November 2003 2 - Bryant R.V. Services

1 1 November 2003 INTRODUCTIONThe 2004 edition of the Atwood Hardware Service Manual is a resource created to help servicetechnicians identify Atwood product diagnose service problems and efficiently and effectively processwarranty manual should be used in conjunction with the current Installation Operation Manual (IOM) for theproduct being serviced. To obtain a current IOM please contact Atwood Mobile Products at theaddress listed of the manuals within this series offers a general overview of the product as well as morespecific product information. For each product within the manual, you will find model identification,recommended tools and equipment, a sequence of operation, warnings, annual maintenanceprocedures, parts and troubleshooting guides, warranty procedures, flat rate schedules, andreplacement part reference to the rapidly changing personal computer revolution we have placed troubleshooting informationin a variety of places to make sure that the most accurate information is available.

2 The best place tofind the current information about Atwood products is our website: At ourwebsite brochures may be downloaded, trouble shooting guides reviewed and the latest informationbulletins can be read. In addition all Atwood Authorized Service Centers are listed on our site,accessible via an easy-to-use search for all Atwood products is handled out of our Rockford location. Should you have anyquestions regarding our products or the information contained in this manual simply dial 1-800-825-4328. Atwood Service DepartmentDisclaimer: The data presented in this publication is obtained from the most reliable sources, and is believed to be accurate as of the date ofpublication. Responsibility for typographical errors or omission of data cannot be assumed by the Tongue & A-Frame CouplersSpecialty Couplers & HITCH BALLSYoke Style Coupler Trouble Shoot guide & Coupler BrakesActuatorsFoundation BrakesBrake KitsSurge Brake Trouble Shooting Guide3. CASTERS/FEET & SUPPORT Replacement KitsA- Frame JackSpeciality Jack Jack Screw Square Tube Jack Bolt Swivel Jack Implement Swivel Jack Retaining Ring Swivel Jack Manual Tongue Jacks - Trouble Shooting GuideStabilizer Jack JACKS (CONTINUED).

3 12-29 Telescoping StabilizersPower Jacks Trouble Shooting GuidePower & Marine JacksDuralegRemote Control EBSJ Trouble Shooting GuideTruck Camper JacksSwing Out Bracket5. 5TH WHEEL LANDING :1 Gear Box Replacement5th Wheel Parts BreakdownGear Replacement Kits5th Wheel Leveling System7. 5TH WHEEL PIN FOLDING HITCH BALL ..4010. GOOSENECK COUPLER SYSTEMS5TH WHEEL WARRANTY & MUST RETURN PARTS HARDWARE FLAT A-Frame CouplersABCABCABC80072, 84176,848008010181911, 81912,81915 ABC88007, 88010, 88555, 88600,88000, 88005 ABCABC82680**84035 Atwood Straight Tongue Couplers8006082311, 8231580131 ABCABCABCABCEDF80186, 80082, 80083 ACSTRAIGHT TONGUE COUPLER SELECTION guide B dimension is the inside dimension relating to channel sizePart *CDEFKITCap. lbs. " ball, 3" channel, bolt-on painted157753,500293/8238376112797/8223/ 419376800552" ball, 3" channel, bolt-on zinc-plated157753,500293/8238376112797/8 223/419376800562" ball, weld-between, 3 channel157753,500293/8238376112797/8223/ 419376unpainted, zinc plated latch823112" ball, weld-between, painted157753,500275/819437691/4235 823152" ball, weld-between, 157753,500275/819437691/4235 unpainted, zinc plated latch800602" ball, 3" channel, painted157755,000393/823837611279 800822" ball, 2" channel, painted157755,000391/224125111279 800832" ball, 2" channel157755,000391/224125111279 unpainted, zinc plated latch & clamp801862" ball, 2" channel, painted157756,000391/224125111279 8013125/16" ball, 3" channel, painted075328,50041230531/87914356 80051, 80055, 80056A-FRAME COUPLER SELECTION guide ** Top plate 82740 is packed with 82680 coupler.

4 82681 coupler is the same as 82680 except it is packed without a support plate. Top plate 22375 can also be used with 82680 or 82681 coupler if a Top Mount A-Frame Jack (5,000 lbs. max) is used in this application.* Various aspects of design, including the latch handle design, are registered as a trademark of Atwood Industries, " ball, painted, weld-on, yoke style157755, 3123/831491/423514356841762 " ball, unpainted, weld-on, yoke style zinc latch 157755, 3123/831491/423514356840352 " ball, painted, weld-on, yoke style157755, 3133/8340103/8264147/8378848002" ball, painted, weld-on, yoke style157756, 3123/831491/423514356885552 " ball, painted, weld-on, thumb latch style880518, 497/825193/4248117/8302886002 " ball, unpainted, weld-on, thumb-flip latch style880518, 497/825193/4248117/83028010125/16" ball, painted, weld-on, yoke style157748, 41230510254143568800725/16" ball, painted, weld-on, flip latch style8806110, 4107/8276103/8264133308801025/16" ball, unpainted, weld-on, flip latch style8806110, 4107/8276103/8264133308191125/16" ball, painted, weld-on, thumb latch style NA10, 411279107/8276123/43248191525/16" ball, unpainted, weld-on, thumb latch style NA10.

5 411279107/8276123/43248191225/16" ball, painted, weld-on, thumb latch styleNA13, 411279105/8270123/43248268025/16" ball, painted, weld-on, thumb latch styleNA13, 411279105/8270131/8333880002" ball, OBSOLETE- OLD STYLE MARVEL880508800525/16" ball, OBSOLETE- OLD STYLE MARVEL88060 Thumb Latch Release Ball ClampWrap-Around Yoke Style LatchClassic Marvel Flip Latch Style113 DABCFEA twood Hitch BallsHITCH BALL SELECTION GUIDEEach Atwood hitch ball comes complete with a lock washer andhex nut for quick, secure installation, and meets all and standards. The hitch ball should always be checked for correct size. Match coupler and check for wear and roundness. Always replace hitch ball and coupler if components are damaged or " forged hitch ball40,00021/85411/43221/26413/83513/445 21/8548021225/16" forged hitch ball13,00025111/43221/26413/83525121/854 802022" hitch ball8,0001 9/164013/163021/45713/83515/84121/854825 512" forged hitch ball6,0001 3/44513/83525112511/23811/238802012" forged hitch ball5,0001 3/44513/83525112511/23811/238 Atwood Specialty CouplersUnique - 8007583461 50 Coupler83462 50 Coupler84140 50 Coupler83549 60 Coupler83551 60 Coupler84060 60 CouplerABCBCABCABEFACDFlat Nose Coupler - 75074 SPECIALTY COUPLER SELECTION GUIDEU nique - 80073 ABCABCA djustable - 80281*Adjustable - 80290 Mobile home only 25/16 ball, straddlemount thumb latch80285 Part lbs.

6 " ball, galvanized, bolt-on, yoke style157755,0003123/831491/423514356 800752" ball, rack jack mount, 157755,0003133/8340103/8264147/8378 painted, yoke style latch802854 hole bracket for adj. coupler 12,000 2516152 8028125/16" ball, adj. coupler w/o brkt0753212,000 71783769229 8029025/16" ball, adj. coupler weld on0753212,000 71783769229 75074flat nose coupler, painted 25,000 615241/211463/417133/49541/2114615283461 coupler 50 , paintedNA32,000 820367/817597/8251 83551coupler 60 , paintedNA32,000 820377/820097/8251 84140coupler 50 , paintedNA40,000 820367/817597/8251 84060coupler 60 , unpaintedNA40,000 820377/820097/8251 83462coupler 50 , unpaintedNA44,000 820377/820097/8251 83549coupler 60 , unpaintedNA44,000 820367/817597/8251 ABCBAS traddlemountStraddlemount114 Yoke Style CouplerTROUBLE SHOOTING GUIDEE ffective: 6/26/98 Guides are only intended for use on Atwood products byservice technicians who have successfully completed Atwood training.

7 This guide should be used in conjunction with theappropriate Instruction Manual provided with the product andany applicable Industry Standards. This is not intended to be acomplete list. Please direct questions concerning service ofAtwood products to 800-825-4328 before proceeding. WARNINGPERSONAL INJURY AND/OR PRODUCT DAMAGE If any of the following conditions develop, the trailer must not beused until proper corrective action is WITH SOLUTIONSC hucking or ClatterLack of ball with conventionalautomotive grease or commerciallubricant made for hitch ballsLoose hitch hitch ball and tightenHitch ball worn or too ballWorn ball couplerWorn ball couplerMulti-piece with one piece ballRelease Handle Does Not Close EasilyOversize ball sizeBall not fully inserted ..Check for proper ball size. Checkinto ball see if jack is fully retracted. Insurerelease handle is open when release handle release handle and yokeassemblyObstruction in ball ball socketSeized ball clamp with SAE 30 oil orreplace MAINTENANCE CHECKLIST MONTHLY CLEAN AND the ball socket or ball clamp show any signs of unusual wear ordeformation, the entire coupler should be replaced.

8 The ball clamp is notreplaceable. REGULARLY CHECK THE HITCH AND BALL FOR mounting hardware on the hitch should be tight and any worn bolts,washers or nuts should be replaced. The ball should not show any signsof unusual wear or scoring. If this is present, the ball should be replacedand the coupler socket should be checked for dirt or obstructions and afilm of grease applied to the socket. REGULARLY OIL ALL SLIDING PARTS OF THE COUPLER 30 primary parts this pertains to are the bolt that the ball clamp andyoke latch swivel on and the thumb latch. REGULARLY INSPECT THE COUPLER closely for hairline cracks and if any are visible, grind the weld offand re-weld according to the instructions provided in the product the coupler is bolted to the frame, inspect the mounting bolts. Tightenthem or replace if necessary. REGULARLY INSPECT THE COUPLER BODY FOR ANY CRACKS OR any exist, do not attempt to weld the cracks or straighten the the coupler. REGULARLY CHECK THE LATCH MECHANISM MOVES it does not, remove any obstructions.

9 If the spring in the mechanismis damaged, replace the entire yoke # 15773 Latch Replacement Kit (2 Ball) - STRAIGHT TONGUE & A-FRAMEI ndex #Description B1-latch assembly C1-bolt F1-hex nut E 1-spacer ADCKIT # 15774 Clevis Latch Replacement Kit (2-5/16 Ball) - A-FRAME ONLYI ndex # Description A 1-latch assembly C 1-bolt D 1-hex nut KIT # 07532 Lock Lever & Plunger(not shown for coupler 80131 - 2-5/16 ball)COUPLER REPAIR KIT075321. Plunger, link springassembly2. Cam and handleassembly3. RivetCOUPLER REPAIR KITS88060/88050 1. Lock and shoeassembly2. Coupler spring5. Handle6. Roll pinCOUPLER REPAIR KITS88061/88051 1. Lock and shoeassembly2. Coupler spring3. Retainer spring4. Spring retainer5. Handle6. Roll pin123123456115 TERMINOLOGYDEFINITIONB acking Platethe round thin machinedplate of the foundationbrake that attaches tothe axle flange and towhich all the brakecomponents Clampthe device in the ballsocket that retains thehitch Socketthe nose casting of theactuator that receivesthe hitch Nutthe threaded nut on thewheel cylinder castingused in bleeding thebrake Brakesthe process in which theair is purged from thehydraulic protective externalrubber seal of the wheelcylinder and Linetypically 3/16 steeltubing that transfershydraulic fluid from theactuator to thefoundation Shoethe steel web andattached asbestos liningthat produce the frictionagainst the drum Devicethe actuator deviceconnected tot he towvehicle that immediatelylocks up the brakesystem should the towvehicle and trailerbecome disconnected term used todescribe the condition ofa jerky braking Down Springsthe springs that retainsthe shoes to the backingplate of the Leverthe device on theactuator

10 That inactivatesthe brake so that thetrailer can be backed Cylinderthe reservoir housed inthe actuator thatcontains and supplies allof the brake fluid to thesurge inside workings ofthe master cylinder andwheel cylinder thatpump hydraulic Rodthe heavy coiled rod thatengages the inlet of themaster Handlethe thumb latchingmechanism on the top ofthe actuator that opensand closes the Absorberthe gas filled piston inthe actuator that smoothout the braking Boltthe bolt that links the ball socket,shock absorber and push Brake Actuatorthe entire brake housing and itscomponents that are attached tothe tongue of the Brake Systema hydraulic self-contained systemof components that requireforward motion of the trailer Brakesindicates that there is brakingonly in the forward motion oftrailer. The pistons on the trailerbrakes face Cylinderthe casting on the foundationbrake that transfers hydraulicpressure from the master cylinderto the brake System Terminology226222018171651591414 (4)8112428292928625726272443431330232431 2135 HYDRAULIC BRAKE ACTUATORSTO ORDER:All kit available for field replacement are numbered.