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MAINTENANCE
1. Frequently check brake fluid level. (Fluid must be approved, clean and uncontaminated.)
2. Make sure actuator mounting bolts are secure, and coupler is free to telescope inside outer case.
3. Inspect actuator, replace bent, worn or damaged parts.
4. Be constantly aware of systems braking quality, make periodic checks as described in brakes owners
manual. Consult certified brake specialist to make necessary adjustments or repairs. Failure to do so
could result in loss of braking.
SERVICING THE EMERGENCY LEVER
If emergency lever (#11) of actuator is applied, it can be disengaged by using a screwdriver to lift
upward on front of flat emergency lever spring (#17) while pulling lever forward until released.
A thorough inspection of emergency lever, emergency lever spring, and cable with S-hooks is required.
Damaged parts must be replaced as follows:
a. Using two wrenches, loosen brake line from fitting (#24) at back of master cylinder (#23). Take
care not to allow fitting to become loose in master cylinder.
b. Remove cable S-hook (#14) from emergency lever (#11).
c. Remove two bolts (#15) and emergency lever spring (#17).
d. Press pushrod assembly (#8) rearward to allow emergency lever (#11) to pass by and remove it
through cross slot in top of outer case (#21).
e. To install new emergency lever, press pushrod assembly rearward and hold it there, while putting
emergency lever through cross slot in top of outer case. Emergency lever should overlap front of
pushplate when assembled properly.
f.
Install new emergency lever spring (#17) with bend upward, using two new self tapping bolts
(#15).
g. Install emergency cable with S-hook (#13) by inserting S-hook through hole in emergency lever
(#11) and squeezing hook shut.
h. Tighten fitting (#24) and brake line. Make sure to use two wrenches, so fitting isn’t overtightened
in master cylinder.
i.
Add brake fluid if necessary and bleed brake system as described per instructions 4-6 in
the installation instructions.
5. Once bleeding is completed, refill master cylinder to within 1/2
”
of top. and attach cap (#18)
securely. Replace emergency lever spring, lever guide, lock washers and 5/16" hex head
bolts. Wipe up any excess brake fluid immediately to prevent paint damage.
6. Test brakes by pulling emergency lever (#11) forward until it locks into its second notch
position. (Lever should be approximately straight up.) Attempt to rotate wheels in a forward
direction. If any wheels rotate, brakes must be adjusted. To adjust brakes, release
emergency lever from locked position, set each wheels brake adjustment up 2 or 3 notches
(per instructions in appropriate brake cluster manual). Repeat test procedure as necessary.
