TITAN MODEL 6 - Titan International
Contents
1. Z WARNING A The trailer safety chains length MUST be set short enough so the actuator s break away cable is NOT pulled if the coupler separates from the tow vehicle s hitch but remains connected by the safety chains The break away system should only be activated after BOTH the trailer s coupler AND safety chains have failed and allowed the trailer to completely separate from the tow vehicle Provide just enough slack in the trailer safety chains to allow tight turns The chains should not drag on the ground Safety chains must be used 5 The break away system should only operate after both the coupling and safety chains have failed The break away is not a parking brake Z WARNING A The break away system is not designed to operate if the trailer does not separate completely fram the tow vehicle or if the trailer tongue submarines and goes beneath the tow vehicle DO NOT use the break away system as a parking brake NOTE lt gt is the reference number shown in the assembly diagram of the actuator located at the end of this manual Page 4 of 9 HITCHING TRAILER cont 6 Resetting the Break away Lever Refer to the parts diagram on page 9 When the break away lever item 7 is engaged it is in the vertical position It must be reset before the trailer is moved First carefully loosen the pressure line fitting to the master cylinder to relieve hydraulic pressure Figure 3 below Then remove the four bolt2. materials or components not obtained former approved in writing by TITAN O 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 with in this period shall conclusively be deemed waived If requested by TITAN purchaser shall return the alleged defective product to TITAN for examination at Titan 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
3. 8 NC 2 x 20 0782000 Washer 3 8 2 x 21 1027400 Spring 2 22 1242600 Damper 1 23 0829100 Rear Roller 2 24 1777300 Master Pin 1 25 0815200 Cotter Pin 1 26 1777200 Damper Pin 1 27 4391600 Inner Slide w Ball Latch Bolt and Locknut 1 28 1831600 Washer 1 29 1806600183 Cover 1 o 30 2338100 Latch Bolt Multifit Coupler 1 o 31 1809000 Lock Plate 1 o 32 4335800 Ball Latch 1 o 33 4336800 Compression Spring 1 o 34 2338300 Hand Wheel Lock 1 o 35 2420000 Hand Wheel 1 o 36 2339000 Bolt Hex 7 16 x 2 5 8 NF 1 o 37 2339100 Locknut 7 16 NF thin 1 38 4045600 Inner Slide w 3 Lunette Eye 1 39 4067700183 Inner Slide w 2 5 16 Coupler 1 1502600 Master Cylinder Repair Kit 1 4045400 Multi Fit Coupler Repair Kit 1 1848700 2 5 16 Ball Coupler Repair Kit 1 40 4748800 Solenoid Backup Valve 1 4 4836800183 Backup Valve Cover plated 1 These parts are included in the master cylinder assembly 1777401 amp 1777405 These parts are included in the 4045400 Coupler Repair Kit Page 7 of 9 MODEL 6 PARTS DIAGRAM Page 8 of 9 OTITAN 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 Q Freight damage Q Parts accessories
4. an insurer THE REMEDIES SET FORTH IN THIS WARRANTY SHALL CONSTITUTE THE EXCLUSIVE REMEDIES AVAILABLE TO THE PURCHASER OR USER AND ARE IN LIEU OF ALL OTHER REMEIDIES EXPRESS OR IMPLIED THE LIABILITY OF TITAN WHETHER 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 Q Model number serial number and all other data on the specific component which appears to be involved in the difficulty Q The date and from whom you purchased your TITAN product O State your difficulty being sure to mention at least the following Application Nature of load involved and Weight of the load Field Service If field service at the request of the purchaser is rendered and the difficulty is found not to be with TITAN S product the purchaser shall pay the time and expense at the prevailing rate at the time of service of the seller s field representative s Charges for service labor and other expenses that have been incurred by the purchaser its customer or agent without prior written authorization of TITAN will not be accepted TITAN EXTENDS NO WARRANTY EXPRESS OR IMPLIED ON PRODUCTS NOT MANUFACTURED BY TITA
5. 00183 4745100183 4748101 leveler channel 4717600183 4745100183 4022300 multi fit coupler 4391600 2493201 4057900 less coupler A frame 1776900 2493000 1777401 master cylinder w mtg brackets 7777405 master cylinder w mtg brackets NOTE lt gt is the reference number shown in the assembly diagram of the actuator located at the end of this manual Page 6 of 9 MODEL 6 ACTUATOR PARTS LIST ref diagram on page 8 Key No Part No Description Qty Reqd 1A 2480100183 Outer Case Assy 1 1B 2493000 A Frame Outer Case 1 2 1242700 Bearing 0 075 thick 2 3 1776300 Front Roller 1 4 1776600 Front Roller Pin 1 5 0799700 Cotter Pin 1 8 x 3 4 2 6A 1776700 Front Roller Cover 6000 1 6B 4350700183 Front Roller Cover 7500 1 6C 4655900183 Front Roller Cover 8000 1 7 4594100 Break away Lever wiPin 1 8 1055500 S Hook Part of 4594100 1 9 1780300 Break away Spring 1 10 1781500 Hex Bolt 5 16 x 1 2 Self Tapping 4 11 1861900 Washer nylon 1 x 12 1776200 Cylinder Mounting Plate 1 x 13 1027300 Hex Bolt 3 8 x 5 NC 2 x 14 4390500 Push Rod Assy 1 o 15 2496400 Lock Ring 1 x 16A 1027100 Master Cylinder Drum Brake 1 x gt 168 4747000 Master Cylinder Disc Brake 1 x 17 1755600 Master Cylinder Cap diaphragm type 1 x 18 1209800 Orifice Connector 0 015 drum brake use 1 x 19 0797600 Nut Hex 3
6. INSTALLATION INSTRUCTION AND SERVICE MANUAL Actuator Trailer Dealer Please provide these instructions to the consumi Consumer Read and follow these instructions Keep them with the trailer for future reference TITAN MODEL 6 SURG O MATIC ACTUATOR FOR TRAILER BRAKES 4744901 J3 Leveler Channel d C 2492800 Multi fit A Frame 9 joo 4079200 i lt lt S 25 16 Coupler Surge actuators of this type provide a service life of approximately five years with proper installation usage and maintenance However a well cared for actuator can often exceed this estimate To get the most benefit from your TITAN surge actuator follow the instructions given in this manual and use common sense in caring for the TITAN MODEL 6 actuator and your entire trailer brake system RATED CAPACITY AND USAGE WARNING DO NOT exceed these ratings 8 000 POUNDS MAXIMUM GROSS LOAD with 2 5 16 bolt on coupler 7 500 POUNDS MAXIMUM GROSS LOAD with 3 lunette eye or leveler channel or A Frame in lunette or 2 5 16 This is the weight of the trailer fully loaded with all cargo and equipment To find your trailers Gross Load use a commercial vehicle scale at a truck weigh station grain elevator etc 6 000 POUND MAXIMUM GROSS LOAD with 2 multi fit ball coupler 800 POUND MAXIMUM TONGUE LOAD with 2 5 16 bolt on coupler 600 POUND MAXIMUM TONGUE LOAD with other Model 6 actuators This is the weight applied downward by the fully loaded trai
7. N 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 SUPERSEDES ALL PRIOR WARRRANTIES WRITTEN OR IMPLIED Page 9 of 9
8. brake fluid using a vacuum type or pressure type brake bleeding system Both types of brake bleeding systems should be available at your local automotive jobber Follow the manufacturer s instructions Brake Fluid Filling and Bleeding 3a After completing the Installation instructions remove the master cylinder cap and fill the reservoir to three quarters full with DOT 3 4 brake fluid DO NOT allow brake fluid to contact painted surfaces since it will damage the finish Wipe up any spills immediately and wash the area with water 3b If you choose to manually bleed the system an assistant makes the job easier Please note the diagram in figure 1 on the next page Disconnect the trailer from the tow vehicle and hook the safety chains NOT the actuator break away cable together to form a loop The loop should be centered below the actuator s coupler as shown in Figure 1 3c Place a sturdy board such as a 2 x 4 into the safety chain loop below the coupler The board should be four feet long or more so it will extend well above the actuator Position the board to press against the front end of the actuator s coupler and use it to force the coupler case into the actuator s outer housing This pumps the brake fluid into the trailer braking system Manually pull the coupler case back to fully extended position and repeat the process NOTE lt gt is the reference number shown in the assembly diagram of the actuator located at the end o
9. f this manual Page 2 of 9 INSTALLATION cont Brake Fluid Filling and Bleeding cont 3d When the air bubbling stops inside the master cylinder install a bleeder hose on the bleeder screw of the first wheel cylinder or disc brake caliper to be bled Be sure to use the bleeder screw on top of the caliper Start with the rear axle on tandem axle trailers Submerge the other end of the hose in a glass container of clean brake fluid so that air bubbles can be observed Open the bleeder screw one turn before pushing the coupler case in When the coupler is pushed completely in the bleeder screw should be closed to prevent air from being pulled back into the system Air trapped in the brake lines will greatly reduce your braking efficiency Repeat this process until no more bubbles are released with each stroke Be sure to close the bleeder screw securely DO NOT use the actuator s break away lever or cable to bleed the brake system 3e Repeat the bleeding operation at each wheel cylinder During the bleeding process replenish the brake fluid so the level does not fall below half full level in the master cylinder reservoir When bleeding is complete fill the reservoir to within 3 8 of the top Install the filler cap securely TESTING TITAN SURGE BRAKE SYSTEMS Z WARNING It should be noted that the field test procedure indicates only if the trailer brake system is functional but DOES NOT provide information on how efficiently
10. it will operate Regular inspection maintenance and adjustment of all brake system components including the surge actuator tubing hoses brake clusters drums or disc brake calipers and rotors and associated hardware support structure are still required to ensure maximum brake performance and smooth even brake operation T Hydraulic surge actuator systems provide automatic and smooth trailer braking without special application by the tow vehicle driver While this is extremely convenient it can sometimes be difficult to determine if the surge setup is functioning properly The following steps provide a quick field test to confirm that the trailer brake system is operational 2 Move the trailer to flat level ground pulling FORWARD several feet before parking This forward motion will ensure trailers equipped with free backing brakes are in their normal operating mode Disconnect the trailer from the tow vehicle and jack the trailer s tongue until it is horizontal 3 Hook the trailer s safety chains NOT the actuator s break away cable chain together to form a loop which is centered below the FIG 1 FIELD TEST SETUP actuator s coupler as shown in Figure 1 4 Place a sturdy board such as a 2 inch by 4 inch piece of lumber into the chain loop below the coupler The board should be 4 feet or longer so it will extend several feet above the actuator Keep the end of the board a few inches off the ground and position it to press again
11. ler s coupler on the tow vehicle s hitch Measure your trailer s Tongue Load with the tongue in a horizontal towing position using a commercial scale Upward tongue loads are not permissible The Model 6 actuator is intended for use with recreational trailers subject to more frequent use light utility trailers and light occasional use industrial trailers which Ss TITAN are towed by passenger cars and pickups The actual in service rating is limited before to that of the ball and hitch being used or the trailer manufacturer s G V W R 2345 East Market Street shown on the certification label whichever is lower SOREN tA coo SRGaee Page 1 of 9 FAX 515 265 9301 24034 05 07 INSTALLATION ZA WARNING DO NOT submerge the actuator Internal corrosion may result and cause brake failure Salt water granular ferti and other corrosive materials are destructive to metal To minimize the damaging effect of corrosion on a braking system used under corrosive conditions we recommend that the actuator be externally flushed after use with a high pressure water hose Be sure to lubricate all moving parts after the unit has dried Whenever the unit will be out of service for an extended period of time or after hard use remove the brake drums and clean inside the brakes Pack wheel bearings with grease before the drum is installed Failure to properly and adequately grease and maintain the actuator could weaken it and or cause it to fail and result in se
12. rious injury and or property damage Surge braking requires the installation of an actuator at the tongue of the trailer The surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brake As the trailer pushes against the tow vehicle the actuator telescopes together and applies the force to the master cylinder supplying hydraulic pressure to the brakes The Model 6 Actuator is completely assembled and ready to bolt or weld into place 1 Bolt or weld the actuator to the tongue Light weight tongues require spacer tubes inside for reinforcement when bolting Attachment strength should equal 1 1 2 times trailer G V W R a Install hydraulic brake lines on the trailer as described in the installation manual supplied with the brakes Be sure to use a flexible hose when connecting the master cylinder to the hydraulic line on the trailer This is necessary because the master cylinder is spring mounted to provide overload protection ZA WARNING Failure to complete the BRAKE FLUID FILLING AND BLEEDING procedures promptly after installation may result in internal master cylinder corrosion and cause brake failure ZA WARNING Use only fresh brake fluid from a sealed container DO NOT reuse fluid After filling and bleeding remember to refill the actuator Failure to maintain an adequate fluid level may cause brake failure 3 Fill the system with DOT 3 4 heavy duty
13. rom a sealed container DO NOT reuse fluid After filling and bleeding remember to refill the actuator Failure to maintain an adequate fluid level may cause brake failure Examine the actuator for wear bent parts corroded seized parts or other damage Have the affected components replaced with genuine TITAN service parts Check to determine that the actuator mounting bolts where applicable are tightened to eighty 80 foot pounds torque using a torque wrench Test the actuator and brake function as described in the TESTING TITAN SURGE BRAKE SYSTEMS section of this manual Actuator travel over one inch indicates that the brakes need adjustment or that the actuator has been structurally damaged Actuator travel is the distance the coupler case assembly lt 2 gt moves relative to the outer case lt 1 gt during braking Adjust the brakes following the instructions given in the brake installation manual In general back off adjusters ten clicks from locked drum rotation Adjust free backing brakes by rotating in the forward direction only Failure to adjust brakes will result in loss of braking a A film of grease on the hitch ball will extend coupler and ball life while eliminating squeaking Wipe clean and renew film each time trailer is used 3 Before towing examine the actuator for bent parts or wear Replace parts as necessary Check to determine that mounting bolts are tight and welds not cracked 4 There are no adjustmen
14. s item 10 that secure the master cylinder assembly to the outer case Figure 3 below The flat front tab of the U shaped break away spring item 9 can then be placed in the top notch of the break away lever Then position the back tab of the break away spring on the top of the master cylinder mounting bracket item 12 as you line up the master cylinder assembly bolt holes Tighten the bolts and check the break away lever position it should be at about a forty five degree angle Figure 3 below Tighten the brake line fitting and re bleed the brakes as necessary ZA WARNING A The hydraulic pressure held in the system may cause the lever to snap back quickly Keep hands and fingers clear as you reset the break away mechanism Te Sway control devices that restrict operation of the actuator cannot be used The actuator must be free to telescope in response to braking requirements FIG 2 SAFETY CHAIN AND BREAK AWAY CABLE ATTACHMENT top view shown i CLOSE UP VIEW OF SAFETY CHAIN amp BREAK AWAY CABLE Safety Chain i CONNECTION POINT Break Away Cable Te va KOOK ete side maen E Tae way SS 1 Sook z Iw Ton venucte niren Trailer Tow Vehicle CONNECTION POINT Actuator Hitch H oo 8 If the break away lever and cable are not FIG 3 BREAK AWAY LEVER located correctly as described above due to either the cable being pulled during use or by Taas OD accident it MUST be re
15. set prior to the trailer Poston o L ojja being moved Handwheel Handwhesl tat 9 When this actuator is used with disc brakes or non free backing brakes our solenoid back up valve part number 4748800 will allow the trailer to be backed without activating the brakes Do not block actuator movement in and out to back up the trailer Failure to remove the blocking device will prevent all trailer braking Laveen Fitting ert in ENGAGED 2 renown Oo o Co elo AWARNINGA An incorrect lever or chain position may cause the trailer brakes to drag and overheat or may keep the brakes from being applied in a break away situation After any usage of the break away mechanism either real or accidental check all system components lever cable S hooks catch spring and pin push rod assembly etc for damage Replace any damaged items with genuine TITAN service parts NOTE lt gt is the reference number shown in the assembly diagram of the actuator located at the end of this manual Page 5 of 9 MAINTENANCE 1 Before towing check that brake fluid reservoir is at least half full If not re fill to 3 8 inch below the top of the reservoir with DOT 3 4 brake fluid Check for leaks and repair as required Check that the brake fluid reservoir is three quarters full of DOT 3 or DOT 4 brake fluid Check for leaks and repair as required ZA WARNING Use only fresh brake fluid f
16. st the front end of the actuator s coupler PUSH 5 Stand in front of the trailer and face the rear Apply force to the top end of the board to use it as a lever Press back towards the rear of the trailer The board will begin moving the coupler case inner slide into the actuator s outer housing NOTE lt gt is the reference number shown in the assembly diagram of the actuator located at the end of this manual Page 3 of 9 TESTING TITAN SURGE BRAKE SYSTEMS cont 6 Keep pressing the top of the board to stroke the actuator and its internal master cylinder If the trailer brake system is operational the brakes will apply and keep the trailer from rolling away from you Properly adjusted uni servo or duo servo type brakes will prevent you from moving the trailer back more than a few inches Free backing type brakes will initially provide rolling resistance but continued force on the board will switch them into free backing mode and you ll be able to move the trailer backwards 7 If you have uni servo or duo servo brakes and stroking the actuator as described previously causes the trailer to roll away from you freely or with only minimal resistance the brakes are NOT applying properly If you have free backing brakes and stroking the actuator as described previously causes the trailer to roll away without initial resistance the brakes are NOT applying properly The brake system MUST be evaluated to de
17. termine the cause of the problem and corrective action MUST be taken before the trailer is used 8 Use this procedure each time you tow your trailer to check your surge brake system operation Z WARNING To ensure proper engagement of the actuator s coupler to the tow ball DO NOT use a multi piece ball an incorrectly sized ball or a worn damaged ball HITCHING TRAILER 1 The towing hitch and ball must have a rating equal to or greater than trailer GVWR 2 Multi fit Ball coupler will accept 1 7 8 50MM and 2 trailer balls Tighten hand wheel to secure ball in socket Make certain ball latch is in correct position to retain the ball and that the hand wheel lock is clicking while tightening You must depress the lock to loosen hand wheel in order to un hitch trailer Do not tow trailer if coupler is damaged see Figure 3 on page 5 3 Connect safety chains using crossed pattern under tongue or follow trailer manufacturer s directions see Figure 2 on page 5 Z WARNINGA An incorrect lever or chain position may cause the trailer brakes to drag and overheat or may keep the brakes from being applied in a break away situation After any usage of the break away mechanism either real or accidental check all system components lever cable S hooks catch spring and pin push rod assembly etc for damage Replace any damaged items with genuine TITAN service parts 4 Connect break away S hook see Figure 2 on page 5
18. ts on the actuator 5 Actuator travel over one inch shown by front roller path indicates a need to adjust the brakes Adjust per instructions found in brake installation manual In general back off adjusters 10 clicks from locked rotation Adjust Free Backing brakes by rotating in forward direction only Failure to adjust may result in loss of braking 6 Before storage or after extended use TITAN recommends applying motor oil to the coupler components lockout mechanism and the three internal rollers to keep them moving freely and to prevent corrosion MODEL 6 ACTUATOR PRODUCT LIST Part Drum Part Disc Description inner Outer 4079200 25 16 coupler 4067700183 2480100783 4747200 25 16 coupler 4067700183 2480100183 4747210 25 16 coupler with cover 4067700183 2480100183 4747220 25 16 coupler wibackup valve amp cover 4067700183 2480100183 4079200317 25 16 coupler 4067700317 2480100317 4067600 25 16 coupler A frame 4067700183 2493000 4093200 3 lunette eye 4045600183 2480100183 4748000___ _3 lunette eye 4045600183 2480100183 4045500 3 lunette eye A frame 4045600183 2493000 2480000 multi fit coupler 4391600 2480100183 4747900 multi fit coupler 4391600 2480100183 2492800 multi fit coupler A frame 4391600 2493000 4744900 leveler channel 4717600317 4745100317 4748100 leveler channel 4717600317 4745100317 47449017 Teveler channel 47176
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