brake actuating systems - brakes | electric | hydraulic ... - brake actuation.pdfbrake actuators,...

Section L-1

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Brake Actuating Systems

Electronic Brake Controls ................................. L-2-L-6

Brake Control Installation Kits ................................. L-7

Brake Control Accessories ........................................ L-8

Side-Post Mount Battery Adapter Kit ...................... L-8

“The Engager” Breakaway Kit .................................. L-8

Breakaway Kits ......................................................... L-9

Breakaway Kit Accessories ...................................... L-10

Actuators:

Carlisle Hydrastar Elec-Hyd Brake Actuators ....L-11

Demco Hydraulic Brake Actuators .........L-12 & L-13

Titan Brake Actuators ......................................... L-14

Atwood Brake Actuators ...................................... L-14

Balcrank Brake Actuators .................................... L-14

Dexter Elec/Hyd Brake Actuator ......................... L-15

This section consists of various ways to ac ti vate and actuate your trailer brakes and includes the following: Electric Brake Controls, Breakaway Kits, Hydraulic Surge Brake Ac tu a tors, Plumbing Line Kits, Electric/Hydraulic Brake Systems and Brake Ac tu at ing Sys tems for Air/Hydraulic or Straight Air Brake Systems.

Hydraulic Line Kits ................................................ L-15

Air Trailer Kits ....................................................... L-16

ABS Air Trailer Kits ............................................... L-17

Air/Hydraulic Trailer Kits ...................................... L-17

Miscellaneous Brake System Parts .......................... L-18

Hydraulic Fittings ................................................... L-19

Hydraulic Lines and Brackets ................................. L-19

Dexter Electric Brake Trouble Shooting Guide ..... L-20

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Section L-2

Brake Controls

• True Proportional Braking Power: Inertia Activated Sensor, nomanual leveling.

• Two Control System: Controls power output to brakes and brakingresponse.

• Manual Override: Aids in setting controls and allows manual ap pli ca-tion of brakes.

• Digital Display: Shows voltage to trailer during braking, plus diag-nostic features.

• Installation: Control design allows multiple angles of control posi-tioning.

• Warranty: Limited lifetime warranty.



• Manual Override: Aids in setting controls and allows manual ap pli ca-tion of brakes.

• Digital Display: Indicates voltage readout and NC (no connection) ifconnection is missing Visual warning if trailer becomes disconnected.

• Installation: Control design allows multiple angles of control posi-tioning.


PART NO. REF. NO. DESCRIPTION

9030A 416430 NEW “VOYAGER”, ALL ELECTRONIC FOR 1-4 AXLES

PART REF.NO. NO. DESCRIPTION90160 416632 “PRIMUS IQ”, ALL ELECTRONIC FOR 1-3 AXLES

PART REF.NO. NO. DESCRIPTION90885 416634 “PRODIGY P2”, 1-4 AXLES7686 416637 REPLACEMENT “POCKET” BRACKET ONLY FOR 90885

PRODIGY CONTROL7894 416638 REPLACEMENT PLUGIN HARNESS FOR

90160/90195/90885

Prodigy P2 Features Include:

Primus IQ Features Include:

Voyager Features Include:

Plug & Play

• True Proportional Braking Power: Inertia Activated Sensor.• Two Control System: Controls power output to brakes and

braking response.• Manual Override: Aids in setting controls and allows manual

ap pli ca tion of brakes.• LED Light Display: Indicates a completed electrical circuit,

aides in setting controls, changes from green to red indicatingrelative braking power.

• Installation: Mounts conveniently under vehicle dash. • Warranty: Limited 5 year warranty.

Section L-3

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Brake Controls

Prodigy P3 Features Include:



• Manual Override: Aids in setting controls and allows manualap pli ca tion of brakes.

• Digital Display: Distinct, easy to see LCD display with multiplecolor and contrast options.

• Installation: Compact, dash hugging design, unique, easy-to-use,clip mounting system.

• Electric/Hydraulic: Allows the user to switch between Electric andElectric Over Hydraulic trailer brakes.


PART REF.NO. NO. DESCRIPTION90195 416636 BRAKE CONTROL, TEKONSHA “P-3”, 1-4 AXLES

• Perfect for use with shared trailers: Rental, Fleet or when multiple tow vehicles are available.• True Proportional Trailer Braking: Forward or reverse, no level adjustment necessary.

• Wireless Communication: between the remote Hand Held Unit (90251, included) and TrailerPower Module eliminates the need for under the dash wiring. No drilling, brackets or clips required.

• Easy to use Remote Hand Control: includes the Prodigy® “Boost” system to allow for different lev-els of customized braking. Unit plugs into any standard 12 volt power accessory adaptor.

• Continual Diagnostic Scanning: with a visual warning in the hand display should a fault conditionoccur.

• 5-Year Limited Warranty: on Hand Held Unit.

• Trailer Power Module is Watertight: and includes asealed 8’ 7-Way vehicle connector.

• Multiple Mounting Options: on the tongue or frontof the trailer.

• Module Powered: through 7-Way Cable from theTow vehicle.

• 15-Year Limited Warranty: on the trailer mountedpower module (1-Year Limited Warranty on Cord)

PART REF.NO. NO. DESCRIPTION90250 416650 PRODIGY RF, 1-3 AXLES90251 416655 HAND-HELD MODULE FOR PRODIGY RF, BRAKE CONTROL

Prodigy RF Features Include:

Remote Hand Held Unit Features Include:

Trailer Mount (Power Module) Unit Features Include:

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Section L-4

• True Proportional Braking Power: Inertia Activated Sensor• Two Control System: Controls power output to brakes and braking

response.• Manual Override: Aids in setting controls and allows manual ap pli-

ca tion of brakes.• LED Light Display: Indicates there is a completed electrical circuit,

and informs operator of vehicle’s braking response and relative brak-ing power.

• Installation: Mounts conveniently on top or under vehicle dash.• Warranty: Limited 5 year warranty.

• Time Actuated Power: Trailer brakes are gradually applied at pre-set rates. Full brake actuation in about 2.5 seconds. 100% solidstate.

• Digital Display: Displays voltage being applied to brakes; pres-ence of short circuit and trailer connection.

• Manual Override: Aids in setting controls and allows manualbrake actuation.

• Installation: Mounts in any position, no leveling required.Digital readout can be reset for installation requiring upside downmounting.


• Self-leveling: Tri-axis accelerometer measures the rate of deceleration orgravitational pull on 3 planes - front-to-rear, left-to-right & up-down.

• Proportional Braking in reverse without using manual lever.• Plug & Socket: Allows unit to be removed and stored when not in use.• Universal QUIK-RECEIVER Mounting Sleeve: Uses VHB tape for

mounting; no screws or tools required.• LCD Display: Large and easy to read: displays battery, stoplight & out-

put voltage. Screen color, intensity and contrast can also be adjusted.• Alarm Mode: Exclusive audible tone warns of any trailer braking related

fault.• Ease of Use: Allows use of electric trailer brakes or hydraulic drum or

disc; simply change setting using LCD screen & up/down buttons.• Boost Feature: Provides easier adjustment based on the weight of trailer

being towed by increasing initial brake gain by 5% to 20%, dependingon setting selected.

PART NO. REF.NO. DESCRIPTION81741B 416225 “ENERGIZE III”, ELECTRIC BRAKE CONTROL, 1-2 AXLES81745 416240 “ENERGIZE XPC”, ELECTRIC BRAKE CONTROL, 1-3 AXLES

PART NO. REF.NO. DESCRIPTION81725 416380 BRAKE CONTROL, HAYES SYNCRONIZER, 1-2 AXLES

PART NO. REF.NO. DESCRIPTION81792K 416400 BRAKE CONTROL, HAYES G2, 1-4 AXLES

Energize III® & Energize XPC® Features Include:

Syncronizer® Features Include:

G2® Features Include:

81745

81741B

Section L-5

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Dexter Brake Control

PART NO. REF.NO. DESCRIPTION58-8 416260 “PREDATOR” DX2 BRAKE CONTROL FOR 1-2 AXLES

• True Proportional Braking Power: Inertia Activated Sensor.• Two Control System: Controls power output to brakes and braking response.• Manual Override: Aids in setting controls and allows manual ap pli ca tion of brakes.• LED Display: Large digital LED displays voltage output, and makes leveling quick and easy.• Mounting Range: Versatile mounting range of -35º to +90º, to accomodate a wide variety of vehicle

interiors.• Warranty: Limited 7 year warranty.

Predator Features Include:

Warner Air Utility Brake Control

PART REF.NO. NO. DESCRIPTION1300-80 417400 AIR OPERATED FOR AIR BRAKE TRUCK TO PULL ELECTRIC TRAILER

It may be used in FMVSS 121 systems. The manual override feature operates trailer brakes only.

The unit displaces only 2.8 cubic inches of air at 100 PSI. It is ad just able for a wide range of vehicle brake system pres sures, with low pressure sensitivity that assures im me di ate and smooth engagement of trailer brakes. The special design of the internal mul ti ple resistor pack provides heat sinking and heat dis si pa tion char ac ter is tics. For use on trailers with up to 8 brakes (4 axles).

The Warner Air Utility Control interconnects with air brake systems of tow vehicles and automatically op er ates electric trailer brakes in sychronization with air brakes.

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Section L-6

• Time Actuated Power: Trailer brakes are graduallyapplied at pre-set rates. Full brake actuation in about 2.5seconds. 100% solid state.

• Manual Override: Aids in setting controls and allowsmanual brake actuation.

• Two Color LED: Indicates completed circuit and brakeactuation.

• Installation: Mounts in any position, no leveling required.• Warranty: Limited 5 year warranty.

• Digital Display: Displays voltage being applied to brakes;presence of short circuit and trailer connection.

• Time Actuated Power: Trailer brakes are gradually appliedat pre-set rates. Full brake actuation in about 2.5 seconds.100% solid state.

• Manual Override: Aids in setting controls and allowsmanual brake actuation.

• Installation: Mounts in any position, no leveling required.Digital readout can be reset for installation requiring upsidedown mounting.


PART NO. REF.NO. DESCRIPTIONTA1000 416310 ELECTRONIC BRAKE CONTROL FOR 1-2 AXLES

PART NO. REF.NO. DESCRIPTIONTA1200 416296 DIGITAL BRAKE CONTROL FOR 1-3 AXLES

Brake Controls

• Time Actuated Power: Trailer brakes are gradually applied atpre-set rates. Full brake actuation in 2 seconds. 100% solidstate.

• Manual Override: Aids in setting controls and allows manualbrake actuation, activates brake lights.

• Multi-color LED: Indicates completed circuit, brake actua-tion and brake wire shorts.

• Installation: Mounts in any position, no leveling required,quick disconnects for easy removal.


PART NO. REF.NO. DESCRIPTIONTA900A 416321 ELECTRONIC BRAKE CONTROL FOR 1-3 AXLES

TA1200 Features Include:

TA1000 Features Include:

TA900A Features Include:

Section L-7

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Redline offers a universal kit, including all wire and electrical items nec es sary for a stan-dard brake control installation. Vehicle specific kits plug directly into the vehicle wiring harness.

Universal Kit

TA05-020

TA05-025 TA05-035

TA05-050

PART REF.NO. NO. DESCRIPTION

TA05-020 417900 UNIVERSAL BRK CNTRL KIT, INCLUDES WIRE, TERMINALS & BREAKER

TA05-025 417902 BRK CNTRL HARNESS W/PRODIGY-P RIMUS ADAPTER FOR 99-02 GM TRUCKS W/TOWING PKG

TA05-026 417903 BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR 03-07 GM TRUCKS W/TOWING PKG

TA05-126 417904 BRK CNTRL HARNESS FOR 99-06 GM TRUCK

TA05-030 417905 BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR 94-04 FORD, 05-08 F150 ONLY

TA05-130 417906 BRK CNTRL HARNESS FOR 94-04 FORD TRUCK, 05-08 F150 ONLY

TA05-031 417907 BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR 05-07 FORD SUPER DUTY

TA05-032 417908 BRK CNTRL HARNESS 08-11 FORD SUPER DUTY TRUCK

TA05-033 417909 BRK CNTRL HARNESS 09-10 FORD F150 W/CNTLR CTR

TA05-035 417915 BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR 95-11 DODGE RAM P/U & DURANGO

TA05-135 417916 BRK CNTRL HARNESS FOR 97-09 DODGE TRUCK

TA05-036 417917 BRK CNTRL HARNESS 2010 DODGE RAM W/CNCTR

TA05-045 417920 BRK CNTRL HARNESS, 06-10 HONDA TRUCKS W/PRODIGY

TA05-050 417925 BRK CNTRL HARNESS, 04-10 NISSAN TRUCKS W/PRODIGY

TA05-055 417930 BRK CNTRL HARNESS, 02-10 TOYOTA TRUCKS W/PRODIGY

Brake Control Installation Kits

All in one pAckAge - everything needed for

proper brAke control in stAl lA tion!

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Section L-8

Side-Post Mount Battery Adapter Kit

Allows direct connection to battery on vehicles using a side-post battery.

Brake Control Accessories

PART REF.NO. NO. DESCRIPTION2180S 418240 PULSE PREVENTER PREVENTS INTERFERENCE BETWEEN 4-WAY

FLASHER & BRAKE CONTROL6560 418250 TEKONSHA TRAILER EMULATOR, 7-WAY RV TYPE CONNECTOR

PART REF.NO. NO. DESCRIPTIONTA05-040 417910 SIDE POST MNT BATTERY ADAPTER KIT, CONTAINS

ADAPTERS, NUTS & CONNECTORS (QTY 2)

Easy to monitor battery condition. A simple “push to test” button on the front activates LED lights. A weld-on mounting bracket is also available.

PART REF.NO. NO. DESCRIPTION BATTERY APPLICATIONBA10-150 419235 “ENGAGER” BRKWY KIT, W/LED CHARGE INDICATOR 5AMP/HR 1-2 AXLESBA10-250 419236 “ENGAGER” BRKWY KIT, FLIP-TOP W/LED INDICATOR 5AMP/HR 1-2 AXLESBA10-150BKT 419238 WELD-ON BRACKET W/STUDS, FITS BA10-15020012 419230 REPLACEMENT PIN & CABLE FOR ENGAGER SWITCH

BA10-150BA10-250

“The Engager” Breakaway Kits

Section L-9

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Breakaway Kits

These Electronic Breakaway Kits feature a re charge able, sealed, maintenance-free battery and an op tion al charger, for trouble-free towing. (Choice of 4 Battery Box Designs.)

•CompactDesign•Rechargeable,sealed,maintenance-free12vBattery•Dependable•Wideoperatingtemperature(-76ºFto+140ºF)•MeetsorexceedsD.O.Tregulations

See next page for Breakaway Kit Accessories.

PART REF. BATTERYNO. NO. DESCRIPTION BATTERY SWITCH CHARGER APPLICATION BOXBA10-140 419229 REDLINE, W/CHRGR 5 AMP/HR BA02-010 YES 1-2 AXLES FRONT LOAD42905 419240 BRKY KIT W/CHGR, LED INDCTR NONE BA02-010 YES 1-2 AXLES TOP LOAD42905K 419241 BRKY KIT W/CHGR, LED INDCTR 5 AMP/HR BA02-010 YES 1-2 AXLES TOP LOAD42906 419242 BRKY KIT W/CHGR, LED INDCTR NONE BA02-010 YES 1-2 AXLES FRONT LOAD42906K 419243 BRKY KIT W/CHGR, LED INDCTR 5 AMP/HR BA02-010 YES 1-2 AXLES FRONT LOADD2903 419260 BRKY KIT W/CHG NONE BA02-010 YES 1-2 AXLES FRONT LOADD2903K 419262 BREAKAWAY KIT 5 AMP/HR BA02-010 YES 1-2 AXLES FRONT LOADD2904 419265 BREAKAWAY KIT NONE BA02-010 NO 1-2 AXLES FRONT LOADD2904K 419267 BREAKAWAY KIT 5 AMP/HR BA02-010 YES 1-2 AXLES FRONT LOADBKW86114 419276 BRKY KIT, PREWIRED QTY 10 5 AMP/HR BA02-010 YES 1-2 AXLES FRONT LOADBKW86140 419286 BRKY KIT, PREWIRED QTY 10 5 AMP/HR BA02-010 NO 1-2 AXLES FRONT LOAD1026 419300 TEKONSHA, NO CHRGR 4 AMP/HR 2005 N/A 1-2 AXLES 20181028A 419312 TEKONSHA, W/CHRGR 4 AMP/HR 2005 1024 1-2 AXLES 20182026 419410 TEKONSHA, NO CHRGR 5 AMP/HR 2010 N/A 1-3 AXLES 20182028 419420 TEKONSHA, W/CHRGR 5 AMP/HR 2010 2024 1-3 AXLES 201820005 419425 TEKONSHA, NO CHRGR 5 AMP/HR 2010 N/A 1-3 AXLES 205120015 419427 TEKONSHA, W/CHRGR 5 AMP/HR 2010 2024 1-3 AXLES 205120010 419430 TEKONSHA, NO CHRGR 5 AMP/HR 2010 N/A 1-3 AXLES 2000020020 419440 TEKONSHA, W/CHRGR 5 AMP/HR 2010 2024 1-3 AXLES 20000

Breakaway kits

D2903K42906

BA10-140

42905

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Section L-10

PART REF.NO. NO. DESCRIPTIONBA01-025 419244 REDLINE BATTERY, 12V, 5AMP BATTERY SEALED, CLAM-PKGDBA01-020 419245 REDLINE BATTERY, 12V, 5AMP/HR FOR 1-2 AXLE TRAILERSUB1250 419246 SEALED LEAD ACID BATTERY, 12V, 5 AMP/HR FOR 1-2 AXLE TRAILERSBA02-010 419250 NYLON BRKY SWITCH W/METAL BRACKET, PKGDBA02-020 419255 12V MAINTENANCE CHARGER FOR BRKY KITS, PKGD20059 419700 LED BREAKAWAY SWITCH, 7” WIRES20051 419710 REPL PIN & CABLE FOR 20059 BREAKAWAY SWTCH20010H 419715 BRKY SWITCH, HOPKINS “NEW” STYLE, 7” WIRES2005A 419750 REPL PIN & CABLE, FITS 2005 BREAKAWAY SWITCH2009 419800 BRKY SWITCH, ALL METAL W/SILVER CONTACT POINTS & BRASS PULL PIN2010 420000 BRKY SWITCH, NYLON CASE, WELDABLE METAL TAB, SILVER CONTACT POINTS, NYLON

PULL PIN2010A 420100 REPL NYLON PULL PIN & CABLE FOR 2010 BRKY SWITCH2018 420210 BATTERY CASE, POLYETHYLENE PLASTIC, A-FRAME OR JACK POST MOUNT20000 420215 BATTERY CASE, POLYETHYLENE PLASTIC, LOCKABLE, FLAT SURFACE MOUNT, WELD-ON2051 420220 BATTERY CASE, POLYETHYLENE PLASTIC, LOCKABLE, FLAT SURFACE MOUNT, BOLT-ON1024 420885 MAINTENENCE BATTERY CHARGER, 12V (WILL NOT FULLY RECHARGE BATTERY)2024 420900 QUICK BATTERY RECHARGER, 12V (WILL RECHARGE BATTERY IN APPROX. 4-5 HRS)

2010

20059

Breakaway Kit Accessories

2-PIECE BA01-020

BA02-010

BA02-020

UB1250

20000

2018 2051

Section L-11

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• 12VDCpoweredelectric-hydraulicpump-styleactuatorforelectroni-cally controlled hydraulic brakes

• Compatiblewithmostindustrystandardelectronicbrakecontrollers.(Use HBA-CAM for controller compatibility issues.)

• “UnloadingPiston”featureinstantlyreleaseshydraulicpressureuponstop of brake signal, eliminates pump-style actuator “brake drag”.

• Completelysealedtobeaweather-tightunit,approvedformarineapplications

• Actuatordesignedforsingleortandemaxleapplications• Compactdesign,measures3.25”Wx5.75”Hx17.5”L• Forusewithindustrystandard5AMP/HOURBreakawayKit• 2-YearWarranty

PART NO. REF. NO. DESCRIPTIONHBA-CAM 247635 CONTROL ADAPTER MODULE

HBA-10 247636 1000 PSI UNIT

CAR-HBA10-2A 247638 1000 PSI DRUM TDM W/9505 LINE KIT & BRKY

CAR-HBA10-2 247640 1000 PSI DRUM TDM W/DELX LINE KIT & BRKY

HBA-16 247645 1600 PSI UNIT

CAR-HBA16-2 247647 1600 PSI DISC TDM W/DELX LINE KIT & BRKY (3.5K-8K)

CAR-HBA16-2HD 247650 1600PSI DISC TDM W/10-12K LINE KIT & BRKY

HBA-BKT 247651 BOLT-ON MOUNTING BRACKET FOR HYDRASTAR

HBA-BC 247634 REP’L FILLER CAP, HBA-SERIES HYDRASTAR

The Carlisle Hydrastar XL uses an on-board microprocessor and accelerometer to sense the amount of braking effort being generated by the tow vehicle. The Hydrastar XL does not require a hard-wired in cab electronic brake controller. The hand held actuator plugs into the cigarette lighter, using the vehicle’s original wiring to transmit signals to the actuator. The Hydrastar XL is great for any situation where multiple tow vehicles may be used to pull a single trailer, especially rental units.

• Nohard-wiredbrakecontrollernecessary.• 17Amp/Hourbreak-awaybatterykitrequired• Nospecialwiringneeded,nocompatibilityconflictsw/factory

vehicle controllers.• Greatforrentalunitsorwhereusingmultipletowvehicleson

a single trailer .

Carlisle Hydrastar XL Electric-Hydraulic Brake Actuator

Cargo Towing Solutions Hydrastar Electric-Hydraulic Brake Actuators HYDRASTAR FEATURES:

HYDRASTAR XL FEATURES:

Hydrastar XLwith controller

HBA-CAM Controller AdApter Module:

• MakestheHydraStar®unitcompatiblewithmostFordOETowCommandcontrollers(whereneeded),&GMFactoryControllers.

• Easytoinstall,simplyspliceinfourwires&mountthemodulewhereconvenient.

• CheckwithyourRedneckCustomerServiceTeamforcurrentapplications.

What’s stopping

your trailer?

PART NO. REF. NO. DESCRIPTION

HBAC10-CLR 247655 XL, 1000 PSI UNIT W/IN-CAB CONTROLLER

CAR-HXL10-2A 247657 XL 1000PSI KIT W/CNTRL, HYD LINE & BRKY

CAR-HXL10-2 247660 XL 1000PSI KIT W/CNTRL, DLX LINE KIT & BRKY

HBA-EBA 419450 17AMP BREAKAWAY KIT FOR HYDRASTAR XL/ELECTRASTAR

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Section L-12

• Mastercylindercaphasadiaphragmprovidingacompletelyenclosed hydraulic brake system on all models.

• Raisedfillplatepreventscontaminantsfromenteringmastercylinder when removing cap on all models.

• Tieloopsoncapcanbeusedforatamperresistantseal.• Bellowbootonpushrodformoistureanddirtpreventionon

all models.• Emergencyleverguidewithcolorcodeddecalindicatesifbrakesareonoroff(allmodels

EXCEPT DA66B).• Brakelinepressurecontrolledbyspringloadedpushrodassembly.• Integratedshockdampeningdesign.• Emergencybrake-awayleverwithcablehook-upandeasyreset.• Corrosionresistantfinishprovideslong-lasting,attractiveappearance.Platedfinishis500hour

salt spray tested.• 6,000lb.to20,000lb.actuatorsutilizeacetalcopolymerlinings.Rollersareeliminatedon

DA91, DA10 and DA20 models.

8202022 8101222

DA9150-2HBC8759122

82043118104311 8605001

Hydraulic Brake ActuatorsHydraulic Brake Actuators

Composite, Corrosion-Free

Master Cylinder!

Section L-13

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Brake Actuators*

Demco Actuator Replacement Parts

6k aCtUatOrPART REF.NO. NO. DESCRIPTION8605001 302170 DA66B ZINC, 3” TONGUE, 2” COUPLER, DRUM

8605101 302175 DA66B ZINC, 3” TONGUE, 2” COUPLER, DISC

8k aCtUatOrPART REF.NO. NO. DESCRIPTION8759122 302200 DA91 W/CHANNEL ONLY, 3” TONGUE, DRUM

DA91-2HBC 302215 DA91 W/ADJ 2” H-BLOW COUPLER (7,000 LB.), DRUM

DA91-2516HBC 302225 DA91 W/ADJ 2-5/16” H-BLOW COUPLER, DRUM

8759522 302275 DA9150 W/CHANNEL ONLY, A-FRAME, DRUM

DA9150-2HBC 302280 DA9150 W/ADJ 2” H-BLOW COUPLER (7,000 LB.), DRUM

DA9150-2516HBC 302285 DA9150 W/ADJ 2-5/16” H-BLOW COUPLER, DRUM

12.5k aCtUatOrPART REF.NO. NO. DESCRIPTION8103102 302775 DA10 W/FIXED 2-5/16” COUPLER, DRUM

8102511 302785 DA10 ZINC, 2 5/16” DROP COUPLER, DRUM

8104311 302787 DA10 ZINC, 2 5/16” DROP COUPLER, DISC

8101222 302815 DA10 W/CHANNEL ONLY, DRUM

DA10-3ADJEYE 302820 DA10 W/3” ADJ EYE, DRUM

DA10-2516ADJ-HBC 302846 DA10 W/ADJ 2-5/16” H-BLOW COUPLER, DRUM

DA10-2516ADJ-ATW 302847 DA10 W/ADJ 2-5/16” ATWOOD COUPLER, DRUM

20k aCtUatOrPART REF.NO. NO. DESCRIPTION8204011 302850 DA20 ZINC, 2 5/16” DROP COUPLER, DRUM

8204311 302854 DA20 ZINC, 2 5/16” DROP COUPLER, DISC

8202022 302875 DA20 W/CHANNEL ONLY

DA20-2516ADJ-ATW 302882 DA20 W/15K, ADJ 2-5/16” ATWOOD CPLR

DA20-3ADJEYE 303020 DA20 W/3” ADJ EYE

16k aCtUatOrPART REF.NO. NO. DESCRIPTION8164311 302849 DA16 ZINC, 2 5/16” DROP COUPLER, DISC

PART REF.NO. NO. DESCRIPTION5650 304002 MASTER CYL, DRUM, FITS ALL MODELS

5672 304003 MASTER CYL, DISC, FITS ALL MODELS

3876 304022 MASTER CYL CAP, FITS ALL MODELS

5692 304042 SHOCK, FITS DA66 ACTUATORS

DS12426 304045 SHOCK, FITS DA91, DA10 & DA20 ACTUATORS

5401 304062 BRKWY CABLE/LEVER FITS DA91, DA10, DA20

DO5400 304065 BRKWY CABLE/LEVER KIT FITS DA66 ACTUATORS

*Disc Brake Actuators feature back-up solenoid pre-installed.

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Section L-14

Atwood Actuators have heavy gauge stamped steel housings, with ball socket as sem blies. Breakaway mechanism sets and locks the trailer brakes in the event of tow vehicle/trailer separation. A unique pivot linkage permits a light weight, more compact design. The “Re verse Lock-Out” lever allows for easier backing of trailer.

Atwood Brake Actuators

Titan Brake Actuators

The Balcrank Actuator has a rugged design with stan dard 50 degree A-frame mount flange. It has a breakaway device which sets and locks the trailer brakes in the event of tow vehicle/trailer separation. The unique shock absorber/coil spring design of this Actuator provides smooth, positive stopping power, eliminating the possibility of dam ag ing peak pres sures to the sys tem. 5,000–6,000 G.V.W.R. capacity, depending on coupler used.

Balcrank Brake Actuators

PART REF.NO. NO. DESCRIPTION82541 302000 ACTUATOR, PAINTED WELD-ON, 2” BALL, 3” TONGUE, 6K CAP, DRUM84132 302100 ACTUATOR, PLATED BOLT-ON, 2” BALL, 3” TONGUE, 6K CAP, DRUM88730 302105 ACTUATOR, PLATED BOLT-ON, 2” BALL, 3” TONGUE, 6K CAP, DISC83000 302725 ACTUATOR, PAINTED WELD-ON, 2” BALL, 3” TONGUE, 8K CAP, DRUM83010 302750 ACTUATOR, PLATED BOLT-ON, 2” BALL, 3” TONGUE, 8K CAP, DRUM84258 304225 REPLACEMENT BOOT KIT FOR 8254185841 304250 REPLACEMENT MASTER CYLINDER FOR 82541, AFTER 1980, DRUM87478 304350 REPLACEMENT MASTER CYLINDER CAP & GASKET FOR 82541, AFTER 198085830 304400 REPLACEMENT SHOCK FOR 82541 ACTUATOR, AFTER 198085852 304450 REPLACEMENT PUSH ROD KIT FOR 82541

PART REF.NO. NO. DESCRIPTION4332900 303080 MODEL 60, 6K ZINC, 1-7/8”or 2”ADJ LVRLOCK CPLR, DRUM4715420 303082 MODEL 60, 6K ZINC, 1-7/8”or 2”ADJ LVRLOCK CPLR, DISC2478100 303090 MODEL 10, 12.5K ZINC, 2-5/16” DROP CPLR, DRUM4750620 303092 MODEL 10, 12.5K ZINC, 2-5/16” DROP CPLR, DISC4042700 303100 MODEL 20, 20K ZINC, 2-5/16” DROP CPLR, DRUM4750720 303102 MODEL 20, 20K ZINC, 2-5/16” DROP CPLR, DISC

PART REF.NO. NO. DESCRIPTION23361 304500 MASTER CYLINDER, DRUM, MODEL 6047142 304501 MASTER CYLINDER, DISC, MODEL 604480701 304550 M-CYL CAP & GASKET, MODEL 6023362 304600 SHOCK, MODEL 6040454 304650 COUPLER REPAIR KIT, MODEL 60, MULTIFIT CPLR43584 304651 COUPLER REPAIR KIT, MODEL 60, LEVERLOCK CPLR23414 304655 M-CYL COVER-GASKET, MODEL 6023566 304660 MASTER CYL COVER, MODEL 60, USE W/2341423744 304700 MASTER CYLINDER, DRUM, MODEL 10 & 2047471 304701 MASTER CYLINDER, DISC, MODEL 10 & 2012099 304720 HYD CONN FITTING, MODEL 10&20 “OLD STYLE”4830600 304750 M-CYL CAP, MODEL 10 & 20DS12426 304045 SHOCK, MODEL 107784 304850 SHOCK, MODEL 20

PART REF.NO. NO. DESCRIPTION16006 302600 ACTUATOR W/2” HAMMERBLOW COUPLER, 5K, DRUM16039 302700 ACTUATOR WITH 2 5/16” HAMMERBLOW COUPLER, 6K, DRUM1745 305205 REPLACMENT NYLON PIVOT BUSHINGS (8 REQUIRED PER ACTUATOR)1753 305220 1/2” - 20 SELF-LOCK PIVOT SHAFT NUT (8 REQUIRED PER ACTUATOR)1808-1 305280 REPLACEMENT PIVOT LINK (4 REQUIRED PER ACTUATOR)1829 305300 PIVOT SHAFT (4 REQUIRED PER ACTUATOR)1844-2 305360 REPLACEMENT SHOCK ABSORBER16500 305381 REPLACEMENT MASTER CYLINDER CAP10614 305400 REPLACEMENT MASTER CYLINDER

Titan Actuator Repair Parts

Model 10

Model 60 Leverlock Drum

Model 60 Leverlock Disc

Model 20

NOTE: Disc Brake Actuators feature back-up solenoid pre-installed.

Section L-15

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• LargeReservoirCapacity• SolidStateElectronics• 2YearLimitedWarranty• Requiresa4-wirehookup.• Minimum9amp/hourBreakawayKit• Dimensions:11”long,6”wide,7”high• Compatiblewithmostelectronicbrake

controllers.

Electric/Hydraulic Brake Actuator

Hydraulic Line Kits come complete with all necessary lines, tee fittings, hoses, brack ets and clips to properly plumb conventional hydraulic brake axles. Torsion axles require additional line kits, (80910 or 80910-T), or use 9579-2 Deluxe kit with limited access flex hoses included.

Hydraulic Line Kits

9579-2

9504 9505


K71-650 247626 DX1000 1,000 PSI ACT (DRUM BRAKE APPLICATION)

K71-650-2A 247627 DX1000 1,000 PSI ACT DRUM TDM W/9505 LINE KIT & BRKY

K71-650-2 247628 DX1000 1,000 PSI ACT DRUM TDM W/DELUXE LINE KIT & BRKY

K71-651 247631 DX1600 1,600 PSI ACT (DISC BRAKE APPLICATION)

K71-651-2 247632 DX1600 1,600 PSI ACT DISC TDM W/DELUXE LINE KIT & BRKY (3.5K - 8K)

K71-651-2HD 247633 DX1600 1,600 PSI ACT DISC TDM W/10-12K LINE KIT & BRKY

34-285 419290 DEXTER 9AMP/HR BREAKAWAY KIT, USE W/K71-650 & K71-651

097-011-01 247625 REPL FILLER CAP W/GASKET

PART REF.NO. NO. DESCRIPTION9504 256500 HYD LINE KIT SINGLE AXLE, DRUM

9505 256525 HYD LINE KIT TANDEM AXLE, DRUM

80910 256550 HYD LINE KIT TF AXLE (1 WHL) USE W/ 9504 & 9505

80910-T 256575 HYD LINE KIT TF AXLE (1 WHL) W/LMTD ACCESS, USE W/ 9504 & 9505

9579-2 256580 HYD LINE KIT, TANDEM AXLE, DELUXE DRUM & 3.5K-8K DISC

9579-01 256585 HYD LINE KIT, 3RD AXLE, DELUXE DRUM & 3.5K - 8K DISC

3057089 259150 ADAPTER FITTING, ADAPTS 9579-2 TO FIT 10K - 12K DISC CALIPERS

34-285

9504 9505 9579-2

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Section L-16

The 8102 Air Trailer kit is designed for tandem axle trailers without spring brakes, that do not comply with revised FMVSS571.121 brake system mandates (effective March 1, 1998), and should only be used on vehicles that are exempt from those compliance requirements.

Kit includes mounting hard ware, fittings, gladhands, one 1488 cu. in. tank, tank drains and all required valves. Air brake tubing is not in clud ed, due to variations in lengths required for in di vid u al in stal la tions.

8102 Air Trailer Kit

The 8202-1 Air Trailer kit is designed for tandem axle trailers with spring brakes that do not comply with revised FMVSS571.121 brake system mandates (effective March 1, 1998), and should only be used on vehicles that are exempt from those compliance requirements.

This Kit will support spring brakes of type 16-24, type 24-30 and type 30-30. The kit in cludes mounting hardware, fittings, gladhands, one 2800 cu. in. tank, tank drain and all re quired valves. Air brake tubing is not in clud ed, due to vari a tions in lengths required for in di vid u al installations.

8202-1 Air Trailer Kit


8102 249800 AIR TRAILER KIT FOR 2 AXLES W/O SPRING BRAKES, DESIGNED

FOR TRAILERS EXEMPT FROM FMVSS571.121

6606-1 249900 3/8” AIR BRAKE TUBING, 100’ ROLL

PART REF.NO. NO. DESCRIPTION8202-1KT 249851 STRAIGHT AIR TRAILER KIT FOR 2 AXLES W/SPRING BRAKES,

DESIGNED FOR TRAILERS EXEMPT FROM FMVSS571.121

6606-1 249900 3/8” AIR BRAKE TUBING, 100’ ROLL

Section L-17

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8200 Series ABS Air Trailer KitsThe 8200 Series ABS kits are designed for tandem axle trailers that are ABS equipped and have spring brakes. These kits have been designed to conform to all FMVSS571.121 re quire ments for brake systems, including antilock brake systems, mandated for air brake trailers man u fac tured after March 1, 2001.

These kits will support spring brakes of type 16-24, type 24-30 and type 30-30. Kits in clude ABS modulator valve(s), ABS warning light, power cord, cable leads, spring brake valve, mounting hardware, fittings, gladhands, and a 2800 cu.in. tank. Air brake tubing is not included, due to variations in lengths required for individual in stal-la tions.

PART REF.NO. NO. DESCRIPTION8202-21-1KT 249861 “2S/1M” ABS AIR TRAILER KIT FOR 2 AXLES W/SPRING BRAKES (ONE AXLE ABS EQUIPPED)

8202-42-1KT 249866 “4S/2M” ABS AIR TRAILER KIT FOR 2 AXLES W/SPRING BRAKES (BOTH AXLES ABS EQUIPPED)

6606-1 249900 3/8” AIR TUBING, 100’ ROLL

The 8500 Series Air/Hydraulic Trailer Kits include control valves, air tank, air/hydraulic booster and a complete hydraulic line kit for tandem axle trailer. ABS kits also include the necessary components for compliance with FMVSS571.121 re quire ments for Antilock Brake Systems, mandated for trailers manufactured after March 1, 2001.

These ABS kits are “2S/1M” systems, requiring 1 axle to be ABS equipped with sensors and tone rings. The axle is the determining factor for which kit should be used.

8500 Series Air/Hydraulic Trailer Kits

* Non-ABS air/hydraulic kits do not comply with revised FMVSS571.121 brake system mandates effective March 1, 1998, and shouldonly be used on vehicles that are exempt from those compliance requirements.

ABS KITS NON-ABS KITS*PART REF. PART REF.NO. NO. DESCRIPTION NO. NO.

8510-21-2KT 249516 DEXTER 3.5K - 15K DRUM 8510-2KT 249511

N/A N/A HAYES/ALKO ALL 9K THRU 12K DRUM 8515-2KT 249611

8516-21-2KT 249626 10K & 12K DISC BRAKES (ALL MANUFACTURERS) 8516-2KT 249621

NOTE: An Air Brake Truck pulling an Air-Hydraulic Brake Trailer is not a balanced brake system! Excessive trailer brake wear may occur. 8500 Series Air-Hy drau-lic System should be used only as last option to operate trailer brakes.

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Section L-18

Miscellaneous Brake System Parts

PART REF.NO. NO. DESCRIPTION11451 255010 EMERGENCY GLADHAND (RED)

11452 255011 SERVICE GLADHAND (BLUE)

AL90006 255025 ABS RELAY VALVE W/ECU, 2S/1M & 4S/2M

AL364040 255028 ABS RELAY VALVE, 4S/2M (SLAVE RELAY)

110376 255055 EMERGENCY SPOOL VALVE, NON-ABS

110380 255060 AIR BRK RELAY VALVE, NON-ABS

110500 255065 SPRING BRAKE VALVE

6482-3 255075 2850 CUBIC INCH AIR TANK

19840 255077 1488 CUBIC INCH AIR TANK

6510 256300 AIR/HYD BOOSTER, 1000PSI (DRUM)

6515-M 256332 AIR/HYD BOOSTER, 1600PSI (DISC)

3057817 256333 3/16 LINE ADAPTER FITTING FOR A/H BOOSTERS ABOVE, 1/2-20M X 3/8-24F INV

11451 & 11452

110380 110500AL90006

110376

6510

Section L-19

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Hydraulic Fittings

Hydraulic Lines and Brackets

301-3

301-4

306-3

307-3

PART REF.NO. NO. DESCRIPTION301-3 257800 STEEL LINE NUT FOR 3/16” HYDRAULIC STEEL LINE (PKG OF 8)301-4 257900 STEEL LINE NUT FOR 1/4” HYDRAULIC STEEL LINE (PKG OF 8)306-3 258000 LINE UNION FOR 3/16” STEEL LINE (PKG OF 4)307-3 258200 LINE TEE FOR 3/16” STEEL BRAKE LINE (PKG OF 2)3057818 259200 3/16” FEMALE X 1/4” MALE ADAPTER FOR HYDRAULIC

BRAKE LINES (PKG OF 4)3057828 259250 1/4” FEMALE X 3/16” MALE ADAPTER FOR HYDRAULIC

BRAKE LINES (PKG OF 4)3087812 262600 AXLE LINE TEE FITTING, 3/16” LINE W/BRACKET (PKG OF 2)3087900 262625 3/16” HYD SERVICE TEE (PKG OF 2)3057089 259150 HYD ADAPTER,10K-12K DISC 7/16-20M x 3/8-24F INV

PART REF.NO. NO. DESCRIPTION322351 260200 HYDRAULIC STEEL LINE, 3/16” X 51”323325 260425 HYDRAULIC STEEL LINE, 3/16” X 25’ COIL323425 261625 HYDRAULIC STEEL LINE, 1/4” X 25’ COIL310798 261800 HYD FLEX BRAKE HOSE, 7/16”-24 FEMALE X 7/16”-20 MALE, 20.5”LONG16196 261802 REPLACEMENT FLEX HOSE, FITS 3/16” LINE FITTINGS, 18.5” LONG

(3/8”-24 M/F)310797 261805 HYD FLEX BRAKE HOSE, 3/8”-24 FEMALE X 3/8”-24 MALE, 20.5” LONG18018-SF 261810 HYD FLEX HOSE 18”L, 3/8-24 MALE END 90º, FEMALE STD309801 262000 STEEL HOSE BRACKET (PKG OF 4)309802 262200 CLIP FOR 309801 BRACKET (PKG OF 4)

322351

310797

30980116196

309802

18018-SF

3057818

3057828

3087812

3087900

3057089

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Section L-20

SURGING BRAKES

HARSH BRAKES

INTERMITTENT BRAKES

OPEN CIRCUITS FIND AND CORRECT

SEVERE UNDER ADJUSTMENT ADJUST BRAKES

FAULTY CONTROLLER TEST AND CORRECT

SHORT CIRCUITS FIND AND CORRECT

NO BRAKES

WEAK BRAKES

LOCKING BRAKES

BRAKES PULL TO ONE SIDE

NOISY BRAKES

DRAGGING BRAKES

Electric Brake Trouble Shooting Guide

GREASE/OIL ON MAGNETS/LININGS CLEAN OR REPLACE

CORRODED CONNECTIONS CLEAN/CORRECT CAUSE

WORN LININGS OR MAGNETS REPLACE

SCORED/GROOVED BRAKE DRUMS MACHINE OR REPLACE

IMPROPER SYNCHRONIZATION CORRECT

UNDER ADJUSTMENT ADJUST BRAKES

GLAZED LININGS REBURNISH OR REPLACE

OVERLOADED TRAILER CORRECT

FAULTY CONTROLLER TEST AND CORRECT

BROKEN WIRES REPAIR OR REPLACE

LOOSE CONNECTIONS FIND AND REPAIR

PROBLEM CAUSES REMEDIES

UNDER ADJUSTMENT ADJUST


FAULTY CONTROLLER TEST & CORRECT

LOOSE, BROKEN BRAKE PARTS REPLACE COMPONENTS

OUT OF ROUND BRAKE PARTS REPLACE COMPONENTS

OUT OF ROUND BRAKE DRUMS MACHINE OR REPLACE

INSUFFICIENT WHEEL LOAD ADJUST SYSTEM RESISTOR

INCORRECT ADJUSTMENT ADJUST

GREASE/OIL ON LININGS/MAGNET CLEAN OR REPLACE

BROKEN WIRES FIND & REPAIR

BAD CONNECTIONS FIND & REPAIR

UNDER ADJUSTMENT ADJUST


IMPROPER CONTROLLER CHANGE


UNDER ADJUSTMENT ADJUST BRAKES

LACK OF LUBRICATION LUBRICATE

BROKEN BRAKE PARTS REPLACE COMPONENT

INCORRECT BRAKE PARTS REPLACE

GREASE/OIL ON LININGS/MAGNET CLEAN OR REPLACE



OVER ADJUSTMENT READJUST


INCORRECT BRAKE PARTS REPLACE

BROKEN BRAKE PARTS REPLACE

FAULTY BREAKAWAY SWITCH REPAIR OR REPLACE

LOOSE WHEEL BEARING ADJ. ADJUST

BENT SPINDLE REPLACE AXLE

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