Page 12
AG20046
Do Not Disassemble or Attempt to Adjust
The Tongue Push-Plate Assembly (34)
The brake tongue is assembled and adjusted at the factory: If
the tongue needs to be reassembled for any reason below is
a list of setting to follow:
A. The push-off assembly with springs should be adjusted via
the adjustment spud on the rear half of the assembly. The
two springs need to be compress to 6-1/2”.
B. The front adjustment spud on the push-off assembly needs
to be adjusted after the male tongue insert is in place and
latched in position. Pull the tongue forward against the
latch and adjust the spud until there is a 3/16” gap
for 650/750 and 7/16” gap for 500 between spud and
rear stop surface of male tongue.
C. Connect and tighten all brake lines.
fill the Master
cylinder with doT 3 or 4 brake fluid. checK foR
ANy leAKs.
Review all of the following instructions before installation and use of the hydraulic brake tongue.
dealers or distributors must review these instructions with the ultimate user. failure to follow these instructions,
or failure to properly maintain the braking system after installation, can result in loss of braking action which could
cause severe property damage, personal injury and/or death.
MAintEnAnCE
1. Frequently check the brake fluid level. (Fluid must be approved,
clean and uncontaminated.)
2. Inspect the brake tongue and brakes and replace bent, worn or
damaged parts.
3. Be constantly aware of the system’s braking quality and make
periodic checks. Consult a certified brake specialist to make the
necessary adjustments and/or repairs. Failure to do so could result
in loss of braking.
SERviCinG thE EMERGEnCy lEvER
If the Emergency Lever of the tongue is applied, it can be disengaged
by using a screwdriver to lift upward on the front of the flat Emergency
Lever Spring while pulling the lever forward until it releases. A thorough
inspection of the Emergency Lever, Emergency Lever Spring, and
the Chain with S-Hooks is required and all damaged parts must be
replaced as follows:
a. Remove the Master Cylinder and the Push Plate Assembly. Be
careful not to get dirt into the Master Cylinder. (A new Master
Cylinder Gasket should be used when reinstalling.)
b. Remove the Safety Chain from the Emergency Lever, Emergency
Lever Guide, and Emergency Lever Spring, then pull the lever out
of the tongue through the slot on the side.
c. Install the new Emergency Lever from the through the slot in,
the tongue. Attach the new Emergency Lever Spring, and the
Emergency Lever Guide.
d. Install a new Master Cylinder Gasket to the Master Cylinder and
put the Push Plate Assembly and Master Cylinder back into the
inside of the tongue.
e. Squeeze shut the S-Hook of the Emergency Chain onto the
Emergency Lever.
f. Add adequate brake fluid to the Master Cylinder and bleed
the brake system per instructions on BLEEDING THE BRAKES.
WARNING:
cAuTIoN
BlEEDinG thE BRAkES
Bleed the brake system using a pressure-type brake bleeder or
manually, as follows:
A. Remove the Lever Guide and the flat Safety Lever Spring.
Remove the Lever Guide and the Emergency Lever Spring.
Using short strokes, pull forward on the Emergency Lever (#14),
pumping the Master Cylinder until the brake fluid within the
Master Cylinder stops bubbling.
B. Attach a bleeder hose to the bleeder valve on one of the
wheels (always begin with wheel farthest from the master cylin-
der and move toward it). Immerse the other end of the hose
into a clean, transparent container partially filled with brake
fluid. Loosen the bleeder valve one turn and, watching the hose
in the transparent container, use the Emergency Lever to pump
the Master Cylinder as long as air bubbles continue to leave the
hose. When the bubbles stop, close the bleeder valve, move to
the next wheel, and repeat the process until all the brakes have
been bled. (Note: Check the fluid level in the Master Cylinder
frequently while bleeding the brakes (every 4 or 5 strokes). Refill
as necessary to keep the level above half full.)
C. Once bleeding is completed, refill the Master Cylinder and
attach the Cap securely. Replace Emergency Lever Spring and
Lever Guide.
D. Test the brakes by pulling the Emergency Lever forward
until it locks into its first detent position. (The lever should be
approximately straight up.) Attempt to rotate the wheels in a
forward direction. If any of the wheels rotate, the brakes must
be adjusted on that wheel. To adjust the brakes, release the
Emergency Lever from its locked position and set the wheel
brake adjustment up 2 or 3 notches (refer to instructions on
page 16). Repeat the test procedure as necessary.
BRAkE tonGUE MAintEnAnCE AnD ADJUStMEnt
REPlACEMEnt PARtS AnD MAintEnAnCE
tonGUE ASSEMBly SEttinGS