TRAILER SUPPLIES
SM
Brake Actuating Systems
This section consists of various ways to ac­ti­vate and actuate your trailer brakes and
includes the following: Electric Brake Controls, Breakaway Kits, Hydraulic Surge
Brake Ac­tu­a­tors, Plumbing Line Kits, Electric/Hydraulic Brake Systems and Brake
Ac­tu­at­ing Sys­tems for Air/Hydraulic or Straight Air Brake Systems.
Electronic Brake Controls.................................. L-2-L-6 Hydraulic Line Kits................................................. L-15
Brake Control Installation Kits.................................. L-7 Air Trailer Kits........................................................ L-16
Brake Control Accessories......................................... L-8 ABS Air Trailer Kits................................................ L-17
Side-Post Mount Battery Adapter Kit....................... L-8 Air/Hydraulic Trailer Kits....................................... L-17
“The Engager” Breakaway Kit................................... L-8 Miscellaneous Brake System Parts........................... L-18
Breakaway Kits.......................................................... L-9 Hydraulic Fittings.................................................... L-19
Breakaway Kit Accessories....................................... L-10 Hydraulic Lines and Brackets.................................. L-19
Actuators:
Dexter Electric Brake Trouble Shooting Guide...... L-20
Carlisle Hydrastar Elec-Hyd Brake Actuators.....L-11
Demco Hydraulic Brake Actuators..........L-12 & L-13
Atwood Brake Actuators....................................... L-14
Balcrank Brake Actuators..................................... L-14
Brake
Actuating
Systems
Titan Brake Actuators.......................................... L-14
Dexter Elec/Hyd Brake Actuator.......................... L-15
Section L-1
TRAILER SUPPLIES
SM
Brake Controls
Voyager Features Include:
Plug & Play
• True Proportional Braking Power: Inertia Activated Sensor.
• Two Control System: Controls power output to brakes and
braking response.
• Manual Override: Aids in setting controls and allows manual
ap­pli­ca­tion of brakes.
• LED Light Display: Indicates a completed electrical circuit,
aides in setting controls, changes from green to red indicating
relative braking power.
• Installation: Mounts conveniently under vehicle dash.
­­• Warranty: Limited 5 year warranty.
PART NO. REF. NO.
DESCRIPTION
9030A
NEW “VOYAGER”, ALL ELECTRONIC FOR 1-4 AXLES
416430
Primus IQ Features Include:
• True Proportional Braking Power: Inertia Activated Sensor, no
manual leveling.
• Two Control System: Controls power output to brakes and braking
response.
• Manual Override: Aids in setting controls and allows manual ap­pli­ca­
tion of brakes.
• Digital Display: Shows voltage to trailer during braking, plus diagnostic features.
• Installation: Control design allows multiple angles of control positioning.
• Warranty: Limited lifetime warranty.
PARTREF.
NO. NO.DESCRIPTION
90160 416632 “PRIMUS IQ”, ALL ELECTRONIC FOR 1-3 AXLES
Brake
Actuating
Systems
Prodigy P2 Features Include:
Section L-2
• True Proportional Braking Power: Inertia Activated Sensor, no
manual leveling.
• Two Control System: Controls power output to brakes and braking
response.
• Manual Override: Aids in setting controls and allows manual ap­pli­ca­
tion of brakes.
• Digital Display: Indicates voltage readout and NC (no connection) if
connection is missing Visual warning if trailer becomes disconnected.
• Installation: Control design allows multiple angles of control positioning.
• Warranty: Limited lifetime warranty.
PARTREF.
NO. NO.DESCRIPTION
90885 416634 “PRODIGY P2”, 1-4 AXLES
7686 416637 REPLACEMENT “POCKET” BRACKET ONLY FOR 90885
PRODIGY CONTROL
7894 416638 REPLACEMENT PLUGIN HARNESS FOR
90160/90195/90885
TRAILER SUPPLIES
SM
Brake Controls
Prodigy P3 Features Include:
• True Proportional Braking Power: Inertia Activated Sensor, no
manual leveling.
• Two Control System: Controls power output to brakes and braking
response.
• Manual Override: Aids in setting controls and allows manual
ap­pli­ca­tion of brakes.
• Digital Display: Distinct, easy to see LCD display with multiple
color and contrast options.
• Installation: Compact, dash hugging design, unique, easy-to-use,
clip mounting system.
• Electric/Hydraulic: Allows the user to switch between Electric and
Electric Over Hydraulic trailer brakes.
• Warranty: Limited lifetime warranty.
PARTREF.
NO. NO.DESCRIPTION
90195 416636 BRAKE CONTROL, TEKONSHA “P-3”, 1-4 AXLES
Prodigy RF Features Include:
• Perfect for use with shared trailers: Rental, Fleet or when multiple tow vehicles are available.
• True Proportional Trailer Braking: Forward or reverse, no level adjustment necessary.
Remote Hand Held Unit Features Include:
• Wireless Communication: between the remote Hand Held Unit (90251, included) and Trailer
Power Module eliminates the need for under the dash wiring. No drilling, brackets or clips required.
• Easy to use Remote Hand Control: includes the Prodigy® “Boost” system to allow for different levels of customized braking. Unit plugs into any standard 12 volt power accessory adaptor.
• Continual Diagnostic Scanning: with a visual warning in the hand display should a fault condition
occur.
• 5-Year Limited Warranty: on Hand Held Unit.
PARTREF.
NO. NO.DESCRIPTION
90250 416650 PRODIGY RF, 1-3 AXLES
90251 416655 HAND-HELD MODULE FOR PRODIGY RF, BRAKE CONTROL
Brake
Actuating
Systems
Trailer Mount (Power Module) Unit Features Include:
• Trailer Power Module is Watertight: and includes a
sealed 8’ 7-Way vehicle connector.
• Multiple Mounting Options: on the tongue or front
of the trailer.
• Module Powered: through 7-Way Cable from the
Tow vehicle.
• 15-Year Limited Warranty: on the trailer mounted
power module (1-Year Limited Warranty on Cord)
Section L-3
TRAILER SUPPLIES
SM
Energize III® & Energize XPC® Features Include:
81741B
81745
• True Proportional Braking Power: Inertia Activated Sensor
• Two Control System: Controls power output to brakes and braking
response.
• Manual Override: Aids in setting controls and allows manual ap­pli­
ca­tion of brakes.
• LED Light Display: Indicates there is a completed electrical circuit,
and informs operator of vehicle’s braking response and relative braking power.
• Installation: Mounts conveniently on top or under vehicle dash.
• Warranty: Limited 5 year warranty.
PART NO. REF.NO. DESCRIPTION
81741B
416225 “ENERGIZE III”, ELECTRIC BRAKE CONTROL, 1-2 AXLES
81745
416240 “ENERGIZE XPC”, ELECTRIC BRAKE CONTROL, 1-3 AXLES
Syncronizer® Features Include:
• Time Actuated Power: Trailer brakes are gradually applied at preset rates. Full brake actuation in about 2.5 seconds. 100% solid
state.
• Digital Display: Displays voltage being applied to brakes; presence of short circuit and trailer connection.
• Manual Override: Aids in setting controls and allows manual
brake actuation.
• Installation: Mounts in any position, no leveling required.
Digital readout can be reset for installation requiring upside down
mounting.
• Warranty: Limited lifetime warranty.
PART NO. REF.NO. DESCRIPTION
81725
416380 BRAKE CONTROL, HAYES SYNCRONIZER, 1-2 AXLES
Brake
Actuating
Systems
G2® Features Include:
• Self-leveling: Tri-axis accelerometer measures the rate of deceleration or
gravitational pull on 3 planes - front-to-rear, left-to-right & up-down.
• Proportional Braking in reverse without using manual lever.
• Plug & Socket: Allows unit to be removed and stored when not in use.
• Universal QUIK-RECEIVER Mounting Sleeve: Uses VHB tape for
mounting; no screws or tools required.
• LCD Display: Large and easy to read: displays battery, stoplight & output voltage. Screen color, intensity and contrast can also be adjusted.
• Alarm Mode: Exclusive audible tone warns of any trailer braking related
fault.
• Ease of Use: Allows use of electric trailer brakes or hydraulic drum or
disc; simply change setting using LCD screen & up/down buttons.
• Boost Feature: Provides easier adjustment based on the weight of trailer
being towed by increasing initial brake gain by 5% to 20%, depending
on setting selected.
PART NO. REF.NO. DESCRIPTION
81792K
416400 BRAKE CONTROL, HAYES G2, 1-4 AXLES
Section L-4
TRAILER SUPPLIES
SM
Dexter Brake Control
Predator Features Include:
•
•
•
•
•
True Proportional Braking Power: Inertia Activated Sensor.
Two Control System: Controls power output to brakes and braking response.
Manual Override: Aids in setting controls and allows manual ap­pli­ca­tion of brakes.
LED Display: Large digital LED displays voltage output, and makes leveling quick and easy.
Mounting Range: Versatile mounting range of -35º to +90º, to accomodate a wide variety of vehicle
interiors.
• Warranty: Limited 7 year warranty.
PART NO. REF.NO. DESCRIPTION
58-8
416260 “PREDATOR” DX2 BRAKE CONTROL FOR 1-2 AXLES
Warner Air Utility Brake Control
The Warner Air Utility Control interconnects
with air brake systems of tow vehicles and
automatically op­er­ates electric trailer brakes in
sychronization with air brakes.
It may be used in FMVSS 121 systems. The
manual override feature operates trailer brakes
only.
Brake
Actuating
Systems
The unit displaces only 2.8 cubic inches of air at 100 PSI. It is ad­just­able for a wide range of vehicle
brake system pres­sures, with low pressure sensitivity that assures im­me­di­ate and smooth engagement
of trailer brakes. The special design of the internal mul­ti­ple resistor pack provides heat sinking and
heat dis­si­pa­tion char­ac­ter­is­tics. For use on trailers with up to 8 brakes (4 axles).
PARTREF.
NO.
NO.DESCRIPTION
1300-80 417400 AIR OPERATED FOR AIR BRAKE TRUCK TO PULL ELECTRIC TRAILER
Section L-5
TRAILER SUPPLIES
SM
Brake Controls
TA900A Features Include:
• Time Actuated Power: Trailer brakes are gradually applied at
pre-set rates. Full brake actuation in 2 seconds. 100% solid
state.
• Manual Override: Aids in setting controls and allows manual
brake actuation, activates brake lights.
• Multi-color LED: Indicates completed circuit, brake actuation and brake wire shorts.
• Installation: Mounts in any position, no leveling required,
quick disconnects for easy removal.
• Warranty: Limited lifetime warranty.
PART NO. REF.NO. DESCRIPTION
TA900A
416321 ELECTRONIC BRAKE CONTROL FOR 1-3 AXLES
TA1000 Features Include:
• Time Actuated Power: Trailer brakes are gradually
applied at pre-set rates. Full brake actuation in about 2.5
seconds. 100% solid state.
• Manual Override: Aids in setting controls and allows
manual brake actuation.
• Two Color LED: Indicates completed circuit and brake
actuation.
• Installation: Mounts in any position, no leveling required.
• Warranty: Limited 5 year warranty.
PART NO. REF.NO. DESCRIPTION
TA1000
416310 ELECTRONIC BRAKE CONTROL FOR 1-2 AXLES
Brake
Actuating
Systems
TA1200 Features Include:
• Digital Display: Displays voltage being applied to brakes;
presence of short circuit and trailer connection.
• Time Actuated Power: Trailer brakes are gradually applied
at pre-set rates. Full brake actuation in about 2.5 seconds.
100% solid state.
• Manual Override: Aids in setting controls and allows
manual brake actuation.
• Installation: Mounts in any position, no leveling required.
Digital readout can be reset for installation requiring upside
down mounting.
• Warranty: Limited lifetime warranty.
PART NO. REF.NO. DESCRIPTION
TA1200
416296 DIGITAL BRAKE CONTROL FOR 1-3 AXLES
Section L-6
TRAILER SUPPLIES
SM
Brake Control Installation Kits
A ll
in one package
- E verything
needed for
proper brake control in ­s tal ­l a ­t ion !
Redline offers a universal kit, including all wire and electrical items nec­es­sary for a standard brake control installation. Vehicle specific kits plug directly into the vehicle wiring
harness.
TA05-035
TA05-025
Universal Kit
TA05-020
TA05-050
PARTREF.
NO.
NO.DESCRIPTION
TA05-020 417900 UNIVERSAL BRK CNTRL KIT, INCLUDES WIRE, TERMINALS & BREAKER
TA05-025 417902 BRK CNTRL HARNESS W/PRODIGY-P RIMUS ADAPTER FOR 99-02 GM TRUCKS W/TOWING PKG
TA05-026 417903 BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR 03-07 GM TRUCKS W/TOWING PKG
TA05-126 417904 BRK CNTRL HARNESS FOR 99-06 GM TRUCK
TA05-030 417905 BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR 94-04 FORD, 05-08 F150 ONLY
TA05-130 417906 BRK CNTRL HARNESS FOR 94-04 FORD TRUCK, 05-08 F150 ONLY
TA05-031 417907 BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR 05-07 FORD SUPER DUTY
TA05-032 417908 BRK CNTRL HARNESS 08-11 FORD SUPER DUTY TRUCK
TA05-033 417909 BRK CNTRL HARNESS 09-10 FORD F150 W/CNTLR CTR
TA05-135 417916 BRK CNTRL HARNESS FOR 97-09 DODGE TRUCK
TA05-036 417917 BRK CNTRL HARNESS 2010 DODGE RAM W/CNCTR
TA05-045 417920 BRK CNTRL HARNESS, 06-10 HONDA TRUCKS W/PRODIGY
Brake
Actuating
Systems
TA05-035 417915 BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR 95-11 DODGE RAM P/U & DURANGO
TA05-050 417925 BRK CNTRL HARNESS, 04-10 NISSAN TRUCKS W/PRODIGY
TA05-055 417930 BRK CNTRL HARNESS, 02-10 TOYOTA TRUCKS W/PRODIGY
Section L-7
TRAILER SUPPLIES
SM
Brake Control Accessories
PARTREF.
NO.
NO.DESCRIPTION
2180S
418240 PULSE PREVENTER PREVENTS INTERFERENCE BETWEEN 4-WAY
FLASHER & BRAKE CONTROL
6560
418250 TEKONSHA TRAILER EMULATOR, 7-WAY RV TYPE CONNECTOR
Side-Post Mount Battery Adapter Kit
Allows direct connection to battery
on vehicles using a side-post battery.
PARTREF.
NO.
NO.DESCRIPTION
TA05-040 417910 SIDE POST MNT BATTERY ADAPTER KIT, CONTAINS
ADAPTERS, NUTS & CONNECTORS (QTY 2)
“The Engager” Breakaway Kits
Easy to monitor battery condition. A simple “push to test” button on the
front activates LED lights. A weld-on mounting bracket is also available.
BA10-250
Brake
Actuating
Systems
BA10-150
Section L-8
­ ART
P
REF.
NO.
NO.
BA10-150
419235
BA10-250
419236
BA10-150BKT 419238
20012
419230
DESCRIPTION
“ENGAGER” BRKWY KIT, W/LED CHARGE INDICATOR
“ENGAGER” BRKWY KIT, FLIP-TOP W/LED INDICATOR
WELD-ON BRACKET W/STUDS, FITS BA10-150
REPLACEMENT PIN & CABLE FOR ENGAGER SWITCH
BATTERYAPPLICATION
5AMP/HR 1-2 AXLES
5AMP/HR 1-2 AXLES
TRAILER SUPPLIES
SM
Breakaway Kits
These Electronic Breakaway Kits feature a re­charge­able,
sealed, maintenance-free battery and an op­tion­al charger,
for trouble-free towing. (Choice of 4 Battery Box Designs.)
•Compact Design
•Rechargeable, sealed, main­te­nance-free 12v Battery
•Dependable
•Wide operating tem­per­at­ ure (-76ºF to +140ºF)
•Meets or exceeds D.O.T regulations
BA10-140
42905
D2903K
42906
Breakaway Kits
Brake
Actuating
Systems
PART
REF.BATTERY
NO. NO.DESCRIPTION
BATTERYSWITCH
CHARGER APPLICATIONBOX
BA10-140 419229 REDLINE, W/CHRGR
5 AMP/HR BA02-010
YES
1-2 AXLES
FRONT LOAD
42905
419240 BRKY KIT W/CHGR, LED INDCTR
NONE
BA02-010
YES
1-2 AXLES
TOP LOAD
42905K
419241 BRKY KIT W/CHGR, LED INDCTR 5 AMP/HR BA02-010
YES
1-2 AXLES
TOP LOAD
42906
419242 BRKY KIT W/CHGR, LED INDCTR
NONE
BA02-010
YES
1-2 AXLES
FRONT LOAD
42906K
419243 BRKY KIT W/CHGR, LED INDCTR 5 AMP/HR BA02-010
YES
1-2 AXLES
FRONT LOAD
D2903
419260 BRKY KIT W/CHG
NONE
BA02-010
YES
1-2 AXLES
FRONT LOAD
D2903K 419262 BREAKAWAY KIT
5 AMP/HR BA02-010
YES
1-2 AXLES
FRONT LOAD
D2904
419265 BREAKAWAY KIT
NONE
BA02-010
NO
1-2 AXLES
FRONT LOAD
D2904K 419267 BREAKAWAY KIT
5 AMP/HR BA02-010
YES
1-2 AXLES
FRONT LOAD
BKW86114419276 BRKY KIT, PREWIRED QTY 10
5 AMP/HR BA02-010
YES
1-2 AXLES
FRONT LOAD
BKW86140419286 BRKY KIT, PREWIRED QTY 10
5 AMP/HR BA02-010
NO
1-2 AXLES
FRONT LOAD
1026
419300 TEKONSHA, NO CHRGR
4 AMP/HR
2005
N/A
1-2 AXLES
2018
1028A
419312 TEKONSHA, W/CHRGR
4 AMP/HR
2005
1024
1-2 AXLES
2018
2026
419410 TEKONSHA, NO CHRGR
5 AMP/HR
2010
N/A
1-3 AXLES
2018
2028
419420 TEKONSHA, W/CHRGR
5 AMP/HR
2010
2024
1-3 AXLES
2018
20005
419425 TEKONSHA, NO CHRGR
5 AMP/HR
2010
N/A
1-3 AXLES
2051
20015
419427 TEKONSHA, W/CHRGR
5 AMP/HR
2010
2024
1-3 AXLES
2051
20010
419430 TEKONSHA, NO CHRGR
5 AMP/HR
2010
N/A
1-3 AXLES
20000
20020
419440 TEKONSHA, W/CHRGR
5 AMP/HR
2010
2024
1-3 AXLES
20000
See next page for Breakaway Kit Accessories.
Section L-9
TRAILER SUPPLIES
SM
Breakaway Kit Accessories
2018
2051
20000
2-PIECE
BA01-020
UB1250
BA02-010
2010
Brake
Actuating
Systems
20059
BA02-020
Section L-10
PARTREF.
NO.
NO.DESCRIPTION
BA01-025 419244 REDLINE BATTERY, 12V, 5AMP BATTERY SEALED, CLAM-PKGD
BA01-020 419245 REDLINE BATTERY, 12V, 5AMP/HR FOR 1-2 AXLE TRAILERS
UB1250 419246 SEALED LEAD ACID BATTERY, 12V, 5 AMP/HR FOR 1-2 AXLE TRAILERS
BA02-010 419250 NYLON BRKY SWITCH W/METAL BRACKET, PKGD
BA02-020 419255 12V MAINTENANCE CHARGER FOR BRKY KITS, PKGD
20059
419700 LED BREAKAWAY SWITCH, 7” WIRES
20051
419710 REPL PIN & CABLE FOR 20059 BREAKAWAY SWTCH
20010H 419715 BRKY SWITCH, HOPKINS “NEW” STYLE, 7” WIRES
2005A
419750 REPL PIN & CABLE, FITS 2005 BREAKAWAY SWITCH
2009
419800 BRKY SWITCH, ALL METAL W/SILVER CONTACT POINTS & BRASS PULL PIN
2010
420000 BRKY SWITCH, NYLON CASE, WELDABLE METAL TAB, SILVER CONTACT POINTS, NYLON
PULL PIN
2010A
420100 REPL NYLON PULL PIN & CABLE FOR 2010 BRKY SWITCH
2018
420210 BATTERY CASE, POLYETHYLENE PLASTIC, A-FRAME OR JACK POST MOUNT
20000
420215 BATTERY CASE, POLYETHYLENE PLASTIC, LOCKABLE, FLAT SURFACE MOUNT, WELD-ON
2051
420220 BATTERY CASE, POLYETHYLENE PLASTIC, LOCKABLE, FLAT SURFACE MOUNT, BOLT-ON
1024
420885 MAINTENENCE BATTERY CHARGER, 12V (WILL NOT FULLY RECHARGE BATTERY)
2024
420900 QUICK BATTERY RECHARGER, 12V (WILL RECHARGE BATTERY IN APPROX. 4-5 HRS)
TRAILER SUPPLIES
SM
Carlisle Hydrastar Electric-Hydraulic Brake Actuators
HYDRASTAR FEATURES:
• 12V DC powered electric-hydraulic pump-style actuator for electronically controlled hydraulic brakes
• Compatible with most industry standard electronic brake controllers.
(Use HBA-CAM for controller compatibility issues.)
• “Unloading Piston” feature instantly releases hydraulic pressure upon
stop of brake signal, eliminates pump-style actuator “brake drag”.
• Completely sealed to be a weather-tight unit, approved for marine
applications
• Actuator designed for single or tandem axle applications
• Compact design, measures 3.25”W x 5.75”H x 17.5”L
• For use with industry standard 5 AMP/HOUR Breakaway Kit
• 2-Year Warranty
Part No.
Ref. No.
HBA-CAM
247635
HBA-10
247636
CAR-HBA10-2A 247638
CAR-HBA10-2
247640
HBA-16
247645
CAR-HBA16-2
247647
CAR-HBA16-2HD 247650
HBA-BKT
247651
HBA-BC
247634
Description
CONTROL ADAPTER MODULE
1000 PSI UNIT
1000 PSI DRUM TDM W/9505 LINE KIT & BRKY
1000 PSI DRUM TDM W/DELX LINE KIT & BRKY
1600 PSI UNIT
1600 PSI DISC TDM W/DELX LINE KIT & BRKY (3.5k-8k)
1600PSI DISC TDM W/10-12K LINE KIT & BRKY
BOLT-ON MOUNTING BRACKET FOR HYDRASTAR
REP’L FILLER CAP, HBA-SERIES HYDRASTAR
What’s
stopping
your
trailer?
HBA-CAM Controller
Adapter Module:
• Makes the HydraStar® unit
compatible with most Ford
OE Tow Command controllers
(where needed), & GM Factory
Controllers.
• Easy to install, simply splice in
four wires & mount the module
where convenient.
• Check with your Redneck
Customer Service Team for
current applications.
Carlisle Hydrastar XL Electric-Hydraulic Brake Actuator
HYDRASTAR XL FEATURES:
The Carlisle Hydrastar XL uses an on-board microprocessor and accelerometer to sense the amount of braking
effort being generated by the tow vehicle. The Hydrastar XL does not require a hard-wired in cab electronic
brake controller. The hand held actuator plugs into the cigarette lighter, using the vehicle’s original wiring to
transmit signals to the actuator. The Hydrastar XL is great for
any situation where multiple tow vehicles may be used to pull a
single trailer, especially rental units.
• No hard-wired brake controller necessary.
• 17 Amp/Hour break-away battery kit required
• No special wiring needed, no compatibility conflicts w/factory
vehicle controllers.
• Great for rental units or where using multiple tow vehicles on
a single trailer­.
Ref. No. Description
HBAC10-CLR
247655
XL, 1000 PSI UNIT W/IN-CAB CONTROLLER
CAR-HXL10-2A 247657
XL 1000PSI KIT W/CNTRL, HYD LINE & BRKY
CAR-HXL10-2
247660
XL 1000PSI KIT W/CNTRL, DLX LINE KIT & BRKY
HBA-EBA
419450
17AMP BREAKAWAY KIT FOR HYDRASTAR XL/ELECTRASTAR
Brake
Actuating
Systems
Part No.
Hydrastar XL
with controller
Section L-11
TRAILER SUPPLIES
SM
Hydraulic Brake Actuators
•Master cylinder cap has a diaphragm providing a completely
enclosed hydraulic brake system on all models.
•Raised fill plate prevents contaminants from entering master
cylinder when removing cap on all models.
•Tie loops on cap can be used for a tamper resistant seal.
•Bellow boot on push rod for moisture and dirt prevention on
all models.
•Emergency lever guide with color coded decal indicates if brakes are on or off (all models
EXCEPT DA66B).
•Brake line pressure controlled by spring loaded push rod assembly.
•Integrated shock dampening design.
•Emergency brake-away lever with cable hook-up and easy reset.
•Corrosion resistant finish provides long-lasting, attractive appearance. Plated finish is 500 hour
salt spray tested.
•6,000 lb. to 20,000 lb. actuators utilize acetal copolymer linings. Rollers are eliminated on
DA91, DA10 and DA20 models.
8204311
8104311
8605001
DA9150-2HBC
Brake
Actuating
Systems
8759122
8202022
Section L-12
Composite,
Corrosion-Free
Master Cylinder!
8101222
TRAILER SUPPLIES
SM
Brake Actuators*
6K ACTUATOR
PARTREF.
NO.
NO.DESCRIPTION
8605001 302170 DA66B ZINC, 3” TONGUE, 2” COUPLER, DRUM
8605101 302175 DA66B ZINC, 3” TONGUE, 2” COUPLER, DISC
8K ACTUATOR
PARTREF.
NO.
NO.DESCRIPTION
8759122
302200 DA91 W/CHANNEL ONLY, 3” TONGUE, DRUM
DA91-2HBC
302215 DA91 W/ADJ 2” H-BLOW COUPLER (7,000 LB.), DRUM
DA91-2516HBC
302225 DA91 W/ADJ 2-5/16” H-BLOW COUPLER, DRUM
8759522
302275 DA9150 W/CHANNEL ONLY, A-FRAME, DRUM
DA9150-2HBC
302280 DA9150 W/ADJ 2” H-BLOW COUPLER (7,000 LB.), DRUM
DA9150-2516HBC 302285 DA9150 W/ADJ 2-5/16” H-BLOW COUPLER, DRUM
12.5K ACTUATOR
PARTREF.
NO.
NO.DESCRIPTION
8103102
302775 DA10 W/FIXED 2-5/16” COUPLER, DRUM
8102511
302785 DA10 ZINC, 2 5/16” DROP COUPLER, DRUM
8104311
302787 DA10 ZINC, 2 5/16” DROP COUPLER, DISC
8101222
302815 DA10 W/CHANNEL ONLY, DRUM
DA10-3ADJEYE
302820 DA10 W/3” ADJ EYE, DRUM
DA10-2516ADJ-HBC 302846 DA10 W/ADJ 2-5/16” H-BLOW COUPLER, DRUM
DA10-2516ADJ-ATW 302847 DA10 W/ADJ 2-5/16” ATWOOD COUPLER, DRUM
16K ACTUATOR
PARTREF.
NO.
NO.DESCRIPTION
8164311
302849 DA16 ZINC, 2 5/16” DROP COUPLER, DISC
20K ACTUATOR
PARTREF.
NO.
NO.DESCRIPTION
8204011
302850 DA20 ZINC, 2 5/16” DROP COUPLER, DRUM
8204311
302854 DA20 ZINC, 2 5/16” DROP COUPLER, DISC
8202022
302875 DA20 W/CHANNEL ONLY
DA20-2516ADJ-ATW 302882 DA20 W/15K, ADJ 2-5/16” ATWOOD CPLR
DA20-3ADJEYE
303020 DA20 W/3” ADJ EYE
Demco Actuator Replacement Parts
Brake
Actuating
Systems
PARTREF.
NO.
NO.DESCRIPTION
5650
304002 MASTER CYL, DRUM, FITS ALL MODELS
5672
304003 MASTER CYL, DISC, FITS ALL MODELS
3876
304022 MASTER CYL CAP, FITS ALL MODELS
5692
304042 SHOCK, FITS DA66 ACTUATORS
DS12426
304045 SHOCK, FITS DA91, DA10 & DA20 ACTUATORS
5401
304062 BRKWY CABLE/LEVER FITS DA91, DA10, DA20
DO5400
304065 BRKWY CABLE/LEVER KIT FITS DA66 ACTUATORS
*Disc Brake Actuators feature back-up solenoid pre-installed.
Section L-13
TRAILER SUPPLIES
SM
Titan Brake Actuators
PARTREF.
NO.
NO.DESCRIPTION
4332900 303080 MODEL 60, 6K ZINC, 1-7/8”or 2”ADJ LVRLOCK CPLR, DRUM
4715420 303082 MODEL 60, 6K ZINC, 1-7/8”or 2”ADJ LVRLOCK CPLR, DISC
2478100 303090 MODEL 10, 12.5K ZINC, 2-5/16” DROP CPLR, DRUM
4750620 303092 MODEL 10, 12.5K ZINC, 2-5/16” DROP CPLR, DISC
4042700 303100 MODEL 20, 20K ZINC, 2-5/16” DROP CPLR, DRUM
4750720 303102 MODEL 20, 20K ZINC, 2-5/16” DROP CPLR, DISC
Titan Actuator Repair Parts
Model 10
Model 20
Model 60
Leverlock Drum
Model 60
Leverlock Disc
PARTREF.
NO.
NO.DESCRIPTION
23361
304500 MASTER CYLINDER, DRUM, MODEL 60
47142
304501 MASTER CYLINDER, DISC, MODEL 60
4480701 304550 M-CYL CAP & GASKET, MODEL 60
23362
304600 SHOCK, MODEL 60
40454
304650 COUPLER REPAIR KIT, MODEL 60, MULTIFIT CPLR
43584
304651 COUPLER REPAIR KIT, MODEL 60, LEVERLOCK CPLR
23414
304655 M-CYL COVER-GASKET, MODEL 60
23566
304660 MASTER CYL COVER, MODEL 60, USE W/23414
23744
304700 MASTER CYLINDER, DRUM, MODEL 10 & 20
47471
304701 MASTER CYLINDER, DISC, MODEL 10 & 20
12099
304720 HYD CONN FITTING, MODEL 10&20 “OLD STYLE”
4830600 304750 M-CYL CAP, MODEL 10 & 20
DS12426 304045 SHOCK, MODEL 10
7784
304850 SHOCK, MODEL 20
NOTE: Disc Brake Actuators feature back-up solenoid pre-installed.
Atwood Brake Actuators
Atwood Actuators have heavy gauge stamped steel housings, with ball socket as­sem­blies.
Breakaway mechanism sets and locks the trailer brakes in the event of tow vehicle/trailer
separation. A unique pivot linkage permits a light­weight, more compact design. The
“Re­verse Lock-Out” lever allows for easier backing of trailer.
PARTREF.
NO.
NO.DESCRIPTION
82541 302000 ACTUATOR, PAINTED WELD-ON, 2” BALL, 3” TONGUE, 6K CAP, DRUM
84132 302100 ACTUATOR, PLATED BOLT-ON, 2” BALL, 3” TONGUE, 6K CAP, DRUM
88730 302105 ACTUATOR, PLATED BOLT-ON, 2” BALL, 3” TONGUE, 6K CAP, DISC
83000 302725 ACTUATOR, PAINTED WELD-ON, 2” BALL, 3” TONGUE, 8K CAP, DRUM
83010 302750 ACTUATOR, PLATED BOLT-ON, 2” BALL, 3” TONGUE, 8K CAP, DRUM
84258 304225 REPLACEMENT BOOT KIT FOR 82541
85841 304250 REPLACEMENT MASTER CYLINDER FOR 82541, AFTER 1980, DRUM
87478 304350 REPLACEMENT MASTER CYLINDER CAP & GASKET FOR 82541, AFTER 1980
85830 304400 REPLACEMENT SHOCK FOR 82541 ACTUATOR, AFTER 1980
85852 304450 REPLACEMENT PUSH ROD KIT FOR 82541
Balcrank Brake Actuators
Brake
Actuating
Systems
The Balcrank Actuator has a rugged design with stan­dard 50 degree A-frame mount flange. It has a breakaway device which
sets and locks the trailer brakes in the event of tow vehicle/trailer separation. The unique shock absorber/coil spring design of
this Actuator provides smooth, positive stopping power, eliminating the possibility of dam­ag­ing peak pres­sures to the sys­tem.
5,000–6,000 G.V.W.R. capacity, depending on coupler used.
Section L-14
PARTREF.
NO.
NO.DESCRIPTION
16006 302600 ACTUATOR W/2” HAMMERBLOW COUPLER, 5K, DRUM
16039 302700 ACTUATOR WITH 2 5/16” HAMMERBLOW COUPLER, 6K, DRUM
1745
305205 REPLACMENT NYLON PIVOT BUSHINGS (8 REQUIRED PER ACTUATOR)
1753
305220 1/2” - 20 SELF-LOCK PIVOT SHAFT NUT (8 REQUIRED PER ACTUATOR)
1808-1 305280 REPLACEMENT PIVOT LINK (4 REQUIRED PER ACTUATOR)
1829
305300 PIVOT SHAFT (4 REQUIRED PER ACTUATOR)
1844-2 305360 REPLACEMENT SHOCK ABSORBER
16500 305381 REPLACEMENT MASTER CYLINDER CAP
10614 305400 REPLACEMENT MASTER CYLINDER
TRAILER SUPPLIES
SM
Electric/Hydraulic Brake Actuator
•
•
•
•
•
•
•
Large Reservoir Capacity
Solid State Electronics
2 Year Limited Warranty
Requires a 4-wire hookup.
Minimum 9 amp/hour Breakaway Kit
Dimensions: 11” long, 6” wide, 7” high
Compatible with most electronic brake
controllers.
PARTREF.
NO.
NO.DESCRIPTION
K71-650
247626
DX1000 1,000 PSI ACT (DRUM BRAKE APPLICATION)
K71-650-2A
247627
DX1000 1,000 PSI ACT DRUM TDM W/9505 LINE KIT & BRKY
K71-650-2
247628
DX1000 1,000 PSI ACT DRUM TDM W/DELUXE LINE KIT & BRKY
K71-651
247631
DX1600 1,600 PSI ACT (DISC BRAKE APPLICATION)
K71-651-2
247632
DX1600 1,600 PSI ACT DISC TDM W/DELUXE LINE KIT & BRKY (3.5K - 8K)
K71-651-2HD 247633
DX1600 1,600 PSI ACT DISC TDM W/10-12K LINE KIT & BRKY
34-285
419290
Dexter 9amp/hr Breakaway Kit, use w/K71-650 & K71-651
097-011-01
247625
REPL FILLER CAP W/GASKET
34-285
Hydraulic Line Kits
Hydraulic Line Kits come complete with all necessary lines, tee fittings, hoses, brack­ets and clips to properly
plumb conventional hydraulic brake axles. Torsion axles require additional line kits, (80910 or 80910-T), or use
9579-2 Deluxe kit with limited access flex hoses included.
9504
9505
9579-2
9504
9505
9579-2
Brake
Actuating
Systems
PARTREF.
NO. NO.DESCRIPTION
9504
256500 HYD LINE KIT SINGLE AXLE, DRUM
9505
256525 HYD LINE KIT TANDEM AXLE, DRUM
80910
256550 HYD LINE KIT TF AXLE (1 WHL) USE W/ 9504 & 9505
80910-T 256575 HYD LINE KIT TF AXLE (1 WHL) W/LMTD ACCESS, USE W/ 9504 & 9505
9579-2
256580 HYD LINE KIT, TANDEM AXLE, DELUXE DRUM & 3.5K-8K DISC
9579-01 256585 HYD LINE KIT, 3RD AXLE, DELUXE DRUM & 3.5K - 8K DISC
3057089 259150 ADAPTER FITTING, ADAPTS 9579-2 TO FIT 10K - 12K DISC CALIPERS
Section L-15
TRAILER SUPPLIES
SM
8102 Air Trailer Kit
The 8102 Air Trailer kit is designed for tandem axle trailers without spring brakes, that do not comply with
revised FMVSS571.121 brake system mandates (effective March 1, 1998), and should only be used on vehicles
that are exempt from those compliance requirements.
Kit includes mounting hard­ware, fittings, gladhands, one 1488 cu. in. tank, tank drains and all required valves.
Air brake tubing is not in­clud­ed, due to variations in lengths required for in­di­vid­u­al in­stal­la­tions.
PARTREF.
NO. NO.DESCRIPTION
8102
249800
AIR TRAILER KIT FOR 2 AXLES W/O SPRING BRAKES, DESIGNED
FOR TRAILERS EXEMPT FROM FMVSS571.121
6606-1
3/8” AIR BRAKE TUBING, 100’ ROLL
249900
8202-1 Air Trailer Kit
The 8202-1 Air Trailer kit is designed for tandem axle trailers with spring brakes that do not comply with
revised FMVSS571.121 brake system mandates (effective March 1, 1998), and should only be used on vehicles
that are exempt from those compliance requirements.
Brake
Actuating
Systems
This Kit will support spring brakes of type 16-24, type 24-30 and type 30-30. The kit in­cludes mounting
hardware, fittings, gladhands, one 2800 cu. in. tank, tank drain and all re­quired valves. Air brake tubing is not
in­clud­ed, due to vari­a­tions in lengths required for in­di­vid­u­al installations.
Section L-16
PARTREF.
NO. NO.DESCRIPTION
8202-1KT 249851 STRAIGHT AIR TRAILER KIT FOR 2 AXLES W/SPRING BRAKES, DESIGNED FOR TRAILERS EXEMPT FROM FMVSS571.121
6606-1
249900 3/8” AIR BRAKE TUBING, 100’ ROLL
TRAILER SUPPLIES
SM
8200 Series ABS Air Trailer Kits
The 8200 Series ABS kits are designed for tandem axle trailers that are ABS equipped and have spring brakes.
These kits have been designed to conform to all FMVSS571.121 re­quire­ments for brake systems, including antilock
brake systems, mandated for air brake trailers man­u­fac­tured after March 1, 2001.
These kits will support spring brakes of type 16-24, type 24-30 and type 30-30. Kits in­clude ABS modulator
valve(s), ABS warning light, power cord, cable leads, spring brake valve, mounting hardware, fittings, gladhands,
and a 2800 cu.in. tank. Air brake tubing is not included, due to variations in lengths required for individual in­stal­
la­tions.
PARTREF.
NO.
NO.DESCRIPTION
8202-21-1KT 249861 “2S/1M” ABS AIR TRAILER KIT FOR 2 AXLES W/SPRING BRAKES (ONE AXLE ABS EQUIPPED)
8202-42-1KT 249866 “4S/2M” ABS AIR TRAILER KIT FOR 2 AXLES W/SPRING BRAKES (BOTH AXLES ABS EQUIPPED)
6606-1
249900 3/8” AIR TUBING, 100’ ROLL
8500 Series Air/Hydraulic Trailer Kits
­­
The
8500 Series Air/Hydraulic Trailer Kits include control valves, air tank, air/hydraulic booster and a complete
hydraulic line kit for tandem axle trailer. ABS kits also include the necessary components for compliance with
FMVSS571.121 re­quire­ments for Antilock Brake Systems, mandated for trailers manufactured after March 1, 2001.
These ABS kits are “2S/1M” systems, requiring 1 axle to be ABS equipped with sensors and
tone rings. The axle is the determining factor for which kit should be used.
NOTE: An Air Brake Truck pulling an Air-Hydraulic
Brake Trailer is not a balanced brake system! Excessive
trailer brake wear may occur. 8500 Series Air-Hy­drau­
lic System should be used only as last option to operate
trailer brakes.
8510-21-2KT
N/A
249516 DEXTER 3.5K - 15K DRUM
N/A
HAYES/ALKO ALL 9K THRU 12K DRUM
8516-21-2KT 249626 10K & 12K DISC BRAKES (ALL MANUFACTURERS)
NON-ABS KITS*
PART
NO.
REF.
NO.
8510-2KT
249511
8515-2KT
249611
8516-2KT
249621
Brake
Actuating
Systems
ABS KITS
PART
REF.
NO.
NO.DESCRIPTION
* Non-ABS air/hydraulic kits do not comply with revised FMVSS571.121 brake system mandates effective March 1, 1998, and should
only be used on vehicles that are exempt from those compliance requirements.
Section L-17
TRAILER SUPPLIES
SM
Miscellaneous Brake System Parts
11451 & 11452
110376
AL90006
110500
110380
Brake
Actuating
Systems
6510
PARTREF.
NO.
NO.DESCRIPTION
11451
255010 EMERGENCY GLADHAND (RED)
11452
255011 SERVICE GLADHAND (BLUE)
AL90006 255025 ABS RELAY VALVE W/ECU, 2S/1M & 4S/2M
AL364040 255028 ABS RELAY VALVE, 4S/2M (SLAVE RELAY)
110376
255055 EMERGENCY SPOOL VALVE, NON-ABS
110380
255060 AIR BRK RELAY VALVE, NON-ABS
110500
255065 SPRING BRAKE VALVE
6482-3
255075 2850 CUBIC INCH AIR TANK
19840
255077 1488 CUBIC INCH AIR TANK
6510
256300 AIR/HYD BOOSTER, 1000PSI (DRUM)
6515-M
256332 AIR/HYD BOOSTER, 1600PSI (DISC)
3057817
256333 3/16 LINE ADAPTER FITTING FOR A/H BOOSTERS ABOVE, 1/2-20M x 3/8-24F INV
Section L-18
TRAILER SUPPLIES
SM
Hydraulic Fittings
301-3
306-3
301-4
3057818
3087812
3057828
307-3
PARTREF.
NO.
NO.DESCRIPTION
301-3
257800 STEEL LINE NUT FOR 3/16” HYDRAULIC STEEL LINE (PKG OF 8)
301-4
257900 STEEL LINE NUT FOR 1/4” HYDRAULIC STEEL LINE (PKG OF 8)
306-3
258000 LINE UNION FOR 3/16” STEEL LINE (PKG OF 4)
307-3
258200 LINE TEE FOR 3/16” STEEL BRAKE LINE (PKG OF 2)
3057818 259200 3/16” FEMALE X 1/4” MALE ADAPTER FOR HYDRAULIC
BRAKE LINES (PKG OF 4)
3057828 259250 1/4” FEMALE X 3/16” MALE ADAPTER FOR HYDRAULIC
BRAKE LINES (PKG OF 4)
3087812 262600 AXLE LINE TEE FITTING, 3/16” LINE W/BRACKET (PKG OF 2)
3087900 262625 3/16” HYD SERVICE TEE (PKG OF 2)
3057089 259150 HYD ADAPTER,10K-12K DISC 7/16-20M x 3/8-24F INV
3087900
3057089
Hydraulic Lines and Brackets
322351
310797
18018-SF
16196
Brake
Actuating
Systems
PARTREF.
NO.
NO.DESCRIPTION
322351 260200 HYDRAULIC STEEL LINE, 3/16” X 51”
323325 260425 HYDRAULIC STEEL LINE, 3/16” X 25’ COIL
323425 261625 HYDRAULIC STEEL LINE, 1/4” X 25’ COIL
310798 261800 HYD FLEX BRAKE HOSE, 7/16”-24 FEMALE X 7/16”-20 MALE, 20.5”LONG
16196
261802 REPLACEMENT FLEX HOSE, FITS 3/16” LINE FITTINGS, 18.5” LONG
(3/8”-24 M/F)
310797 261805 HYD FLEX BRAKE HOSE, 3/8”-24 FEMALE X 3/8”-24 MALE, 20.5” LONG
18018-SF 261810 HYD FLEX HOSE 18”L, 3/8-24 MALE END 90º, FEMALE STD
309801 262000 STEEL HOSE BRACKET (PKG OF 4)
309802 262200 CLIP FOR 309801 BRACKET (PKG OF 4)­­
309801
309802
Section L-19
TRAILER SUPPLIES
SM
Electric Brake Trouble Shooting Guide
PROBLEM
­­­­­­­­
WEAK BRAKES
­­­­­­­­
LOCKING BRAKES
INTERMITTENT BRAKES
Brake
Actuating
Systems
NO BRAKES
Section L-20
BRAKES PULL TO ONE SIDE
HARSH BRAKES
NOISY BRAKES
SURGING BRAKES
DRAGGING BRAKES
CAUSES
REMEDIES
OPEN CIRCUITS
SEVERE UNDER ADJUSTMENT
FIND AND CORRECT
ADJUST BRAKES
FAULTY CONTROLLER TEST AND CORRECT
SHORT CIRCUITS
FIND AND CORRECT
GREASE/OIL ON MAGNETS/LININGS
CLEAN OR REPLACE
CORRODED CONNECTIONS
CLEAN/CORRECT CAUSE
WORN LININGS OR MAGNETS
REPLACE
SCORED/GROOVED BRAKE DRUMS
MACHINE OR REPLACE
IMPROPER SYNCHRONIZATION
CORRECT
UNDER ADJUSTMENT
ADJUST BRAKES
GLAZED LININGS
REBURNISH OR REPLACE
OVERLOADED TRAILER
CORRECT
UNDER ADJUSTMENT
ADJUST
IMPROPER SYNCHRONIZATION
CORRECT
FAULTY CONTROLLER
TEST & CORRECT
LOOSE, BROKEN BRAKE PARTS
REPLACE COMPONENTS
OUT OF ROUND BRAKE PARTS
REPLACE COMPONENTS
OUT OF ROUND BRAKE DRUMS
MACHINE OR REPLACE
INSUFFICIENT WHEEL LOAD
ADJUST SYSTEM RESISTOR
FAULTY CONTROLLER
TEST AND CORRECT
BROKEN WIRES
REPAIR OR REPLACE
LOOSE CONNECTIONS
FIND AND REPAIR
INCORRECT ADJUSTMENT
ADJUST
GREASE/OIL ON LININGS/MAGNET
CLEAN OR REPLACE
BROKEN WIRES
FIND & REPAIR
BAD CONNECTIONS
FIND & REPAIR
UNDER ADJUSTMENT
ADJUST
IMPROPER SYNCHRONIZATION
CORRECT
IMPROPER CONTROLLER
CHANGE
FAULTY CONTROLLER
TEST & CORRECT
UNDER ADJUSTMENT
ADJUST BRAKES
LACK OF LUBRICATION
LUBRICATE
BROKEN BRAKE PARTS
REPLACE COMPONENT
INCORRECT BRAKE PARTS
REPLACE
GREASE/OIL ON LININGS/MAGNET
CLEAN OR REPLACE
OUT OF ROUND BRAKE DRUMS
MACHINE OR REPLACE
FAULTY CONTROLLER
TEST & CORRECT
OVER ADJUSTMENT
READJUST
OUT OF ROUND BRAKE DRUMS
MACHINE OR REPLACE
REPLACE
INCORRECT BRAKE PARTS
BROKEN BRAKE PARTS
REPLACE
FAULTY BREAKAWAY SWITCH
REPAIR OR REPLACE
LOOSE WHEEL BEARING ADJ.
ADJUST
BENT SPINDLE
REPLACE AXLE