INSTALLATION, INSTRUCTION AND SERVICE MANUAL Actuator/Trailer Dealer – Please provide to consumer. Consumer – Read and follow instructions. Keep with trailer for reference.
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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1. Introduction ...... 3
2. General Information ...... 3
3. Safety Information ...... 4
4. Maintenance ...... 4
5. Installation ...... 5
6. Solenoid Backup Valve ...... 6
7. Bleeding Brakes ...... 7
8. Testing Surge Brake Systems ...... 8
9. Hitching Trailers ...... 9-10
10. Model 10 Assembly ...... 10
11. Actuator Parts Diagram ...... 11-12
12. Actuator Product List ...... 13-14
13. Troubleshooting ...... 15
14. Warranty ...... 16
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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Coupler Max GVWR Max Tongue Load Fixed 2 5/16" Ball Coupler Fixed 3" Lunette Eye Adjustable 2 Bolt 3" Lunette Eye 20,000 2,000 Adjustable 3 Bolt 2 5/16" Ball Coupler Adjustable 3 Bolt Clevis Hitch Adjustable 2 Bolt 2 5/16" Ball Coupler 14,000 1,400 Adjustable 2 Bolt Clevis Hitch *Adjustable hitch ratings given for both 4 and 6 hole leveler channels
WARNING DO NOT exceed the GVWR of the coupler listed above at any time during use. Serious damage or injury may occur due to equipment failure if given ratings are exceeded.
Thank you for purchasing a TITAN Model 10 Surg-O-Matic Actuator system. TITAN’s Model 10 actuator is designed for trailers rated up to 12,500 pound Gross Vehicle Weight Rating (GVWR). TITAN Model 10 tongue options vary from standard 2 5/16” ball couplers, to adjustable 3” lunette eye.
Surge braking is accomplished by replacing a trailer’s standard tongue coupler with an actuator and adding hydraulic brake assemblies. A trailer’s “surge” or “Push” toward tow vehicles during deceleration automatically synchronizes trailer brakes with tow vehicle brakes. As trailer pushes against vehicle, actuator telescopes together applying force to master cylinder, supplying hydraulic pressure to trailer’s brakes.
Surge actuators provide a service life of approximately five years with proper installation, usage, and maintenance. A well-cared for actuator can often exceed this estimate. Follow instructions given in this manual and use common sense in caring for TITAN Model 10 actuator.
TITAN’s Model 10 actuator is offered in a variety of tongue styles. Figure 1 shows capacity ratings for each style. Coupler Max GVWR Max Tongue Load Fixed 2 5/16" Ball Coupler MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR) is Fixed 3" Lunette Eye weight of trailer fully loaded with cargo, equipment, and Adjustable 2 Bolt 3" Lunette Eye 12,500 1,250 Adjustable 2 Bolt 2 5/16" Ball Coupler trailer weight itself. To find trailer’s GVWR, check serial Adjustable 2 Bolt Clevis Hitch label affixed to trailer. This information is typically based *Adjustable hitch ratings given for 4 and 6 hole leveler channels on axle capacity and configuration. Consult trailer Figure 1 Model 10 Tongue Capacities manufacturer if information is unable to be located.
MAXIMUM TONGUE LOAD is weight applied downwards by fully loaded trailer’s coupler onto tow vehicle’s hitch. Trailer tongue load may be checked using a commercial scale. Make sure tongue is in horizontal position and jack is only component on scale. Upwards tongue loads are not permissible.
RECOMMENDED USE for Model 10 is for use on heavier recreational and light industrial trailers. The actual in-service rating is limited to ball and hitch used or trailer manufacturer’s GVWR shown on certification label, whichever is lower.
WARNING DO NOT exceed GVWR of coupler at any time during use. Serious damage or injury may occur.
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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1) Actuator installation, maintenance, or repair should ONLY be performed by qualified persons who have training or knowledge of actuators and brake systems
2) When installing, maintaining, or repairing TITAN equipment, wear eye protection as well as other necessary personal protective equipment.
3) TITAN equipment must be maintained in safe working order at all times. Trailer equipment should be inspected before, during, and after use for wear and damage.
4) Perform frequent and regular inspection of trailer and equipment.
a. Brake Fluid – Check for proper brake fluid level. Should be ¾ full b. Actuator – Check for worn, bent, or corroded/seized parts, replace with genuine TITAN service parts.
c. Actuator Travel – Verify actuator function and travel of tongue shown by front roller path do not exceed one inch. Excessive travel may require brake adjustment. d. Greased hitch – Slightly greased hitch ball helps extend coupler life.
5) Confirm brake actuator being used can supply enough hydraulic pressure and volume to actuate disc brakes. As a common rule, disc brakes require more pressure and larger volume of fluid than drum brakes of same size.
6) Use DOT3 or DOT4 brake fluid. Failure to use correct brake fluid may result in brake failure.
7) Be familiar with state laws in operation of towed vehicles, especially with regard to brake and braking
requirements. Towing a trailer may require additional braking time and distance. Allow for this in driving habits while towing.
8) Make certain equipped trailer is safely supported at all times during installation, maintenance or repair.
9) After every hookup, test and confirm trailer brake system is operating correctly and adequately before transportation on roads.
1. Before each towing, perform these steps:
- Check that brake fluid reservoir is three-quarters full of fresh, clean DOT3 or DOT4 brake fluid. Check for leaks. Repair as required.
- Examine actuator for wear, bent parts, corroded/seized parts, or other damage. Have affected components replaced with genuine TITAN service parts. Verify actuator mounting bolts (if applicable) are tightened to eighty (80) foot-pounds.
- Test actuator and brake function as described in “Testing Surge Brake Systems” section. Actuator travel should not exceed one inch. Actuator travel is distance coupler case moves relative to outer case during braking. Adjust brakes following instructions given in brake installation manual. Failure to properly adjust brakes will result in loss of braking.
2. Film of grease on hitch ball will extend coupler and ball life. Wipe clean and renew grease film each time trailer is used.
3. There are no adjustments on Model 10 actuators.
4. Before storage or after extended use, TITAN recommends applying motor oil to coupler components, lockout mechanism, and internal roller to keep them moving freely and prevent corrosion.
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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WARNING DO NOT submerge actuator. Internal corrosion may result and cause brake failure. Salt water, granular fertilizers, and other corrosive materials are destructive to metal. To minimize damaging effect of corrosion on a braking system used under corrosive conditions, TITAN recommends actuators be externally flushed after use with high pressure water hose. Lubricate all moving parts after unit has dried. Failure to properly and adequately grease and maintain actuator could result in serious injury and/or property damage.
1. Before beginning installation of actuator system, make sure all components match and have correct specifications. For surge actuators, verify device being used is able to support disc brakes or drum brakes, whichever trailer is equipped with. Disc brakes require higher pressures and higher volumes of fluid versus drum brakes to operate properly. 2. TITAN Model 10 Actuators are completely assembled and ready to bolt or weld into place onto straight three inch wide trailer tongues. Welding will make repair or replacement difficult but may be preferred. If actuator must be painted for aesthetic reasons, TITAN recommends painting outer case ONLY and disassembling prior to painting. Application of heavy coats of paint may interfere with operation. If actuator is welded on, be sure to weld in well- ventilated areas with appropriate safety equipment. After welding, confirm coupler and breakaway mechanisms work properly before use. Store actuators indoors in original shipping carton until time of installation. 3. For bolt on applications, bolt actuator to tongue using two 5/8 inch by 4 inch long or three 1/2 inch by 4 inch long grade **Dimension: 5 or stronger bolts, nuts, and lock washers. Figure 2 shows Max of 2 ½” standard mounting patterns used on three inch wide trailer Min of ¾” tongues. Light weight tongues require spacer tubes inside ** for reinforcement when bolting. HD applications may use all 5 bolt holes. Tighten mounting bolts to eighty (80) foot- pounds of torque. 4. Install hydraulic brakes and brake lines on trailer as described in installation manual supplied with brakes. TITAN recommends 3/16 inch brazed double wall tubing per SAE J527 for use with all our actuator and brake products. Use *Dimension: forty-five degree (45°) double-flare tube ends per SAE J533. Max of 1” DO NOT remove or modify orifice connector at rear of Min of ¾” actuator’s master cylinder. It connects directly to brake * tubing ensuring proper fluid flow characteristics. FLEXIBLE BRAKE LINE HOSE MUST BE USED to connect orifice connector at master cylinder to hydraulic brake line on trailer. This is necessary because master cylinder is spring mounted to provide overload protection and moves relative Figure 2 Model 10 Mounting Channel Templates to outer case. 5. After installing actuator, brakes, and brake lines, making sure all connections are tight without leaks, fill system with DOT3 or DOT4 heavy-duty brake fluid. Brake systems may be bled manually or with a vacuum or pressure brake bleeding system. Both types of brake bleeding equipment should be available at local automotive supply stores. If using vacuum or pressure equipment, follow equipment instructions. If you are manually bleeding, see section of this manual on "Bleeding Breaks" for instructions. Failure to complete “Bleeding Brakes” procedure promptly after actuator installation may result in internal master cylinder corrosion and cause brake failure. 6. Once bleeding of entire system is complete, proceed to manually check that actuator and brakes are in working order. Checking process should not only be done after initial installation, but every time trailer is hooked up to tow vehicle. See section of manual for testing surge brake system for instructions.
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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(For Surge Brake Trailers Only) For surge brake trailers, a backup valve is typically required to allow backing up of trailers. This is due to disc brakes working well in either a forward or reverse direction when paired with a surge actuator. Unlike disc brakes, uni-servo drum brakes require very little pressure to work in forward direction, and much greater pressure in reverse direction. This allows tow vehicles to overpower brakes during backing up without a backup valve. This can also be alleviated by installing free-backing drum brakes.
Checklist for disc brakes: Make sure backup solenoid is screwed directly into back of master cylinder. No fittings should be used between master cylinder and backup solenoid. Confirm solenoid has correct orientation. Male threads of solenoid screw directly into master cylinder.
Note: If backup solenoid is not used, ensure orifice connector on back of master cylinder hole size is 1/8” (.125”) to allow for disc brakes to work properly. Confirm solenoid is wired to back-up light circuit. A distinct click sound will be heard when tow vehicle’s transmission is switched into reverse. See Figure 3 for wiring instructions for TITAN’s solenoid backup valve. Note location for tightening valve to master cylinder.
WARNING - Confirm Model 10 is designed for disc brakes. Failure to do so may result in premature brake wear or brake failure. - NEVER tighten or loosen solenoid by small hex fitting on top of solenoid. Only tighten by bottom larger portion as shown in Figure 3. Failure to do so can cause internal damage to solenoid. - Never tow trailers equipped with surge actuator and backup solenoid if backup light circuit is ON other than when tow vehicle’s transmission is in reverse. This may cause brake system to be disabled during transporting.
Figure 3 Solenoid Backup Valve Instructions
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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Instructions are to be used with brake manufacturer’s instructions for bleeding brakes. These instructions pertain to disc and drum brake actuator units.
WARNING -Use fresh DOT3 or DOT4 brake fluid from sealed container. DO NOT reuse brake fluid. Failure to use fresh brake fluid increases chance of brake failure. -Use care when handling brake fluid. DO NOT allow brake fluid to contact painted surfaces. It will damage surface finishes. Wipe up spills immediately and wash area with water. -This is a high pressure system. ALL air must be removed. Any air in brake lines will cause brakes not to function properly. Bleed brake system completely.
1. Confirm all brake lines run flat as possible. Air bubbles gather in high spots. Doing this helps reduce chances of air pockets forming at locations away from bleeder ports.
2. For Model 10s, set trailer so actuator is low as possible, and brake calipers high as possible during bleeding process. This helps direct air bubbles to calipers to be bleed.
3. Remove master cylinder cap and fill reservoir three-quarters full with DOT3 or DOT4 brake fluid.
4. If system is bleed manually, an assistant makes it easier. Pull actuator out to fully extended position. It may be necessary to block wheels and use a tow vehicle to pull forward on coupler to fully extend actuator. Loosen four bolts on breakaway lever locks. Remove back two bolts, rotate breakaway locks away and tighten front two bolts. Using a pipe to help, pull lever forward until nearly vertical and return it to normal operating position. Repeat stroking action until air stops bubbling inside master cylinder. This pumps brake fluid into trailer braking
system. Refill reservoir as needed. Caution: If lever is actuated to forcefully, brake fluid may squirt out of master cylinder and cause operator eye injury or damage painted surfaces.
5. Install bleeder hose (A small section of hose run into clear container partially filled with brake fluid and submerged. This is to observe bubbling) on top bleeder port of wheel cylinder or caliper farthest from actuator.
6. Proceed to pressurize system by opening bleeder screw one turn. Pull breakaway lever completely forward or vertical and close bleeder screw to prevent air being pulled back into system. Air trapped in brake lines will greatly reduce braking efficiency and system will need to be re-bled. After bleeder screw is closed push breakaway lever down to a flat position.
7. Waiting several seconds between steps, Repeat step 6 as necessary until no air bubbles are released with each stroke. Close bleeder screw securely when finished
8. Repeat steps 5-7 for each wheel cylinder or caliper working from rear axle forward. During bleeding process,
replenish brake fluid so reservoir does not fall below half full.
9. When bleeding process is complete for all wheels, fill reservoir to within ¾” of top. Install filler cap securely. Reset breakaway lever by loosening front two bolts. Position breakaway lever to a flat position and rotate two
breakaway locks to original operating or “ready” position. Install two rear bolts with lock washers and tighten all four bolts to 90-120 inch pounds.
10. Check proper function of actuator and brakes before transport.
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
Page 7 of 16 #24032 10-2014
WARNING Field-test procedure indicates only if trailer brake system is functional. Field-tests DO NOT provide information on how efficiently it will operate. Regular inspection, maintenance, and adjustment are required to ensure maximum brake performance.
Hydraulic surge actuator systems provide automatic and smooth trailer braking without special application by tow vehicle drivers. While extremely convenient, it can be difficult to determine if surge setup is functioning properly. Proceeding steps provide a quick field-test to confirm that trailer brake system is operational. Use testing procedure every time trailer is transported for proper brake function.
1. Move trailer to flat, level ground, pulling FORWARD several feet before parking. Forward motion will ensure trailers equipped with free-backing brakes are in normal operating mode. Disconnect trailer from tow vehicle and jack trailer’s tongue until horizontal.
2. Hook trailer’s safety chains (NOT actuator’s break- away chain) together to form a loop, which is centered below actuator’s coupler show in Figure 4.
3. Place a sturdy board, such as 2 inch by 4 inch piece of lumber, into chain loop below coupler. Board should be 4 feet or longer so it extends several feet above actuator. Keep end of board a few inches off ground, and position to press against front end of Figure 4 Field Test Setup Diagram actuator’s coupler.
4. Stand in front of trailer and face rearward. Apply force to top of board to use as a lever. Press back towards rear of trailer. Begin moving coupler case (inner slide) into actuator’s outer housing.
5. Keep pressing on top of board to stroke actuators internal master cylinder. If trailer brake system is operational, brakes will apply and keep trailer from rolling away. Disc brakes, uni-servo, and duo-servo brakes will prevent trailer from moving back more than a few inches. Free-backing brakes will initially provide rolling resistance, but continued force will switch them into free backing mode. Trailer will then move backwards without resistance from brakes.
6. If stroking actuator (as described previously) causes trailer to roll away freely or with minimal resistance, brakes are NOT applying properly. If stroking actuator with free-backing brakes (as described previously) causes trailer to roll away without initial resistance, brakes are NOT applying properly. Brake system MUST be evaluated to determine cause of problem, and corrective action MUST be taken before trailer is used.
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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1. Confirm towing hitch and ball have ratings equal or greater than trailer GVWR. Properly secure trailer to tow vehicle. Hitch MUST be installed so trailer tongue horizontal when coupled.
WARNING -For proper engagement of actuator’s coupler to tow ball, DO NOT use a multi-piece ball, incorrectly sized ball, or worn/damaged ball as equipment failure may occur. -Incorrect lever or chain position may cause trailer brakes to drag and overheat, or may keep brakes from being applied in
breakaway situation. After usage of break-away mechanism, real or accidental, check all system components (lever, chain,
clasp, break-away bolts etc.) for damage. Replace damaged items with genuine TITAN service parts. -Trailer safety chains’ length MUST be short enough so actuator’s break-away cable is NOT pulled if coupler separates from tow vehicle’s hitch but remains connected by safety chains. Break-away system should only activate if BOTH coupler AND safety
chains fail allowing trailer to completely separate from tow vehicle. Provide enough slack in trailer safety chains to allow tight
turns. Chains should not drag on ground. Safety chains must be used. See trailer manufacturer’s safety chain requirements. 2. To hitch 2-5/16 inch coupler, perform following procedure. Open coupler by lifting handle assembly’s lock trigger to unhook it from locked position. Swing top of handle toward rear of actuator. Lower coupler onto ball confirming ball is fully seated. Swing handle back forward until lock trigger hooks into locked position. Verify ball has been trapped in socket. Properly adjusted coupler with have 1/64 to 1/32 inch of free play between ball and socket. Do not tow trailer if coupler is damaged. 3. To hitch 3” lunette eye, perform following procedure. Fully open tow vehicle’s pintle hitch locking mechanism, (see manufacturer’s operation manual for more instructions) then lower trailer lunette eye onto pintle hitch horn. Once lunette eye is in place, close and lock the latch of the pintle hitch and install any applicable retaining devices. To uncouple, block trailer wheels and performs steps in reverse. To hitch ¾” or 1” clevis, perform following procedure. Remove any pin or retaining device from tow vehicle and trailer hitch. Position 4. draw bar on tow vehicle between two arms of coupler. Verify all three holes line up and insert retaining pin. Secure pin with retaining clip or similar safety device. To uncouple, block trailer wheels and perform steps in reverse. 5. Check actuator’s coupler, lunette eye, or clevis is attached securely to tow vehicle by extending trailer’s tongue jack to ground. Lift trailer tongue and tow vehicle hitch two to four inches. Actuator and hitch should remain engaged. DO NOT tow trailer unless actuator is securely connected to tow vehicle. Retract trailer tongue jack before towing. 6. 2-5/16 inch ball coupler mechanism may be further secured by performing following steps. With handle in locked (down) position, insert standard padlock or spring pin through hole in side of handle assembly. This will lock handle in down position. Do not use padlocks or pins which interfere with telescoping action of actuator thereby compromise braking performance. To uncouple trailer, block wheels to keep trailer from rolling. Lift actuator handle fully to disengage hitch ball. Use tongue jack to lift trailer tongue off hitch ball. 7. Your tow vehicle’s hitch provides safety chain holes or rings on each side as shown in Figure 5. Consult trailer manufacturer for proper safety chain recommendations. Attach trailer’s safety chains securely to these connection points. Make sure to cross chains UNDER trailer tongue. Safety chains MUST be used. This will prevent trailer tongue from dropping if coupler separates from tow vehicle’s hitch. If tow vehicle’s hitch does not provide safety chain connection points, have appropriate ones added by reputable hitch installer. 8. Attach actuator’s break-away chain snap hook securely to tow vehicle hitch’s safety chain connection point (see Figure 5). Confirm trailer’s safety chains are adjusted relative to actuator’s breakaway chain. DO NOT loop breakaway chain around bracket and hook it back onto itself. 9. Before towing, check break-away lever and chain for proper position as shown in Figure 6. If break-away lever and chain are not located correctly as described above, due to chain being pulled during use or accident, it MUST be reset prior to trailer being moved.
Figure 5 Safety Chain And Break-Away Chain Attachment
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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8. Resetting Break-Away Lever (See Figures 4 & 5) carefully loosen brake line fitting going into actuator. After pressure is gradually released, retighten fitting. Remove two rearward bolts on each side of break-away lever. Loosen, but do not remove two remaining bolts. This allows locks to swing aside and lever can be pushed into its resting position. Rotate break- away locks to their original positions and use torque wrench to tighten all four bolts to 90-120 inch-pounds.
9. When actuator is used with disc brakes or non-free-backing brakes, our solenoid backup valve part number 4748800 allows trailer to be backed without activating brakes. Do not block actuator movement to back up trailer. Failure to remove blocking device will prevent ALL trailer braking. See manual section on Solenoid Backup Valve additional information.
Figure 6 Breakaway Lever Positions
WARNING -Hydraulic pressure in system may cause lever to snap back. Keep hands and fingers clear as break-away mechanism is reset. -Break-away system is not designed to operate if trailer does not separate completely from tow vehicle, or if trailer tongue “submarines” going beneath tow vehicle. DO NOT use break-away system as parking break.
1. Over time, TITAN Model 10 may require disassembly for service or component replacement. Follow proceeding steps to assemble actuator, checking manual’s assembly diagram and parts list for reference.
2. Position small diameter end of damper <29> inside inner slide <18>. Align damper with lower holes in front of inner slide. Install damper pin <33>. Secure with cotter pin <6>. Repeat process for second damper in upper holes of inner slide.
3. Reassembly of inner slide may be made easier by making to “dummy” pins from ¾”diameter wooden dowels cut to same length as width of inner slide. Insert dowel into front edge of top slot. Inside inner slide, slide dowel through rear roller <30> with chamfered edge out, through end of damper (damper in extended position), finally through another rear roller with chamfered edge out. Spacer should rest in each slot on both sides of inner slide. Repeat process for bottom damper. Insert push rod block <28> through square holes at rear of inner slide. Insert until flush with outside face of inner slide and hold in position.
4. Carefully insert inner slide <18> into outer case <1>. Maintain position of components on dowels. Take master pin <31> and position end to end with top dowel. Use master pin to slide dowel through inner slide and components. Install nylon washer <48> on master pin and secure with cotter pin <32>. Repeat process for bottom master pin.
5. Take front rollers <4> and place in front roller cover <7>. Line up holes in roller cover and outer case <1>. Insert front roller bolt <5> through outer case, roller cover, and front roller. Secure bolts with lock washers <40> and nuts <41>. Tighten nut to 75 ft.-lbs. Roller bolt should not be tightened where it inhibits roller movement.
6. Place breakaway lever assembly <10> in rectangular opening in top of outer case. Install weather seal <11> with slot forward on top of brackets. Position right <13> and left <12> breakaway locks and start four 5/16” bolts <15> with lock washers <14>. Move breakaway lever to vertical position. Use locking pliers to clamp breakaway locks around lever assuring tabs will hold lever in position. Tighten bolts to 90-120 inch-pounds while clamping locks around lever. Using rod or prying device, spread top of breakaway locks enough to allow breakaway lever to move down to normal operating position (about 45 degrees).
7. Remove filler cap from master cylinder <21>. Slide assembly into back of outer case. Line up front holes installing two 5/16” bolts <15> and star lock washers <14>. Repeat process for rear two bolts. Tighten all bolts. Reinstall filler cap into master cylinder and install cylinder cover <16>. Assembly is complete.
*NOTE: <#> is reference number shown in assembly diagram and parts table located on page 11 & 12 of manual.
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
Page 10 of 16 #24032 10-2014
*NOTE: <#> is reference number shown in assembly diagram and parts table located on page 11 & 12 of manual.
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
Page 11 of 16 #24032 10-2014
Model 10 Actuator Parts List Ref No. Part No. Description Quantity 1 1601600 Outer Case, Painted 1 2 1020900 Bearing (Top and Bottom) .125" Thick 6 3 1242700 Bearing (Side) .075" Thick 8 4 1601900 Front Roller 1 5 0828800 Front Roller Bolt 1 6 0799700 Cotter Pin 1/8" x 1" 2 7 1601800 Front Roller Cover 1 8 0776800 Breakaway Chain 1 9 1055500 S-Hook 1 10 1054100 Breakaway Lever Assembly 1 11 1055200 Weather Seal 1 12 1052600 Breakaway Lock - Left Hand 1 13 1052700 Breakaway Lock - Right Hand 1 14 0793800 Lockwasher, 5/16" Standard 8 15 0794900 Hex Bolt 5/16" - 18 NC x 5/8" Long 4 16 1507000 Cylinder Cover 1 17 0794800 Hex Bolt 5/16" -18 NC x 1/2" Long 4 18 1593300 Inner Slide 1 * 1608700317 Inner Slide, 4-Hole Leveler 1 * 4848700183 Inner Slide, 6-Hole Leveler, Offset 1 * 4867800317 Inner Slide, 6-Hole Leveler, Centered 1 19A 2374400 Master Cylinder, 1-1/4" Bore, Drum Brake 1 * 4831600 Master Cylinder, Drum Brake with 1209800, Orifice 1 19B 4747100 Master Cylinder, 1-1/4" Bore, Disc Brake 1 20 0838800 Cylinder Bracket, Right Hand 1 21 4830601 Filler Cap with Diaphragm 1 22 4877300 Snap Hook 1 23 1209800 Orifice Connector Drum, .015", 1/8" NPT 1 * 1209900 Orifice, Drum, Early Type, 1/2" NF Thread 1 * 0774500 Gasket, For Use with Earlier 1209900 Orifice 1 24 0838900 Cylinder Bracket, Left Hand 1 25 0827100 Hex Bolt, 3/8" - 16 NC x 3" Long 2 26 0797600 Hex Nut 3/8" NC 2 27 1255200 Star Lockwasher 3/8" 2 28 0830100 Push Rod Block 1 29 1242600 Damper 2 30 0829100 Rear Roller 2 31 1593500 Master pin 2 32 0815200 Cotter Pin 3/16" x 1-1/4" 2 33 1593400 Damper Pin 2 34 0897800 Leveler Channel 1 35 0897900 3/4" Clevis, 2 Bolt 1 36 0909300 Bolt, Hex 5/8" NC x 4 1/2" Long 2 37 1040500 Lock Nut 5/8" NC 2 40 0793700 Lockwasher, 1/2" Standard 1 41 0798500 Hex Nut 1/2" - 13 NC 1 42 0144901 Grease Zerk 1 44 1882000 2 5/16" Adjustable Ball Coupler 1 45 1613700 3" Lunette Eye 1 46A 2477700183 Outer Case, 2.5" Offset Mounting Channel, Plated 1 46B 2477700317 Outer Case, 2.5" Offset Mounting Channel, Painted 1 47A 2478200 Outer Case, 1" Offset Mounting Channel, Plated 1 47B 1685500 Outer Case, 1" Offset Mounting Channel, Painted 1 48 1861900 Nylon Flat Washer 2 * 2374600 Drum Brake Master Cylinder Assy with Brackets 1 * 4749501042 Disc Brake Master Cylinder Assy with Brackets 1 50A 4836100183 Backup Valve Cover, Plated 1 50B 4836100 Backup Valve Cover, Painted 1 * 1018700 1-1/4" Master Cylinder Repair Kit For 2374400 1 * 4359100 Master Cylinder Boot 1 52 4748800 Solenoid Backup Vlave, Male 1/8" NPT and 3/8" x 24 NF with Inverted Seat 1 * = Not Shown
*NOTE: <#> is reference number shown in assembly diagram and parts table located on page 11 & 12 of manual.
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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Part No. Drum Part No. Disc Description Attachment Inner Outer 1608000* No Coupler, Painted Weld-On 1593300 1601600 1664900* No Coupler, 2.5" Offset Mounting Channel Bolt-On 1/2" 1593300 2477700317 2404600* 4838000* 4-Hole Leveler Channel, Painted Weld-On 1608700317 1601600 4836700 4-Hole Leveler Channel, 1" Offset Mounting Channel, Painted Bolt-On 5/8" 1608700317 1685500 4809700* 4809900* 4-Hole Leveler Channel, Plated Bolt-On 5/8" 4721700 2478200 4809800 4810000 4-Hole Leveler Channel with Lunette Eye Bolt-On 5/8" 4721700 2478200 4810020 4-Hole Leveler Channel with Lunette Eye Valve and Cover Bolt-On 5/8" 4721700 2478200 4721600 4-Hole Leveler Channel, 2.5" Offset, Plated Bolt-On 1/2" 4721700 2477700183 2324800 4-Hole Leveler Channel, 2.5" Offset, Painted Bolt-On 1/2" 1608400317 2477700317 1607500* 4749600* 2-5/16" Coupler, Straight, Painted Weld-On 1608400317 1601600 4749610 2-5/16" Coupler, with Cover Weld-On 1608400317 1601600 4749620 2-5/16" Coupler,with Solenoid Valve and Cover Weld-On 1608400317 1601600 1664300 2-5/16" Coupler, 2.5" Offset, Painted Bolt-On 1/2" 1608400317 2477700317 2477600* 4750800* 2-5/16" Coupler, 2.5" Offset, Plated Bolt-On 1/2" 1608400183 2477700183 4750810 2-5/16" Coupler, 2.5" Offset, Plated, Cover Bolt-On 1/2" 1608400183 2477700183 4750820 2-5/16" Coupler, 2.5" Offset, Valve and Cover Bolt-On 1/2" 1608400183 2477700183 1735200* 4830300* 2-5/16" Drop Coupler, Painted Weld-On 2478300317 1601600 4837900 2-5/16" Drop Coupler with Valve and Cover Weld-On 2478300317 1601600 1772700 4830100 2-5/16" Drop Coupler, 1" offset Mounting Channel Bolt-On 5/8" 2478300317 1685500 2478100* 4750600* 2-5/16" Drop Coupler, Plated Bolt-On 5/8" 2478300183 2478200 4750610 2-5/16" Drop Coupler, Plated, with Cover Bolt-On 5/8" 2478300183 2478200 4750620 2-5/16" Drop Coupler, Plated, with Solenoid Vavle and Cover Bolt-On 5/8" 2478300183 2478200 4299600 2-5/16" Drop Coupler, 2.5" Offset Mounting Channel Bolt-On 1/2" 2478300183 2477700183 1890900 4-Hole Leveler Channel with 2-5/16" Coupler Weld-On 1608700317 1601600 4238300 4-Hole Leveler Channel with 2-5/16" Coupler Bolt-On 5/8" 1608700317 1685500 1607900 4-Hole Leveler Channel with 2 Bolt Clevis Hitch Weld-On 1608700317 1601600 1891100 4-Hole Leveler Channel with Lunette Eye and Bolts Weld-On 1608700317 1601600 4238500 4-Hole Leveler Channel with Lunette Eye and Bolts Bolt-On 5/8" 1608700317 1685500 1607700* 3" Lunette Eye, Painted Weld-On 1608600 1601600 1664500 3" Lunette Eye, 2.5" Offset Mounting Channel Bolt-On 1/2" 1608600 2477700317 4848900 4848800 6-Hole Offset, with Lunette Eye and Bolts Weld-On 4848700317 1601600 4850600 6-Hole Offset, Flat Mounting Plate Weld-On 4848700317 4850500317 4857200* 6-Hole Offset Bolt-On 5/8" 4848700183 2478200 4857220 4857020 6-Hole Offset, with Solenoid Valve and Cover Bolt-On 5/8" 4848700183 2478200 4857320 4857120 6-Hole Offset, Painted, with Solenoid Valve and Cover Bolt-On 5/8" 4867800317 1685500 4857520* 4857420* 6-Hole Offset, with Solenoid Valve and Cover Weld-On 4867800317 1601600 4867500 6-Hole Centered Bolt-On 5/8" 4867800317 1685500 4867510 6-Hole Centered with Cover Bolt-On 5/8" 4867800317 1685500 4867520 6-Hole Centered With Solenoid Valve and Cover Bolt-On 5/8" 4867800317 1685500 4867400 6-Hole Centered Bolt-On 5/8" 4867800183 2478200 4867410 6-Hole Centered with Cover Bolt-On 5/8" 4867800183 2478200 4867420 6-Hole Centered With Solenoid Valve and Cover Bolt-On 5/8" 4867800183 2478200 4866500 6-Hole Centered Bolt-On 5/8" 4867800183 2478200 * Numbers marked with asterisk have photo shown on Page 14
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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2478100, 4750600 1735200, 4830300 1607500, 4749600
4809700, 4809900 2404600, 4838000 2477600, 4750800
4857200 4857520, 4857420 1607700
1664900 1608000
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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SYMPTOM: Weak Or No Brakes CAUSES REMEDY Broken/Kinked Brake Line Replace or Repair As Required Air In Brake System Bleed Brake System Excessively Worn Or Damaged Brake Pads Replace Brake Pads Excessively Worn Or Damaged Rotor/Drum Replace Rotor/Drum Overloaded Capacity Lighten Load Malfunctioning Actuator Troubleshoot System Foreign Material In Brake Line Flush and Clean Thoroughly. Re-Bleed System Low Hydraulic Fluid Fill With New Brake Fluid To 3/8” From Top Of Master Cyl. Check Tightness Of Brass Adapters Between Brake Line And Leaky Master Cylinder Master Cylinder Housing Rebuild Master Cylinder SYMPTOM: Locking/Dragging Brakes CAUSES REMEDY Check Tow Vehicle Back-Up Light Circuit. Check 12V Solenoid. (Should Be Able To Hear A "Click" When 12V DC Is Applied To Lead Wire) (In Reverse) 12V Solenoid Valve Is Inoperative Check Connection To Tow Vehicle Back-Up Light Circuit. Check Trailer Ground Connection (Do Not Depend On Hitch Connection To Provide Ground.) Trailer Should Have Dedicated Ground Wire Connected To Grounding Lug Check For Foreign Material In Brake Lines And Flush Fluid Caliper Piston Or Wheel Cylinder Not Retracting Check For Internal Corrosion Check For Proper Movement Improper Fluid Flush And Replace With DOT3 or DOT4 Brake Fluid Breakaway Cable Partially Engaged Inspect And Release Breakaway Cable Worn Wheel Bearings Check Wheel Bearings And Raceways, Replace As Required SYMPTOM: Noisy Brakes CAUSES REMEDY Wheel Mounting Bracket Bolts Loose Tighten And/Or Replace As Necessary Spindle Nut Loose Check Threads And Tighten To Specifications
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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LIMITED WARRANTY
Limited Warranty Titan Tire Corporation (TITAN) warrants its products to be free from defects in material and workmanship for one year from date of delivery to the original purchaser when properly installed, used, and maintained by the purchaser.
This warranty does not apply to damage or loss caused by any or all of the following circumstances or conditions: Freight damage. Parts, accessories, materials or components not obtained former approved in writing by TITAN. Misapplication, misuse and failure to follow the directions or observe cautions and warnings on installation, operation, application, inspection or maintenance specified in any TITAN quotations, acknowledgements, sales literature, specification sheet or installation instructions and service manual (“applicable literature”)
If any TITAN products are found upon TITAN’s examination to have been defective when supplied, TITAN will either: credit the purchaser’s account for the purchase price of the TITAN product; or repair the product. TITAN has sole discretion in choosing which option to provide. For this LIMITED WARRANTY to apply, TITAN must receive notice of the alleged defect within 30 days of either the discovery of the alleged defect or the expiration of the warranty period, whichever is earlier. Any claim not made within this period shall conclusively be deemed waived.
If requested by TITAN, purchaser shall return the alleged defective product to TITAN for examination at TITANS’s direction and expense. TITAN will not pay for expenses incurred in returning a product to TITAN without TITAN’s prior written authority. TITAN shall not be liable for any other expenses purchaser incurs to remedy any defect. Purchasers waive subrogation on all claims under any insurance.
Limitation of Liability It is expressly agreed that the liability of TITAN is limited and TITAN does not function as an insurer. THE REMEDIES SET FORTH IN THIS WARRANTY SHALL CONSTITUE THE EXCLUSIVE REMEDIES AVAILABLE TO THE PRUCHASER OR USER AND ARE IN LIEU OF ALL OTHER REMEDIES, EXPRESS OR IMPLIED. THE LIABILITY OF TITAN, WHEATHER IN CONTRACT, IN TORT, UNDER ANY WARRANTY OR OTHERWISE, SHALL NOT EXCEED THE PURCHASE PRICE OF THE PARTICULAR PRODUCT MANUFACTURED, SOLD OR SUPPLIED BY TITAN.
To Obtain Technical Assistance To enable TITAN to respond to a request for assistance or evaluation of customer or user operation difficulty, please provide at a minimum the following information by calling 1-800-872-2327 or within Iowa 1-515-265-9200: Model number, serial number and all other data on the specific component which appears to be involved in the difficulty. The date and from whom you purchased your TITAN product. State your difficulty, being sure to mention at least the following: Application, Nature of load involved, and Weight of the load.
TITAN EXTENDS NO WARRANTY, EXPRESS OR IMPLIED, ON PRODUCTS NOT MANUFACTURED BY TITAN OR TO TITAN’S DESIGN SPECIFICATION, INCLUDING BUT NOT LIMITED TO SUCH ITEMS AS NON-TITAN TIRES, BRAKES, ACTUATORS, BEARINGS, HOSE AND TUBING, PURCHASER’S RECOURSE SHALL BE LIMITED TO ANY WARRANTY OF THE PERSPECTIVE MANUFACTURERS.
THIS WARRANTY EXCLUDES ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY PURPOSE.
THIS WARRANTY DOES NOT COVER NOR EXTEND TO INCIDENTAL OR CONSEQUENTIAL DAMAGE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.
No representative has authority to make any representation, promise or agreement except as stated in this Limited Warranty. TITAN reserves the right to make design and other changes upon its products without any obligation to install the same on any previously sold or delivered products.
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THOSE DESCRIBED ABOVE. EFFECTIVE JANUARY 1, 1998 THIS WARRANTY SUPERSEDEDS ALL PRIOR WARRANTIES, WIRTTEN OR IMPLIED.
A Titan Company 2345 East Market Street Des Moines, IA 50317 PHONE: 800-USA-BEAR or 800-872-2327 FAX: 515-365-9212
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