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TABLE OF CONTENTS Introduction Safety Information Break-in Period for Electric Drum Brakes Hubs/Drums/Bearings Hub Removal Brake Drum Inspection Bearing Inspection Bearing Lubrication - Oil Bearing Lubrication - Grease Seal Inspection and Replacement Bearing Adjustment/Hub Replacement Electric Brakes How to Use Lippert Electric Brakes Properly General Maintenance - Electric Brakes Brake Adjustment Lubricate Brakes Clean and Inspect Brakes Magnets Shoes and Linings Axle and Suspensi
Introduction Combining years of experience in the trailer frame and recreational vehicle industry with the newest and most innovative technology, Lippert Components, Inc. introduces it’s 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 - Oil If your axles are equipped with oil lubricated hubs, then your lubrication procedure is to periodically fill the hub with a high quality hypoid gear oil to the level indicated on the clear plastic oil cap. The oil can be filled through the rubber plug hole in the cap. 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.
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.
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.) 6.
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.
Torsion Suspension System 1. The Lippert Components, Inc. Torsion Suspension system is designed to offer superior qualities over leaf spring technology. The Lippert Components, Inc. Torsion Suspension system is bracketed to the trailer’s frame and housed inside the trailer axle’s tube. 2.
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 on page 13 for correct torque values. Worn spring eye bushings or sagging or broken springs should be replaced using the following method: 1. Support the trailer with the wheels just off the ground.
Wheels Wheel Selection When specifying or replacing your trailer wheels it is important that the wheels, tires, and axle are properly matched. The following characteristics are extremely important and should be thoroughly checked when replacement wheels are considered: 1. Bolt Circle. Wheels have many bolt circle variations and some are so close that it could be possible to attach an inappropriate wheel that does not match the axle hub. 2. Capacity. Wheel load capacity should match tire and trailer max.
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 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: 03.18.2014 Page 23 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 BATTERY CHARGE 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 BRAKES BROWN GROUND YELLOW AUXILIARY WH IT E G BL AC K E EN RE 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 24 GR WN BRO Rev: 03.18.
3,500-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION I H G F D E C B A Callout A Part # Description 122065 Rubber plug for lubed grease caps 122067 Dust cap, for 2" bore, super lube B 122099 Dust cap, for 2" bore, non-lube C 122075 Cotter pin D 122081 Spindle nut, 6 slot E 119214 Spindle washer, round ID E1 119215 Spindle washer, for spindle with D-flat E2 119216 Spindle locking tang washer Use E1 and E2 in place of C and E if spindle has no hole for cotter pin and has D-flat on all axles built pri
3,500-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Electric Brake Assembly Part # 122258 1222581 1222582 1222583 139380 122450 1224501 1224502 12244503 139381 Description Electric Brake - 10" x 2.25" (Left Hand) Electric Brake - 10" x 2.25" APG (Left Hand) Electric Brake - 10" x 2.25" Long Lead (Left Hand) Electric Brake - 10" x 2.25" Self-Adjusting (Left Hand) Electric Brake - 10" x 2.25" with Park (Left Hand) Electric Brake - 10" x 2.25" (Right Hand) Electric Brake - 10" x 2.
3,500-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Hydraulic Brake Assembly Part # 132047 132048 179868 179869 Description Hydraulic Brake - 10" x 2.25" (Right Hand) Hydraulic Brake - 10" x 2.25" (Left Hand) Hydraulic Brake - 10" x 2.25" Free Backing (Right Hand) Hydraulic Brake - 10" x 2.25" Free Backing (Left Hand) Contact us: Lippert Components Inc. - www.lci1.com/customerservice - Phone: (574) 537-8900 - Email: warranty@lci1.com Rev: 03.14.
3,500-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Axle U-Bolt Service Kit (2 3⁄8" Beam) Part #173229 B E A C D F G H I Callout A B C D E F G H I J K Part # 122073 122087 122081 122079 122084 119216 122075 119215 119214 122085 122086 J Description U-Bolt; 1/2 - 20 x 5.1, 2.375 Tube Diameter Yellow Dich Seal; 1.666 x 2.565 x 5 (2,800 - 3,500) Castle Nut; 1 - 14 Yellow Zinc Nut; .5 - 20 Sealed Wire Connector Tang Washer; 1.58 x .033 Cotter Pin; .120 x 1.75 D-Flat Spindle Washer; 1 x 1.
3,500-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Axle U-Bolt Service Kit (3" Tube) Part #260525 C D B E H G I F A J K Callout A B C D E F G H I J K Part # 2139541 122087 119214 122081 122075 122085 122086 170997 122084 182274 2139521 Description U-Bolt; 9/16 - 18 x 6.625, 3" Tube YZ Seal; 1.666 x 2.565 x 5 (2,800 - 3,500) Round Spindle Washer; 1 ID x 1.68 OD Castle Nut; 1 - 14 Cotter Pin; .120 x 1.
5,200-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION H G I F E D B C A Callout A Part # Description 122065 Rubber plug for lubed grease caps 122064 Dust cap, for 2.5" bore, super lube B 122071 Dust cap, for 2.
5,200-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION NOTE: This diagram is for reference only. The parts specified here are only available to the OEM. Please use the parts listing on the previous page for replacement part information. H G I F E D B C A Callout A Part # Description 122065 Rubber plug for lubed grease caps 122064 Dust cap, for 2.5" bore, super lube B 122071 Dust cap, for 2.
5,200-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Electric Brake Assembly Part # 122259 1222592 1222593 122451 1224512 1224513 Description Electric Brake - 12" x 2" (Left Hand) Electric Brake - 12" x 2" Long Lead (Left Hand) Electric Brake - 12" x 2" Self-Adjusting (Left Hand) Electric Brake - 12" x 2" (Right Hand) Electric Brake - 12" x 2" Long Lead (Right Hand) Electric Brake - 12" x 2" Self-Adjusting (Left Hand) Disc Brake Assembly Part # 130111 Description Disc Brake; 655 - 1/2" Studs (5,200
5,200-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Axle U-Bolt Service Kit Part #232996 B C A D E I F G H Callout A B C D E F G H I Part # 2139541 119214 122088 170997 122077 122081 122084 182274 122075 Description U-Bolt; 9/16 - 18 x 6.625" for 3" Tube Round Spindle Washer - 1 ID x 1.68 OD Double Lip Grease Seal (5,200-7,000) Flat USS Hardened Washer - 9/16" Brake Nut Locking Keps Clear Dich Castle Nut - 1 - 14 Sealed Wire Connector Hex Nut; 9/16" - 18 GR8 Cotter Pin; .120" x 1.
6,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION H G I F E D B C A Callout A Part # Description 122065 Rubber plug for lubed grease caps 122064 Dust cap, for 2.5" bore, super lube B 122071 Dust cap, for 2.
6,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Electric Brake Assembly Part # 122259 1222592 1222593 122451 1224512 1224513 Description Electric Brake; 12" x 2" (Left Hand) Electric Brake; 12" x 2" Long Lead (Left Hand) Electric Brake; 12" x 2" Self-Adjusting (Left Hand) Electric Brake; 12" x 2" (Right Hand) Electric Brake; 12" x 2" Long Lead (Right Hand) Electric Brake; 12" x 2" Self-Adjusting (Left Hand) Disc Brake Assembly Part # 130111 Description Disc Brake; 655; 1/2" Studs (5,200 - 6,00
6,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Axle U-Bolt Service Kit Part #232996 B C A D E I F G H Callout A B C D E F G H I Part # 2139541 119214 122088 170997 122077 122081 122084 182274 122075 Description U-Bolt; 9/16" - 18 x 6.625" for 3" Tube Round Spindle Washer; 1 ID x 1.68 OD Double Lip Grease Seal (5,200-7,000) Flat USS Hardened Washer; 9/16" Brake Nut Locking Keps Clear Dich Castle Nut; 1 - 14 Sealed Wire Connector Hex Nut; 9/16" - 18 GR8 Cotter Pin; .120" x 1.
7,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION I H G F D E C B A Callout A B C D E E1 E2 F G H I Part # Description 122065 Rubber plug for lubed grease caps 127300 Dust Cap, for 2.75" Bore, Super lube 127206 Dust Cap, for 2.
7,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Electric Brake Assembly Part # 122259 1222592 1222593 122451 1224512 1224513 139383 139384 Description Electric Brake; 12" x 2" (Left Hand) Electric Brake; 12" x 2" Long Lead (Left Hand) Electric Brake; 12" x 2" Self Adjusting (Left Hand) Electric Brake; 12" x 2" (Right Hand) Electric Brake; 12" x 2" Long Lead (Right Hand) Electric Brake; 12" x 2" Self Adjusting (Right Hand) Electric Brake; 12" x 2" (Left Hand) Electric Brake; 12" x 2" (Right Hand)
7,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Axle U-Bolt Service Kit Part #232997 B C A D E I F G H Callout A B C D E F G H I 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 2.00 OD Double Lip Grease Seal (5,200-7,000) Flat USS Hardened Washer; 9/16" Brake Nut Locking Keps Clear Dich Castle Nut; 1 - 14 Sealed Wire Connector Hex Nut; 9/16" - 18 GR8 Cotter Pin; .120" x 1.
7,000-LB AXLE WHEEL END COMPONENTS AXLES AND SUSPENSION Axle U-Bolt Service Kit Part #309893 (Disc Brake Axle Application Only) B C A D I E F G J Callout A B C D E F G H I J 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 .
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 setup 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.
