Table of Contents
Introduction
Important Safety Notice ......................................................................................................4
Getting Started - Setup and Adjustment ..............................................................................4
Braking Systems - Electric
Electric Brakes ....................................................................................................................5
Features .............................................................................................................................6
Parking Brake Option .................................................................................................6
Self Adjusting Feature ...............................................................................................6
Brake Controllers .......................................................................................................7
Typical Trailer Wiring .................................................................................................10
How to Use Your Electric Brakes Properly .................................................................11
Trailer Wire Size Chart ..............................................................................................11
Synchronizing Your Trailer Brakes .............................................................................12
General Maintenance Electric Brakes ................................................................................13
Brake Adjustment ....................................................................................................13
Brake Cleaning and Inspection ................................................................................14
Brake Lubrication ....................................................................................................14
Magnets ...........................................................................................................................15
Shoes and Linings ............................................................................................................16
Introduction to Troubleshooting .........................................................................................17
Troubleshooting ................................................................................................................17
Troubleshooting Chart - Electric ...............................................................................18
How to Measure Voltage ..........................................................................................20
How to Measure Amperage ......................................................................................20
Magnet Amperes Chart ............................................................................................21
Braking Systems - Hydraulic
Hydraulic Brakes...............................................................................................................23
Hydraulic Drum Brake Operation .......................................................................................24
Duo-Servo ...............................................................................................................24
Uni-Servo ................................................................................................................24
Self-Adjusting Mechanism for 12 1/4" Brakes ........................................................25
Hydraulic Parking Brake Option ...............................................................................25
Hydraulic Disc Brakes..............................................................................................27
Actuation Systems ............................................................................................................28
Electrical Schematic ................................................................................................28
Troubleshooting Guide .............................................................................................29
General Maintenance - Hydraulic Brakes...........................................................................31
Drum Brake Adjustment - Manual ............................................................................31
Wheel Cylinders ......................................................................................................32
Brake Lines .............................................................................................................32
Shoes and Linings ...................................................................................................32
Hardware ................................................................................................................33
Instructions for Brake Caliper Kit - 3.5K Disc Brakes ................................................33
Instructions for Brake Rotor Kit - 3.5K Disc Brakes ..................................................34
Instructions for Brake Rotor Kit - 6K or 8K Disc Brakes ............................................36
Instructions for Brake Hub/Rotor Kit - 7K Disc Brakes .............................................37
Instructions for Brake Pad Kit - 6K, 7K or 8K Disc Brakes ........................................39
Instructions for Brake Caliper Kit - 6K, 7K or 8K Disc Brakes ...................................42
Introduction to Troubleshooting .........................................................................................45
Troubleshooting Chart - Hydraulic ............................................................................46
Hubs/Drums/Bearings
Hubs/Drums/Bearings ............................................................................................48
Hub Removal - Standard Bearings ...........................................................................49
Brake Drum Inspection ............................................................................................49
Bearing Inspection ..................................................................................................50
Bearing Lubrication - Grease ..................................................................................52
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