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ELECTRIC BRAKE AXLESINITIAL ADJUSTMENTFor controllers fitted with hydraulic plungeradjustment.Before road use the controller lever should be turned toset the adjustment in the mean position.During initial road tests adjust the hydraulic plunger ifnecessary to give the optimum performance. Slightvariations may be carried out by rotation of thecontroller ever during towing to suit requirements.CHECKING THE ELECTRICAL CIRCUITTEST INSTRUMENTIn order to check the electrical circuit and components,a D. C. ammeter should be used (0-15 amps for 2 to 4brakes). However, in an emergency an automotivelamp may be used as a test bulb. Be sure to use anautomotive test bulb of the same voltage (6 volt or 12volt) as the trailer brakes.TESTING THE CIRCUITFirst check the continuity of the system. To do thisconnect the trailer to the towing vehicle, then place theammeter or test bulb in the circuit as shown in diagram.NOTE: Whenever connecting the ammeter, you canavoid possible damage to the ammeter by connectingone lead then just touching the other lead quickly. If theneedle goes over the wrong way the polarity is reversed.To correct, simply reverse the leads, then complete theconnection. Now operate the controller slowly. The cutinlowest current should read from 1 to 1Ö amp. Thereading will vary, depending on the voltage and thenumber of brakes in the system. For 8” and 9” dia. 2braked axles the amperage reading should be 5-6 for 12volt towing systems. If the ammeter registers the correcthigh and low readings and shows smooth current modulationyou may assume that the controller is functioningproperly. If you do not show the correct high and low or themodulation is poor, check the following electrical circuitproblems.If you are using a test light instead of an ammeter, the bulbshould be ‘out’ when the controller is ‘off’, burn dimly ascontroller application starts, and gradually burn morebrightly as the controller handle is moved toward ‘on’. In full‘on’ position the bulb should burn with maximumbrightness.CHECK WITHOUT TRAILERIf trailer is not available a quick check of the towing vehiclecircuit may be made by inserting the test bulb at the towingvehicle connector socket. Operate the controller slowly. If,as the controller handle is moved toward ‘on’ the light goesfrom dim to bright or the ammeter shows a gradual rise, thetowing vehicle circuit is probably alright.CHECKING THE ELECTRICAL COMPONENTSWhen, after checking the circuit the trouble is located in aspecific component (such as the controller or a brakemagnet) it is advisable to remove this component andcheck it on the bench.1 AUTOMATIC CONTROLLER BENCH CHECKTo bench check the controller, connect to ammeter or testlight as shown in diagram.BE SUREPOLARITYIS CORRECTFOR METERUSE .5 OHMMINIMUMRESI STANCEIN CIRCUIT.
The ammeter or test light should vary smoothly from‘off’ to ‘on’. If it does not vary smoothly or shows nocurrent when the controller is at full ‘on’, remove thecontroller cover and inspect the resistor coil. If the coilis burned out, it must be replaced. A burned out coilcan be detected by visual inspection.CAUTION. The resistor coil should last indefinitelyunder normal operating conditions. If the coil is burnedout, carefully check the entire electrical system for ashort circuited condition. A short circuit can damageany electric brake controller.After replacing the coil be sure there is at least .020”clearance between the contactor strip and the coilwhen the controller handle is unapplied.HYDRAULIC.CYLINDER.020” GAPRESISTORCOIL.020” GAP3 HYDRAULIC CYLINDER LEAKAGEWhen checking the electrical circuit of the controller it isadvisable to check its hydraulic cylinder at the sametime, to be sure it is tight and free Of leakage.If leakage does occur it is recommended that thecomplete hydraulic cylinder assembly be replaced,When reconnecting the controller into the hydraulicsystem of the towing vehicle, bleed and checkconnections.4 MAGNET ASSEMBLYWithout removing the magnet assembly from the brake,inspect the magnet for wear and flatness. If the magnetrubbing surface is flat it need not be replaced until thefriction element shows signs of wearing through. To checkthe wearing surface for flatness lay a straight edge onthe magnet.ORIGINAL SURFACEABNORMALWEAR:STLAJ G~EDGENORMALWEAR~EPLACEMAG.ASSY.)j2 STOP LIGHT SWITCHAll K.H. controllers are now equipped with a separatestop light switch which allows full current supply to thetrailer stop lights throughout brake application. It shouldThis gap can be adjusted by loosening one screwthrough an access hole in the bottom of the controllercase.Before replacing with a new magnet determine thecause of the improper wear. First check the magnetlever pivot. A worn pivot bushing can cause the magnetlever to cock,. thus allowing the magnet to tip against thearmature plate.If this condition exists the lever assembly should bereplaced. When reinstalling magnets, be sure to install theloom (lead wires) properly, avoiding kinks and allowingample clearance for the lever to move through its full travel.Operate the lever in both directions to be sure the loommoves properly without binding, kinking, or interferingwith lever movement.7
Page 3 and 4: INDEXPageGENERAL INSTRUCTIONS 2ASSE
Page 5 and 6: ADJUSTMENTFITTING(e) The inner bear
Page 7: TORSION BAR AXLESREPLACEMENTTo repl
Page 11 and 12: BOAT TRAILER ELECTRIC BRAKESSpecial
Page 13: NOSE WEIGHTS1973 1974M 2 103 lbs 10

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