DICO Trailer Brake Unit

[George Van Parys]

MODEL 60 ACTUATOR INSTALLATION INSTRUCTIONS

Surge braking is accomplished by the installation of an actuator in the tongue of the trailer.

The "surge" or "push" of the trailer toward the automobile automatically synchronizes the trailer brakes with the automobile brake. As the trailer pushes against the car, the actuator telescopes together and applies the force to the master cylinder, supplying hydraulic pressure to the brakes.

The Model 60 Actuator is completely assembled and ready to bolt or weld into place. Welding will destroy the plated surfaces and make repair or replacement difficult.

1. Bolt the actuator to the tongue using (2) 1/2 x 4 grade 5 bolts, nuts and lock washers. Fits standard coupler mounting holes on popular 3" wide tongue. Light weight tongues require spacer tubes inside for reinforcement. We suggest using 3/4 OD x 11 GA tubing. Tighten bolts to 80 Ft. lbs. torque.

2. Install the hydraulic brake lines on the trailer as described in the installation manual supplied with the brakes.

3. Fill the system with clean DOT-3 heavy duty hydraulic brake fluid using a pressure type brake bleeder. (This type of brake bleeder is available at your local automotive jobber.) Follow manufacturer's directions.

To bleed the system manually, proceed as follows: Fill the master cylinder with fluid. Depress push rod by using a screwdriver as a lever. The hole located below push rod is a good leverage point. Use short strokes until bubbling stops inside master cylinder.

Install bleeder hose on first wheel cylinder to be bled; if tandem axle trailer, bleed rear axle first. Have loose end of hose submerged in a glass container of brake fluid to observe bubbling.

By loosening the bleeder screw located in the wheel cylinder one turn, the system is open to the atmosphere through the passage drilled in the screw. The bleeding operation is complete when bubbling stops. Be sure to close bleeder screw securely.

Repeat bleeding operation at each wheel cylinder. During the bleeding process, replenish the brake fluid so the level does not fall below half full level in the master cylinder reservoir.

After bleeding is completed, make sure master cylinder reservoir is filled and filler cap is securely in place.

RATED CAPACITY

The Model 60 Brake Actuator has a maximum rating of 6,000 lbs. GVWR. and 600 lbs. tongue load. The actual in-service rating is limited to that of the ball and hitch being used or the trailer manufacturers GVWR shown on the certification label, whichever is lower.

HITCHING TRAILER

1. The towing hitch and ball must have a rating equal to or greater than trailer GVWR.

2. Coupler will accept 1-7/8'', 50 mm and 2" trailer balls. Tighten hand wheel to secure ball in socket. Make certain ball latch is in correct position to retain the ball, and that the hand wheel lock is clicking while tightening. You must depress the lock to loosen hand wheel in order to un-hitch trailer. Do not tow trailer if coupler is damaged.

3. Connect safety chains using crossed pattern under tongue, or follow trailer manufacturer's directions.

4. Connect breakaway S-hook.

5. The breakaway system should only operate after both the coupling and safety chains have failed. The breakaway is not a parking brake.

6. Should the breakaway be accidentally applied while un-hitching, remove cover and pry the spring clip out of notch to release lever. Replace cover.

7. Sway control devices that restrict operation of the actuator cannot be used. The actuator must be free to telescope in response to braking requirements.

8. Weight distributing (equalizing) hitches may be used. Allow six to eight inches free chain length. Chain must be vertical (straight up and down) under pulling load. Tongue weight beyond rating will interfere with performance.

9. The actuator is designed for use with Free-Backing trailer brakes. Do not block action in order to back up with other type brakes. Failure to remove block will also prevent forward braking.

MAINTENANCE
1. Before towing check the brake fluid reservoir is at least half-full. If not, re-fill with DOT 3 brake fluid. Check for leaks and repair as required.

2. A film of clean grease on the ball will extend coupler and ball life while eliminating squeaking. Wipe ball clean and renew film each time trailer is used.

3. Periodic lubrication is not normally required, but you may wish to oil the four (4) rollers after prolonged use or storage. Use motor oil.

4. Before towing, examine the actuator for bent parts or wear. Replace parts as necessary. Check to determine that mounting bolts are tight. (80 ft. Lbs.).

5. The only adjustments on the actuator are the self-locking nuts on the two roller bolts. Over tightening will restrict operation. Correct adjustment is 11/2 turn back from zero side play.

6. Actuator travel (over one inch) shown by front roller path indicates a need to adjust the brakes. Adjust per instructions found in brake installation manual. In general, back-off adjusters 10 clicks from locked rotation. Adjust Free-Backing brakes by rotating in forward direction only. Failure to adjust will result in loss of braking.

WARNING:

Saltwater, granular fertilizers and other corrosive materials are destructive to metal. To prolong the life of a braking system used under corrosive conditions, we recommend that the Actuator be flushed periodically with a high pressure water hose. Be sure to re-grease bearings and oil all moving parts after the unit has dried. At the end of the season, when unit is to be stored, remove the brake drums and clean inside the brakes. Pack wheel bearings before drum is installed.