Saturday, 04 February 2012

Actuator Installation Instructions

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Actuator installation, maintenance and bleeding instructions:

 Actuator to be installed as per welding instructions contained in this manual or bolted according to accepted methods with approved fasteners.

 

  • 1) Connect and tighten all brake lines using backup wrenches where necessary.
  • 2) Fill master cylinder with DOT # 3 or # 4 brake fluid.
  • 3) Bleed brake system using a pressure bleeder or manually as follows:

 

SPECIAL NOTE - WHEN PRESSURE BLEEDING BRAKES IT IS STILL NECESSARY TO SHORT STROKE THE MASTER CYLINDER SEVERAL TIMES TO ELIMINATE TRAPPED AIR BUBBLES.

 

Refer to actuator parts breakdown page to locate referenced part numbers associated with procedures below:

Visually inspect actuator to ensure the inner slide is fully extended.  This can be verified by making sure the black co-polymer slides (#19,#20,#21,#22) are flush with leading edge of outer case. 

 

► Failure to perform this function will prevent bleeding of system ◄

 

  • § Loosen or remove two 5/16" bolts (#16) that hold the lever guide and flat emergency

               lever spring (#14).  Remove master cylinder fill cap (#10).                 

  • Using short strokes, pull forward on emergency lever (#15), pumping master cylinder until brake fluid in master cylinder reservoir (#18)stops bubbling.
  • § Attach a bleeder hose to a bleeder valve on one of the wheels ( starting at wheel farthest from master cylinder ) and submerge other end into a transparent container partially filled with brake fluid to prevent possible splashing from container.
  • § Loosen bleeder valve one turn and while watching fluid in container, use emergency lever (#15) to pump fluid as long as bubbles continue to leave submerged hose. When bubbles stop, close bleeder valve, move to next wheel and repeat until all brakes are bled. ( Note: Check master cylinder often (every 4-5 strokes) and refill above half full as needed )
  • § Refill master cylinder and securely attach cap (#10). Reinstall emergency lever spring,

lever guide, lock washers and 5/16" hex head bolts.  When tightening the bolts, make sure the lever moves freely in the groove in the guide.

Test brakes by pulling emergency lever (#15) forward until it locks into the second notch position.  Lever will be pointing approximately straight up.  Attempt to rotate wheels in a forward direction.  If any wheel rotates, brakes assemblies must be adjusted. 

Jack up trailer and secure on adequate capacity jack stands. Follow trailer manufacturer's recommendations for lifting and supporting the unit. Make sure the wheel and drum rotates

freely.

 

 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate.

 

With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn.

 

Then rotate the star wheel in the opposite direction until the wheel turns freely with a slight lining drag.

 

Replace the adjusting hole cover and lower the wheel to the ground.  Repeat the above procedure on all brakes.  For best results, the brakes should all be set at the same clearance.

 

Retest the brakes by locking the emergency lever on the second notch, and attempt to rotate tires in a forward direction, if any wheel turns there might be trapped air in the system yet.