LITERATURE NUMBER MPD 85778 - …

1 SAFETY ALERT SYMBOLSS afety Symbols alerting you to potential personal safety hazards. Obey all safety messages following these symbols. WARNING CAUTION avoid possible avoid possibleinjury or deathinjury and/or property damageFOR YOUR SAFETYREAD ALL INSTRUCTIONS BEFORE OPERATING brake SYSTEMI nstaller:Provide this instruction to :Keep documents for future SURGE brake SYSTEMI nstallation ..1-3 Straight Tongue ..1-2A-Frame Weld-Between ..2 Painting the brake Actuator ..2 Foundation Brakes ..2 Installation - Disc brake Actuator/Solenoid Back-up Valve ..2-3 Bleed brake .. Storage 1-15 ..6 Replacement installation instructions must be followed to insure safe operation ofAtwood brake actuators and foundation brakes. Failure to install according toinstallation instructions nullifies brake APPLICATIONS: For best performance use Atwood Foundation Brakes with an Atwood BrakeActuator. These components are system brake APPLICATIONS: Use only Atwood 80360, 80366, 88740, 88730 Disc brake Actuators for discbrake applications.

2 Atwood Disc brake Actuators have been tested for compatibility with Kodiakbrand 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 (815-877-5700), KodiakTrailer Components (817-284-2324), or Reliable Tool & Machine (219-347-4000). WARNINGPERSONAL INJURY & PRODUCT DAMAGE Observe maximum trailer weight for Atwood brake actuator Gross VehicleWeight Rating (GVWR) and tongue load. Do not exceed these capacities. Gross Vehicle Weight Rating is total weight oftrailer fully loaded included personal belongings. Know your trailer GVWR. CAUTIONPRODUCT DAMAGE / brake FAILURE Use only a 2 machined or forged ball with Atwood brake actuator. Ballcapacity must be equal to or greater than trailer GVWR. DO NOTuse a wornhitch ball-it is unsafe and must be replaced. DONOT submerge actuator in water. Water may enter and corrode mastercylinder, contaminating brake System, causing brake WARNINGBRAKE FAILURE brake actuator MUST BEinstalled with frame stops in contact with trailer TONGUE - BOLT ON APPLICATION(FIG1)8000 LB.

3 brake ACTUATORS SAE CLASS4- DISC AND drum APPLICATIONS8000 LB. GVWR, MAX. TONGUE LOAD 1000 LB. - DO NOT EXCEED THESE RATINGSPART NO. 83005, 83010 - drum APPLICATION/ PART NO. 80366 - DISC APPLICATION1. Determine proper location of brake actuator on trailer tongue. Set actuatoron trailer tongue, push down and back until frame stops (FIG1-A), makingcontact with Drill 17/32 holes in trailer tongue where bolt holes are Reinforcement of trailer tongue spacer must be 1/2 ID pipe or equiv. (FIG3-A).4. Attach brake actuator to trailer tongue with 1/2 diameter bolts (3) 8 lockwasher (3) and nuts (3) (FIG1-B). Torque nuts to 110-120 ft/ LB. brake ACTUATORS SAE CLASS4 - DISC AND drum APPLICATIONS6000 LB. GVWR, MAX. TONGUE LOAD 900 LB. - DO NOT EXCEED THESE RATINGSPART NO. 82542, 82543, 83153, 83154, 84131, 84132, 84133, 88730, 887401. Determine proper location of brake actuator on trailer tongue. Set actuator ontrailer tongue, push down and back until the frame stops (FIG1-A), makingcontact with Drill 17/32 holes in trailer tongue where bolt holes are Reinforcement of trailer tongue spacer must be 1/2 ID pipe or equiv.

4 (FIG3-A).4. Attach brake actuator to trailer tongue with 1/2 diameter bolts (2) 5 or greater lockwasher (2) and nuts (2) (FIG1-B). Torque nuts to 70-80 ft. lbs. WARNINGBRAKE FAILURE Trailer tongue must have adequate strength to support attachment ofbrake actuator without mounting nuts losing torque during life of trailer. Trailer tongue must be properly reinforced to prevent any potential loosen-ing of brake actuator during service. STRAIGHT TONGUE - WELD ON APPLICATION (FIG2)WELDING INSTRUCTIONS OR STICK- 5/32 fillet weld minimum. WELDING- Use ER 70S-3 or 6 wire or equivalent with adiameter of .035 - .045. The recommended shielding gas mixture is75% - 95% Argon & 25% - 5% CO2. STICK WELDING- Use E6011 welding rod or machine settings for specific electrode diameter areas follows: 1/8 electrode set power between 115-130 Amps DC or5/32 electrode set power between 140-160 Amps LB. brake ACTUATORS SAE CLASS48000 LB.

5 GVWR, MAX. TONGUE LOAD 1000 LB. - DO NOT EXCEED THESE RATINGSPART NO. 83000 - drum APPLICATION/ PART NO. 80360 - DISC APPLICATION1. Determine proper location of brake actuator on trailer tongue. Set actuatoron trailer tongue, push down and back until frame stops (FIG2-A), makingcontact with Using WELDING INSTRUCTIONS weld actuator to trailer with a minimum of 9 weld per side. Make a 5/32 fillet weld (FIG2-B).3. Make sure to return weld on front end of frame of trailer up inside actuatorframe to forward frame stop (see FIG2-C).1 ENGLISH, FRANCAIS(et Canada) Installation Operation MaintenanceEffective 1/15/02 LITERATURE NUMBERMPD 85778 HYDRAULICSURGE brake SYSTEM6000 LB. brake ACTUATORS SAE CLASS4 - DISC AND drum APPLICATIONS6000 LB. GVWR, MAX. TONGUE LOAD 900 LB. - DO NOT EXCEED THESE RATINGSPART NO. 82542, 82543, 83153, 83154 - drum APPLICATION ONLYPART NO. 88740 - DISC APPLICATION ONLY1. Determine proper location of brake actuator on trailer tongue.

6 Set actuatoron trailer tongue, push down and back until frame stops (FIG2-A), makingcontact with Using WELDING INSTRUCTIONS weld actuator to trailer with a minimum of 7 weldper side. Make a 5/32 fillet weld (see FIG2-B).3. Make sure to return weld on front end of frame of trailer up inside actuatorframe to forward frame stop. CAUTIONDAMAGE TO CABLE Breakaway cable and hook must not touch ground during welding - WELD-BETWEEN APPLICATION (FIG4)8000 LB. brake ACTUATORS SAE CLASS4- DISC AND drum APPLICATIONS8000 LB. GVWR, MAX. TONGUE LOAD 1000 LB. - DO NOT EXCEED THESE RATINGSPART NO. 83000 - drum APPLICATION/ PART NO. 80360 - DISC APPLICATION1. Position actuator between A-Frame members with leading edge of A-Framelocated 8 from back of actuator (FIG4).2. Using WELDING INSTRUCTIONS weld actuator to trailer tongue by welding alongentire length where trailer frame contacts actuator. Weld must be a mini-mum of 9 along each side (FIG4).

7 6000 LB. brake ACTUATORS SAE CLASS4 - DISC AND drum APPLICATIONS6000 LB. GVWR, MAX. TONGUE LOAD 900 LB. - DO NOT EXCEED THESE RATINGSPART NO. 82542, 82543, 83153, 83154 - drum APPLICATION ONLYPART NO. 88740 - DISC APPLICATION ONLY1. Position actuator between A-Frame members with leading edge of A-Framelocated 5 from back of actuator (FIG4).2. Using WELDING INSTRUCTIONS weld actuator to trailer tongue by welding alongentire length where trailer frame contacts actuator. Weld must be a mini-mum of 7 along each side (FIG4). CAUTIONPRODUCT DAMAGE Breakaway cable and hook must not touch ground during welding operation. Weld trailer A-frame members together with additional bracing ( cross mem-bers or jack mounting plates (FIG4). brake actuator alone is not designed towithstand torsional twist of trailer. Cross member(s) should be comparable in strength to trailer frame, and locatedas close to brake actuator as : If Atwood top and bottom jack mounting plates are used (MPD 82570 or MPD 80255) (FIG4-A), move jack mounting plates as close to brake actuatoras possible and weld along entire area where plates and trailer frame WELDING THE brake ACTUATORDIP PAINTING PROCEDURENOTE: Carefully perform procedure in order Plug vent hole in master cylinder Fully apply brake Plug master cylinder outlet port (1/8 NPTF thread).)

8 4. Plug master cylinder reservoir port to prevent paint from entering master Paint brake Remove all plugs and fully release brake Inspect for paint contamination of master cylinder and shock absorber shaftafter painting. Replace parts if contaminated with Continue with MANDATORY FUNCTIONAL CHECK AFTER PAINTING PROCEDURES1. Fully apply brake Plug master cylinder outlet port (1/8 NPTF thread).3. Plug master cylinder reservoir port preventing paint from entering master Paint brake Fully release brake actuator & paint unpainted portions of socket Remove all Inspect for paint contamination of master cylinder and shock absorber shaftafter painting. Replace parts if contaminated with FUNCTIONAL CHECK AFTER PAINTING1. Check function of ball socket and latching mechanism by inserting, lockingand removing a 2 diameter hitch ball. Once hitch ball is fully inserted insocket, release handle must close completely and freely when If ball socket and latching mechanism does not close completely and freelyas described Check for paint build-up in ball socket and clean if Lubricate ball socket and latching mechanism with SAE 30 oil and workmechanism by inserting, locking and removing a 2 diameter hitch balluntil latching mechanism does work Move back-up lever to indicated back-up position and brake actua-tor back-up lever, return to towing position freely using only return spring off excess paint andlubricate as necessary to ensure lever assemblyoperates freely.

9 CAUTIONTRAILER COULD DISCONNECT DONOTuse actuator if latching mechanism does not operate freely. ContactAtwood Service Department at BRAKES (FIG5-8)SIZERATED AXLE CAPACITY x1-3/4 1800 lbs. (2500 lb. axle capacity when used with an inte-gral cast hub and drum )10 x2-1/4 3500 x2-1/4 6000 Check if axle has brake flanges (FIG5-A) if so, skip step No. If axle does not have brake flanges, install flanges as follows:a. Secure flange to back of brake assembly (FIG5-B) with 4 bolts (FIG5-C).b. Insert brake assembly into hub and drum assembly (FIG5-D). drum mustcompletely cover surface of brake shoes (FIG6). Be certain brake assemblyback plate does not contact drum edge (FIG6-A), and inside edges ofshoes are not in contact with hub or Adjust brake shoes snugly against drum by inserting brake adjusting tool(FIG7-A & B) through adjusting slot (FIG7-C). Back plate must be centeredwithin drum diameter after adjustment.

10 Visually check for equal spacebetween edge of back plate and edge of Mount brake / drum /flange assembly on spindle and secure with spindlenut. Be sure brake / drum /flange assembly is fully mounted on With trailer level, locate top of brake flange parallel with bottom of trailerframe (FIG8).f. Tack weld flange to axle (a tack weld is a small semipermanent weld usedfor securing).g. Remove brake / drum Finish welding flange securely to axle, using WELDING Mount brake and shoe assembly to flange. Wheel cylinder must be at top ofbrake with rubber boot toward the front of trailer. For 7 brakes use nuts andlockwashers provided (torque to 50 ft. lbs.).4. Mount drum and bearings on axle spindle, secure with washer and spindle 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 : Consult Atwood Engineering Dept. when using non-Atwood brake piping orother components or when questions arise concerning installation or Raise one trailer wheel at a time, remove dust clip from adjusting slot atlower part of back side of brake assembly and insert brake adjusting tool (FIG7).