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INSTALLATION, INSTRUCTION and SERVICE MANUAL Actuator/Trailer Dealer – Please Provide to Consumer

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INSTALLATION, INSTRUCTION and SERVICE MANUAL Actuator/Trailer Dealer – Please Provide to Consumer 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 Page 1 of 16 #24032 10-2014 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 Page 2 of 16 #24032 10-2014 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 Page 3 of 16 #24032 10-2014 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 Page 4 of 16 #24032 10-2014 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
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