(1) HAND TIGHT |e (2) RETIGHT
TOHERE [- TURN .03-.07"

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5 ee, TN

e ALL REPLACEMENT WORK CAN BE DONE WITHIN 5-10 MINUTES WITHOUT
REBLEEDING BRAKE SYSTEM. IF YOU DISASSEMBLE AND LEAVE SOLENOID OPEN
OVER 1 HOUR, YOU NEED TO REBLEED BRAKE SYSTEM TO REMOVE ANY AIR.

Trailer Brake System Bleeding Procedure:

The procedure immediately below assumes that a power bleeder will be used.
Two people will be required to bleed the brakes if bleeding is to be
performed conventionally by manually operating the actuator. Instructions
for manually operating/bleeding the actuators are also included on Page 4
and later in this document under the specific actuator model.

1. To facilitate bleeding of the trailer’s disc brake system it is helpful if the
actuator is lower than the disc brake calipers. It is easier to push the air in the
system up and out rather than trying to force the air down. It is also important
that any rubber flexible brake lines are routed such that the line does not slope
up before sloping down which would create a pocket where air can get
trapped. Before starting, make sure the brake calipers are properly installed
with the bleeder valves on the top side of the caliper. (The calipers are
universal and could have been incorrectly installed upside down.) On a new
trailer, before the actuator is connected to the (empty) main brake line, but
after all calipers are installed and remaining lines are connected to the
calipers, the air lines and calipers should be initially pressurized with dry shop
air (90 psi max) to extend the calipers against the brake pads and rotors (and
initially “adjust” the brakes). This may speed up the rest of the bleeding
procedure. To accomplish this, use a rubber tipped air nozzle to momentarily
put a puff of air into the main brake line. The air pressure should pass through
the brake line system and pressurize all calipers at the same time. When a
new replacement caliper is installed on an existing trailer, a puff of air into the
caliper inlet port (prior to connecting the brake line) works the same way.
After this dry initial pressurization, connect up the remaining brake line.

2. Bench bleeding the actuator prior to installation will also speed manual
bleeding of the brake system, but this is not necessary with a power bleeder.
3. A single person can accomplish bleeding the brake system if you use a

power bleeder and UFP’s bleeder clamp assembly. The pressure in the power
bleeder should not exceed 18 pounds/square inch (psi). Exceeding this
pressure will damage the diaphragm in the master cylinder reservoir, causing
it to leak. Always use clean DOT 3-brake fluid. Never reuse old fluid, as it
will contain contaminants and water moisture. Always seal fluid containers as
soon as possible as brake fluid is hygroscopic and readily absorbs moisture.

4. Attach bleeder clamp assembly to actuator. Make sure clamp assembly
is adjusted properly. If clamp is too tight it will crush and damage the master
cylinder reservoir cover plate. If the clamp is too loose it will not make a good
seal and will leak fluid when bleeding the brake system.

a Turn on valve at pressure bleeder and check for leaks where the bleeder
head enters the master cylinder reservoir.

6. Start bleeding with the brake at the farthest end of the brake line. If
trailer has tandem brake axles, start with the brake at the farthest end of the
brake line on the rear axle first.

7. At the disc brake caliper assembly, connect a bleeder hose to the nipple of the
bleeder screw located on top of caliper body and place the free end of hose

in a suitable container, a 32 ounce clean plastic bottle is suggested.

8. Loosen bleeder screw one turn. When no air bubbles are visible coming
out of the hose end (into the fluid in the bottle) for at least three seconds,
close bleeder screw securely and remove bleeder hose.

9, Repeat steps 6 and 7 above on brake on the opposite side of axle and
then on front axle if so equipped.

10. If installation is tandem axle with brakes on both axles, repeat bleeding
procedure on the rear axle brakes for the second time to assure positive
purging of all air from system.

11. When done bleeding, relieve pressure in bleeder pot then close valve at
bleeder head. Slowly remove bleeder clamp assembly so as not to spill fluid.
12. Check fluid level. Not enough fluid in the reservoir will cause the
reservoir to run dry as the disc brake pads wear. Too much fluid will cause a
overflow situation when the solenoid valve is energized during backing up.
Proper fluid level is when the fluid in the reservoir just touches the end of the
dip stick on the fill plug when it is inserted fully into the fill hole.

13. Wipe off any brake fluid that may have spilled on the top of the
reservoir or actuator body. Do not re-use any old fluid, dispose of properly.
14. Proper bleeding of brake system can be checked by performing one of
the following procedures;

(1) Temporarily disconnect the tow vehicle/trailer electrical connector
and back up the trailer, (without the energizing the backing solenoid valve), to
verify brakes are working.

(2) Pull trailer forward and stop suddenly, pin on side of actuator should
not travel more than about % way in slot for single brake axle or %4 way in slot
for tandem brake axles.

(3) Stroke pushrod assembly with a screwdriver and verify brake rotor
can not be rotated (Note: If using this procedure, make sure you push up on
the pushrod release bracket afterward to fully release the brakes).

15. If brakes are not working properly, there is still air in the brake system
and the system will have to be re-bled.

16. After initial trailer braking test, recheck fluid in actuator and refill as
necessary. Very occasionally, if the calipers were not initially set as
suggested in step 1, the fluid required to fully extend the calipers will exceed
the capacity of the master cylinder, requiring the system to be refilled and re-
bled.

17. Check for leaks at all fittings and connections and tighten or correct as
necessary.

Work Instruction

BRAKE LINE BLEEDING

1/1

FRED WANG 8/15/05

S SHUT-OFF VALVE [BM orcccgee
a GAGE |

| RELEASE VALVE [1

CONNECT BRAKE

ACTUATOR

18" AXLE

LINE

CLAMPING

CONNECT ACTUATOR
TO BRAKE LINE.

PUMP IN FLUID

CLOSE SHUT-OFF VALVE.
ADJUST & CLAMP ON ===}
ACTUATOR.

BLEEDING 18" AXLE

TURN ON SHUT-OFF VALVE.
PUMP PRESSURE POT TO 20 PSI
TO POUR FLUID IN TO ACTUATOR
AND BRAKE LINE.

(LEFT THEN RIGHT)

BLEEDING 2™° AXLE

RELEASE BLEEDER SCREW
% TURN. LET FLUID FLOW
UNTIL THERE ARE NO AIR

BUBBLES.

CLOSE BLEEDER SCREW.

(LEFT THEN RIGHT)

UNCLAMP & RELEASE

SAME AS ABOVE. (PUMP
UP PRESSURE POT IF
NECESSARY TO 20 PSI.)

PRESSURE

BLEEDING TOOL: CLOSE SHUT-OFF
VALVE. / UNCLAMP. / RELEASE PRESSURE.
PUT CAPS BACK ON ACTUATOR.

c Ke

2 PULL UP T!
RELEASE
| PRESSURE

MANUAL BLEEDING OF THE BRAKE SYSTEM

Check that all hydraulic fittings are secure. Read and understand
all instructions before starting. Two people are required for manual
bleeding. It is critical that the fluid hose and catch bottle described
below are used to see/remove all air during manual bleeding.

1 Remove the master cylinder reservoir plug and fill the reservoir with brake fluid. Use
either DOT 3 or DOT 4 automotive brake fluid. Follow instructions on brake fluid container.
Avoid shaking brake fluid container and pour fluid slowly to minimize air entrapment. Let
fluid in reservoir stand until completely free of air bubbles.

2 IMPORTANT: Before bleeding brake lines, bleed the actuator master cylinder. Insert
a screw driver through hole in bottom of inner member and use short strokes to pry on
pushrod (while holding safety release bracket up) until no air bubbles are seen coming from
small orifice hole in the bottom of the master cylinder reservoir.

3 Start the bleeding procedure on the brake furthest from master cylinder.

4 At the caliper or drum, connect a transparent bleeder hose to the bleed screw fitting
and submerge the hose free end into a container partially filled with brake fluid. The use of
this catch bottle is important to see the small bubbles. 320z clear plastic bottles work well.
5 The first person strokes the pushrod slowly while holding safety release bracket up.
The second person then opens the bleed screw fitting. He then closes the bleed screw
fitting BEFORE the first person SLOWLY releases the pushrod. Repeat this procedure

until the fluid expelled from the bleeder hose is free of air bubbles. Remember to always
tighten the bleeder screw before releasing pushrod. During this procedure, the master
cylinder reservoir fluid level must be maintained at no less than 1/2 full.

6 Repeat steps 4 and 5 for the other brake and the brakes on the front axle, if equipped
with tandem brake axles. Do not reuse any fluid purged from the system, dispose of it properly.
7 If installation is tandem axle with brakes on both axles, repeat bleeding procedure on
rear axle brakes for the second time to assure purging of all air in system.

8 As a final check after bleeding is completed, stroke pushrod and check to be sure

brake system is pressurized by attempting to rotate a tire.

9 Push up on the safety release bracket to ensure that pushrod is in released position.

10 After bleeding has been completed, re-check fluid level in master cylinder. Fill the

master cylinder reservoir to indicator on reservoir plug. Do not overfill.

A CAUTION IMPORTANT: DO NOT USE BRAKE FLUID DRAINED FROM

BRAKE SYSTEM TO REFILL MASTER CYLINDER RESERVOIR AS SUCH FLUIDS CONTAIN
CONTAMINANTS FROM SYSTEM WHICH MAY
RESULT IN BRAKE FAILURE OR COSTLY REPAIRS.

PUSHROD

RELEASE

BRACKET
PUSH UP PRY
AND HOLD

PUSHROD

FIGURE 16 STROKING PUSHROD TO BLEED BRAKES
Manually Stroking/Releasing the Actuator to Bleed Brakes

Be sure to check the brake fluid often when bleeding, as the reservoir is small, and will
run out quickly if brake lines are empty. If it runs out of fluid, air will be introduced again into the
brake lines and you will have to start over.

1. With the A60, A75, and A84 actuators, see figure 16 above or on page 25 of
their manual. Insert a 3/16" wide standard screwdriver into the hole in the bottom
of the actuator to press the pushrod. You will have to press the brake release
bracket to release each time after you stroke the pushrod.

Important: When finished bleeding the brakes, press the release one last time so
the brakes will be “off” when the trailer is towed.

Pushrod Access Hole
Pushrod Access Hole Brake Release Tab

2. With the larger A160 actuator, stroking the master cylinder can be done by first
temporarily removing the two 7/16" bolts and the safety stop metal plate on the top
of the actuator (Manual Items 21, 22, and 23) so the breakaway lever can be easily
operated. The master cylinder can then be stroked by pulling the breakaway lever
forward. A pair of vise grips or other tool about 8” long can be used to increase
leverage on the breakaway lever, but be careful and not overstroke/bend the lever
if using a tool. Replace the safety stop metal plate when done.