoir. Keep filled to within 1/2" from top of reservoir.
CAUTION: Do not fill master cylinder reservoir with used brake fluid. Do not fill reservoir beyond 1/2" from top. Do not overfill, brake fluid will damage paint.
4. At the beginning of each year inspect brakes for excessive wear, replace linings if necessary. Adjust brakes referring to Step #7 page 5.
NOTE: Wheel bearing and seals should be inspected and packed at this time.
Extended Storage Instructions
The following preventative maintenance is recommended for extended periods of storage.
1. Check brake system for proper fluid level in master cylinder and bleed all lines.
2. lubricate all links and pivots to prevent any rusting.
3. Remove wheel and drum assemblies and spray a good anti-corrosion compound (CRC formula 5-56) under rubber boot on forward end of brake wheel cylinder. Avoid spraying drum and brake lining.
4. Grease all bearings and reinstall wheel and drum assemblies.
5. Make sure breakaway cable is fully released.
6. After extended storage refer to Maintenance Steps 1 through 4 on page 9, to insure trailer readiness for towing.
TROUBLE SHOOTING
WARNING: If any of the following problems develop, the trailer must be immediately stopped and the proper corrective action taken before the trailer is put back into service.
PROBLEM: Squeaking, Clatter or Chucking
Cause is in the next group below.
1) This could be caused by the hitch ball requiring a bit of lubrication.
2) The linkage and pivots on the brake actuator.
3) Loose hitch ball.
4) Loose hitch.
5) Loose brake actuator.
6) Hitch ball worn or too small.
7) Overheated brakes.
8) Broken brake drum(s).
9) Low brake fluid level.
10) Worn out shock absorber.
11) Partial application of breakaway cable.
12) Brakes improperly adjusted.
13) Broken return spring.
14) Seized actuator master cylinder.
15) Worn out brake shoes.
16) Leaky wheel cylinder.
17) Leaky wheel bearing grease seal. Remedy
Cause
1) Lubricate with conventional automotive grease or commercial lubricant made for hitch balls.
2) Oil linkage and pivots on brake actuator.
3) Inspect hitch ball and tighten.
4) Inspect hitch and tighten.
5) Inspect brake actuator and tighten.
6) Replace.
7) Replace wheel bearing.
8) Replace brake drum(s) and check brake shoes.
9) Fill and bleed brakes (see step 9-16, page
6).
10) Replace.
11) Fully release breakaway cable.
12) Check brakes for adjustments (see step 7, page 6).
13) Replace return spring.
14) Replace/rebuild actuator master cylinder.
15) Replace brake shoes and check brake drums.
16) Replace/rebuild wheel cylinders and replace brake shoes. Clean drums and other hardware.
17) Pack wheel bearings and replace wheel bearing grease seal and wheel bearings. Clean drums and other hardware.
PROBLEM: Release Handle Does Not Close Easily
Probable Cause
1) Oversize ball.
2) Ball not fully inserted into socket.
3) Foreign material in actuator.
Remedy
1) Check ball size.
2) Check for proper ball size. Check to see if tongue jack is fully retracted. Hold release handle open when inserting ball.
3) Clean and lubricate.
PROBLEM: Brake Overheating, Side-pull, Brakes Do Not Operate, Poor Brake Performance
Probable Cause
1) Only one brake is applying.
2) Leaking wheel cylinder.
3) Seized wheel cylinder piston.
4) Foreign material in brake unit.
5) Low hydraulic fluid level.
6) A bent shoulder bolt.
7) A bent push rod in the shock absorber.
8) A damaged socket assembly.
9) Broken or pinched brake lines.
10) Brake actuator frame damaged.
Remedy
1) Check brake adjustment.
2) Check and replace wheel cylinder and bleed brakes
3) Check and rebuild or replace wheel cylinder and bleed system.
4) Clean thoroughly.
5) Fill and bleed brakes.
6)Replace.
7) Replace.
8) Replace.
9) Replace.
10) Replace actuator.