Trailer Axle (8k - 12k) OWNER'S MANUAL Rev: 04.18.
TABLE OF CONTENTS Introduction Safety Information 4 4 5 5 5 6 6 7 8 8 9 9 9 10 10 10 10 10 11 12 12 12 13 13 13 14 14 14 15 15 16 17 17 17 17 18 19 20 20 20 21 22 23 Break-in Period for Electric Drum Brakes Hubs/Drums/Bearings Hub Removal Brake Drum Inspection Bearing Inspection Bearing Lubrication - Grease Seal Inspection and Replacement Bearing Adjustment/Hub Replacement Lubrication Bearing Lubrication - Oil Oil Cap and Oil Seal Periodic Bearing Inspection Spindle nut adjustment Disc
Maintenance Schedule Wiring Diagram Pigtail and Coupler Wiring Color Codes 8,000-LB AXLE WHEEL END COMPONENTS 10,000-LB AXLE WHEEL END COMPONENTS 12,000-LB AXLE WHEEL END COMPONENTS Storage Storage Preparation Extended Storage Inspection Procedures Trip Preparation Checklist Rev: 04.18.
Introduction Combining years of experience in the trailer frame and recreational vehicle industry with the newest and most innovative technology, Lippert Components, Inc. introduces its newest addition, The Axle and Running Gear Division. The following publication is designed to give the customer an easy-to-understand operation and service manual to provide useful and important information.
Break-in Period for Electric Drum Brakes The break-in period is a typical phenomenon with drum brakes and especially electric drum brakes. Electric drum brakes will require a break-in period to achieve full performance. This break-in period applies for new axles and any time new brake shoes and/or magnets are installed as part of regular maintenance. Lippert Components has found through extensive brake testing that the break-in period for our drum brakes can range from 20 to 50 brake applications.
Brake Drum Inspection The brake shoes contact the drum surface and the magnet contacts the armature. These surfaces are subject to wear and should be inspected periodically. The drum surface should be re-machined if wear is more than .030” or out of round by more than .015”. The drum should be replaced if scoring or wear is greater than .090”. The inner surface of the brake drum that contacts the brake magnet is the armature surface.
Bearing Lubrication - Grease Bearing grease should be replaced every 12,000 miles or 12 months, whichever comes first. Remove all old grease from wheel hub and bearings first. Bearings should be packed by machine if possible. Packing bearings by machine is preferable; however, packing by hand is a viable alternative. Follow these procedures to repack bearings by hand: 1. Place grease into the palm of your hand (Fig. 1). 2.
Seal Inspection and Replacement Always check the seal to make sure that it is not damaged, nicked, cracked or torn and is in good working order. If there is any question of condition, replace the seal. Procedure to replace seal: 1. Pull seal from the hub with a seal puller. Never push the seal out with the bearing. The bearing may get damaged. 2. Apply a PERMATEX sealant to the outside of the new seal. Note: Do not use PERMATEX on rubber encased seals. 3.
Lubrication Bearing Lubrication - Oil Your axle bearings are lubricated with a SAE 80-90W hypoid gear oil. Periodically check and refill the hub as necessary to the level indicated on the clear plastic oil cap. The oil can be filled through the cap by removing the rubber plug. In order to check oil level, do so after unit has been parked for a few minutes. Recommended Oil Lube for axle bearings: Oil designation: SAE 90, SAE 80W-90, SAE 75W-90 Union Oil Co. Exxon Co. Mobil Oil Pennzoil Co.
Periodic Bearing Inspection A physical bearing inspection should be conducted every 15,000 miles. An inspection of the bearing condition can detect early bearing issues. Upon inspection, bearings should look brand new and can be reassembled and used if in this condition. If discoloration, pitting, corrosion, flat spots or some abnormal condition is observed, the bearing and race should be replaced at the same time. Bearings are available at auto part stores, see components pages (27-36) for part numbers.
Electric Brakes The basic structure of the Electric Brakes on your trailer will resemble the brakes on your car or tow vehicle, with one major difference; your trailer implements an Electric Actuation system and your tow vehicle utilizes a hydraulic system. The Electric Braking System operates in the following order of steps: (Refer to the Electric Braking System Diagram and the brake diagram below to follow along.) 1.
How to Use Lippert Electric Brakes Properly The Lippert Components, Inc. Electric Braking System is synchronized with the tow vehicle brakes. Never attempt to stop the combined load of the tow vehicle and the trailer by using either the tow vehicle brakes or the trailer brakes only. They are designed to work together. Small manual adjustments may occasionally be necessary to accommodate changing loads and driving conditions.
Lubricate Brakes Prior to reassembling the brake drum assembly, remember to apply a light film of white grease or an antiseize compound on the brake anchor pin, the actuating arm bushing and pin, and the areas on the backing plate that are in contact with the brake shoes and magnet lever arm. In addition, apply a light film of grease on the actuating block mounted on the actuating arm.
Shoes and Linings Linings should be replaced if the material is worn to 1/16” or less. Shoes should also be replaced if they become contaminated with grease or oil or have become scored, pitted or gouged. Heat cracks are normal and rarely require attention. When replacing shoes, both shoes on the same brake and the brakes on the same axle should all be replaced at the same time, once again ensuring even braking capacity.
Double-Eye Leaf Springs Double-eye leaf springs have eyes at either end of the spring assembly with nylon bushings to assist in preventing wear. U-bolts hold the springs to the axle with a plate. The articulation of this suspension occurs when the eyes rotate on the wear surfaces provided in eyes of the springs and on the equalizers. This suspension is also available in single and multiple axle configurations. In trailers with 2 or more axles, the additional movement is maintained by an equalizer.
Inspection All the components of your suspension system should be visually inspected for signs of wear, damage or loose fasteners at least every 6,000 miles. When replacing or tightening loose fasteners, consult the torque specs below for correct torque values.
Suspension Replacement 1. Make sure springs are on straight. Align spring eyes to front hanger. Insert spring eye bolts but do not torque at this point. 2. Assemble springs into equalizer. 3. After leveling equalizer to frame, torque equalizer nuts and spring eye nuts. Adjustable Spring Seats The procedure for setting adjustable spring seats can be found on LIP Sheet 0226, which is available on the Lippert Components Customer Service website: http://lci1.com/images/support/lipsheet/0226.
Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on your trailer axle. Torque wrenches assure the proper amount of torque is being applied to a fastener. Use no other method to torque fasteners. Proper and accurate torque must be maintained to prevent wheels from loosening, studs from cracking and/ or breaking or other possible hazardous breakage resulting in death or serious injury.
Tires Prior to mounting tires onto wheels, be sure the rim size and contour are approved by the Tire and Rim Association Yearbook or the tire manufacturers catalog. In addition, confirm that the tire will carry the rated load. If the load is not evenly distributed on all tires, use the tire rated for the heaviest wheel position. The Rubber Manufacturers Association or the tire manufacturers guidelines should be consulted for mounting procedures.
Introduction to Troubleshooting The following section is a guideline for ensuring operation of your braking system. The safety of you, those traveling with you and those sharing the road is paramount and it starts with the ability to safely stop the tow vehicle and the towed vehicle. Troubleshooting Most brake malfunctions can be corrected by utilizing the Troubleshooting Chart on the next page.
Troubleshooting Chart Problem No brakes Weak brakes Locking brakes Intermittent brakes Brakes pull to one side Harsh brakes Noisy brakes Surging brakes Dragging brakes Probable Cause Open circuits Short circuits Severe under-adjustment Grease or oil on magnets or linings Corroded connections Worn linings or magnets Scored or grooved brake drums Improper synchronization Under-adjustment Glazed Linings Under-adjustment Improper synchronization Loose, bent or broken brake components Out-of-round brake
Measuring Amperage The Braking System amperage is the amount of current flowing through the system when all magnets have been energized. The amperage will change proportionately with the voltage. To ensure that the battery is indicating a full charge, the towing vehicle engine should be running with the trailer coupler connected when checking the voltage. If a resistor is used in the brake system, it must be set at zero or bypassed completely to obtain the maximum amperage reading.
Amperage Chart Amps/Magnet 3.0 Two Brakes 6.0 Four Brakes 12.0 Six Brakes 18.0 Low or no voltage are the most common problem with the Braking System. Amperage at the brakes is also a relatively common issue. Common causes of these conditions are: 1. Low quality electrical connections 2. Open circuits 3. Insufficient wire gauge 4. Broken wires 5. Blown fuses (fusing of brakes is not recommended) 6. Short circuits (indicated by high amperage) Possible causes of shorts are: 1.
Maintenance Schedule Item Function Required Suspension Parts Test that they're operational. Check battery charge and switch operation. Adjust to proper operating clearance. Inspect for wear and current draw. Inspect for wear or contamination. Check for correct amperage and modulation. Inspect wiring for bare spots, fray, etc. Inspect for abnormal wear or scoring. Inspect for corrosion or wear. Clean and repack. Inspect for leakage. Replace if removed. Inspect for wear, loss of arch.
Rev: 04.18.2014 Page 25 Stop and Right Turn Signal Green Terminal 3 License, Tail and Running Lights Stop and Left Turn Signal Electric Brake + - Common Ground White - Terminal 1 Gray - Terminal 8 Blue - Terminal 2 Auxiliary Circuit Auxiliary Circuit Orange - Terminal 9 Brown - Terminal 6 Auxiliary Circuit Yellow - Terminal 7 Battery Charge Black - Terminal 4 Red - Terminal 5 Trailer Fig.
STOP & LH TURN RED GROUND YELLOW AUXILIARY AC K BL BATTERY CHARGE BROWN BRAKES STOP & RH TURN BRAKES GROUND AUXILIARY E AUXILIARY YELLOW G AN OR AUXILIARY RE D STOP & LH TURN 9-PIN COUPLER CK STOP & RH TURN BLA TRAILER BRAKE AND LIGHT COUPLER - OPERATES BRAKES WH ITE GR EEN E BLU CLEARANCE & TAIL LIGHTS 7-PIN COUPLER TRAILER LIGHTS PIGTAIL - DOES NOT OPERATE BRAKES WHITE - GROUND GREEN - RUNNING LIGHTS E WH ITE BLU EEN GR AY Page 26 GR WN BRO Rev: 04.18.
8,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION M L Q E P B O A R C I D H F Callout A B C D E F G H I J K L M N O P Q R Rev: 04.08.2014 J or K N G Part # 277223 277215 183804 122255 122075 122081 179660 129752 168687 175704 175705 134581 176321 148628 2772101 2772121 242080 124287 122066 122088 276712 Description Oil Cap O-Ring Rubber Cap Plug Grease Zerk (Lubed) Cotter Pin; .120" x 1.75" Spindle Nut; 1" - 14 Spindle Washer; 1.06 x 2.
8,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Electric Brake Assembly Part # 156443 156444 Rev: 04.08.2014 Description Brake; Electric; 12.25 x 3.38; 4 Bolt (Left Hand) Brake; Electric; 12.25 x 3.
8,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Axle U-Bolt Service Kit Part #232997 (Grease Setup) B C A D E I F G H Callout A B C D E F G H I Rev: 04.08.2014 Part # 1963511 179660 122088 170997 122077 122081 122084 182274 122075 Description U-Bolt; 8/16 - 18 x 7.25 for 3" Tube YZ Flat Hardened SAE Washer; 1.06 ID x 2.
8,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Axle U-Bolt Service Kit Part #309893 (5 - Bolt Disc Brake Grease Setup) B C A D I E F G J Callout A B C D E F G H I J Rev: 04.08.2014 H Part # 1963511 179660 122088 170997 119072 126030 182274 135835 122081 122075 Description U-Bolt; 9/16" - 18 Hex GR8 Flat Hardened SAE Washer; 1.06 ID x 2.00 OD Double Lip Grease Seal (5,200-7,000) Flat USS Hardened Washer; 9/16" Flange Nut; 3/8" - 16 GR5 Washer; .385" x .68" x .
8,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Axle U-Bolt Service Kit Part #313729 (4 - Bolt Disc Brake Oil Setup) B C D A E F G H I Callout A B C D E F G H I Rev: 04.08.2014 Part # 1963511 179660 122081 122075 162836 162838 122253 182274 276712 Description U-Bolt; 9/16" - 18 Hex GR8 Flat Hardened SAE Washer; 1.06 ID x 2.00 OD Castle Nut; 1 - 14 Cotter Pin; .120 x 1.75 Lock Bolt; 1/2 x .86 x .125 Lock Washer; 1/2 x .86 x .
10,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION J L O I M R K P Q S D B A C N H Callout A B C D E F G H I J K L M N O P Q R S Rev: 04.18.2014 Part # 183772 183805 183804 181899 181894 181895 122066 124287 183662 183168 183463 183807 176692 183128 176321 205048 205049 G F E Description Oil Cap O-Ring (For Oil Cap) Rubber Plug (For Oil Cap) Cotter Pin - 1/4" x 2 1/4" Spindle Nut - 1 1/2" - 12 Spindle Washer - 1.50" x 3.
10,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Electric Brake Assembly A B Callout A B Part # 181935 181936 207576 122086 122085 330792 - Description Electric Brake (LH) 12.25" x 3.38", 7 Bolt Electric Brake (RH) 12.25" x 3.38", 7 Bolt Brake Bolt - 7/16" - 20 x 1 1/2" Brake Lock Washer - 7/16" Brake Hex Nut - 7/16" - 20 Show and Lining Kit - 12 1/4" x 3.38" (8,000-10,000), 1 BRK Magnet Kit - 12 1/4" (8,000-12,000) Disc Brake Assembly C Callout C Rev: 04.18.
10,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Axle U-Bolt Service Kit Part #294378 E F A G H B C D J I K Callout A B C D E F G H I J K Rev: 04.18.
12,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION I N H L Q J P R D A C M K Callout A B C D E F G H I J K L M N O P Q R Rev: 04.18.2014 Part # 183772 183805 183804 181899 330037 293382 293381 297983 293379 293380 295924 183128 176321 205048 205049 O G F E Description Oil Cap O-Ring (For Oil Cap) Rubber Plug (For Oil Cap) Cotter Pin - 1/4" x 2 1/4" Spindle Nut - 1 3/4" - 12 Outer Cone Bearing - 12,000 (28682) Outer Bearing Cup/Race - 12,000 (28622) Pilot Brake Drum Hub - 865 - 5/8"; 4.
12,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Brake Assembly A B Callout A B Rev: 04.18.2014 Part # 297998 2979981 207576 122086 122085 330793 - Description Electric Brake (LH) 12.25" x 5", 7 Bolt (12,000) Electric Brake (RH) 12.
Storage Storage Preparation If your trailer is to be stored for an extended period of time, the trailer will need to be prepared prior to going into storage. Follow these guidelines to set up your trailer for storage: 1. If the trailer has an emergency breakaway battery, remove it and store it inside, out of the weather. Charge the battery at least every 90 days. 2. Jack up the trailer and place jack stands under the trailer frame so that the weight will be off the tires.
Trip Preparation Checklist The following checklist offers several guidelines to prolonging the quality of your running gear and will provide trustworthy and safe trailering for years to come. Using the following checklist before starting a trip with your trailer is highly recommended. Allow plenty of time prior to any trip for any service or repairs that may need to be done before using the trailer. 1. Maintenance schedule should be current. 2. Inspect hitch for corrosion, lubrication and wear. 3.
All information contained within may be distributed as a full document only, unless otherwise permitted by explicit consent of Lippert Components Inc. to distribute individual parts. All information contained within is subject to change without notice. New editions will be posted on www.lci1. com and can be downloaded for free. Information contained within is considered factual until made obsolete by a *NEW* revision. Please recycle all obsolete materials.
