LIPPERTCOMPONENTS, INC. - Prime Time Manufacturing
Contents
1. 18 Amperage Chart 19 Wiring Diagram 20 Coupler Diagram 21 Maintenance Schedule 22 SLOG ad ERE rne ye 23 Storage 23 Extended Storage Preparation 23 Trip Preparation Chart 24 25 Warranty 27 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 The quality of the Lippert name and the finest materials utilized in the production of the Axles and Running Gear provide you with hubs brakes drums and spindles that make trailering and braking the finest in the industry Quality comes threefold in Lippert Components Inc The finest quality materials The latest technology and design The quality standards maintained from materials to final assembly All three points provide the customer with the best product they can possibly buy and the satisfaction of knowing they can trust the equipment on which they have spent their hard earned money Lippert Components Inc th2. LIPPERT COMPONENTS INC TRAILER AxLE OPERATION AND SERVICE MANUAL rev110210 TABLE OF CONTENTS Introduction amp Safety Information 3 IMPORTANT Breaking In Instructions 4 5 5 Hub Remowval 5 Brake Drum Inspection 5 Bearing Inspection s Bearing Lubrication 7 Seal Inspection and Replacement 8 Bearing Adjustment Hub Replacement 8 Electric 9 How to Use Brakes Properly 9 General Maintenance 10 Brake Adjustment 10 Clean and Inspect Lubricate ss 11 Magnets Shoes and Linings 12 Axle amp Suspension Installation 13 Suspension Systems 13 Double Eye Leaf Springs 13 Torsion Suspension 13 Inspection 14 Suspension Replacement 14 5 Wheel Selection Torque Requirements MIPE S eee Tire Wear 16 17 Measuring Voltage 18 Measuring
3. to the tow vehicle or drive axle s Parallel installation allows for correct and safe control prolonged tread life and will all but eliminate dog tracking Proper alignment is most readily achieved by measuring from the center of the trailer king pin to the center of each end of the axles Lippert Components Inc tubular axles are made of high strength steel to prevent metal fatigue and provide the best possible welding conditions The round tubular axles allow for even and uniform structure 12 WARNING Always wear eye protection when servicing the axle brakes hubs springs and wheels Failure to wear eye protection may result in serious injury Suspension Systems The suspension systems incorporated into Lippert Component Inc axles are designed to provide the following benefits 1 Attach the axle to the trailer 2 Dampen the effects of road shock 3 Provide stability to the trailer All Lippert suspension systems are available in single and multiple axle configurations For specific or custom applications please contact Lippert Components Inc Axle Division 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
4. 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 Brakes can be seated in by applying approximately 8 10 volts to the trailer brakes at an initial speed of 40 mph and allowing the truck trailer combination to slow down to 20 or 25 mph For best results do not use truck brakes during this procedure The trailer brakes will seat in faster by using them to stop both the truck and trailer The easiest method is to apply the trailer brakes using the manual activation lever located on the in cab brake controller Care must be taken to not overheat the lining material therefore brake applications conducted at one mile intervals will suffice The driver should feel a noticeable difference in the brake performance during this period sometimes in as few as 10 applications After 50 applications the brake lining material will be fully cured from the heat and develop close to 10096 contact with the brake drum surface This break in period not only seats the shoe lining material but also seats in the brake electromagnets During the break in period the linings will wear at a faster rate than they do after th
5. for proper replacement bearings NOTE Replacing the bearing cup is a very precise process The cup must be perfectly seated when replaced If the cup is not seated correctly damage to the assembly may not be covered by the warranty Consult Lippert Components Inc prior to replacing bearing and bearing cup The trailer should be taken to a certified service center for this work to be done WARNING DO NOT mix Lithium calcium sodium or barium complex greases Chemical compatibility problems may occur If you are changing from one chemical grease to another be sure all old grease is removed prior to applying new grease 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 See Fig 6 2 Press widest end of bearing into the outer edge of the grease pile forcing grease into the inner area of the bearing between two adjacent rollers See Fig 7 3 Repeat this process while turning bearing from roller to roller until all rollers are coated 4 Apply a light coat of grease into the bearing cup surface 5 Reassemble bearing into cup Bearing Lubrication Oil If yo
6. load should be increased to 1596 DO NOT OVERLOAD Consult your trailers i d plate for gross vehicle weight restrictions Tires should be inflated to manufacturer s specs Inspect tires for any damage or wear Inspect lug nuts bolts All should be torqued to spec See Page 15 for Specs Check torque of hanger bolt shackle bolt and U bolt nuts on suspension 10 Check that your trailer is towing level Adjust hitch height if necessary to level trailer 25 ss ppe 3 sseJppy JeuMQ eseuoing 10 ejeq Jo 9124 e xe y 0 Buyum J8QUINN 107 Joyous RIG 10 YOO YSQUINN eres 197 By 918900 OL jlequinN NIA Wea SWEN epon uonduoseg WOD LIO MMMA 34 uo sn 1282 9 998 9 99 NI ueusoo any 265300 2022 pue 9 624 URI SJUSUOduo siu uo AjueJew JNO ejeAnoe HUN INO JO eseuound Jo eui Jo s ep og sjueuoduio2 oi SIU pue ejgissod se se 1no esee d jeseuoung pied AjueJeA oxy 5 Haddr
7. malfunction are traceable to improperly adjusted or nonfunctional controllers See your controller manufacturer s data for proper adjustment and testing procedures For best results all the connection points in the brake wiring should be sealed to prevent corrosion Loose or corroded connectors will cause an increase in resistance which reduces the voltage available for the brake magnets 20 uowWoD Areyixny jeuBig eyxyeig euw uMoJg TEU Siu 8 jeuiuuep ng 9 euiue uMoJg z jeuiuuej ng peue deg HIPIA 5 ueeJt yno LM 8 esueor MOL ceu jeubig 83 dois sa1vdado LHSIT ANVYE NYNL HH SIMVHEE C N ES 9 S3vua Auvnixnv NYNL HH 8 4015 L p S Ty Nun HT uvrixnv 8 4018 HT 4015 JONVYVITO SLHON VL ASH ved 3ONVHV319 H371dNO9D Nid 6 Nid Z SIMVHAH 31VH3dO LON 530 TIVLdId SLHOIT
8. 2 090 The inner surface of the brake drum that contacts the brake magnet is the armature surface If the armature surface is scored or worn unevenly it should not be machined more than 030 The magnets should be replaced whenever the armature surface is refaced and vice versa NOTE Make certain that the wheel bearing cavities are clean and free of contamination before reinstalling bearing and seals Resurfacing procedures can produce metal chips and dust that can contaminate the wheel bearings and cause failure Bearing Inspection Wash all grease and oil from the bearing cone using a suitable solvent Dry the bearing with a clean lint free cloth and inspect each roller completely If any pitting spalling or corrosion is present then the bearing must be replaced The bearing cup inside the hub must be inspected NOTE Bearings must always be replaced in sets of one cone and one cup WARNING Always wear eye protection when servicing the axle brakes hubs springs and wheels Failure to wear eye protection may result in serious injury Follow the procedure below to replace the bearing cup 1 Place hub on a flat surface with bearing cup on the bottom 2 With brass drift punch lightly tap around the small end of the cup to push it out 3 Clean the hub bore Replace the cup by tapping it back in with the brass drift punch Cup should be seated against the retaining shoulder in the hub Consult Bearing Replacement Chart
9. ENT BRAKES Test amp Correct Loose Connections Repair or Replace Faulty Ground Wrong Magnet Lead Wire Color Find amp Repair BRAKES PULL TO ONE SIDE Adjust Incorrect Adjustment Correct Grease or Oil on Linings or Magnets Broken Wires Clean or Replace Find amp Repair Bad Connections Find amp Repair HARSH BRAKES Underadjustment Adjust Improper Synchronization Correct NOISY BRAKES Underadjustment Lack of Lubrication Adjust Lubricate Broken Replace Component Incorrect Brake Components Correct SURGING BRAKES Grease or Oil on Linings or Magnet Clean or Replace Out of Round or Cracked Brake Drums Machine or Replace DRAGGING BRAKES Overadjustment Readjust Out of Round Brake Drums Machine or Replace Incorrect Brake Components Replace Loose Bent or Broken Brake Components Replace Faulty Breakaway Switch Loose Wheel Bearing Adjustment Repair or Replace Adjust Bent Spindle Replace Axle NOTE If all trailer lights and brakes do not work check your wiring plug connection and make sure the ball is making solid contact with the coupler that is how a trailer is grounded Too much grease or not using dielectric grease on the ball and coupler can cause this to happen 18 Measuring Voltage The Braking System voltage is measured at the two lead wires of the magn
10. When energized the electromagnets are attracted to the rotating surface of the drums 4 This moves the actuating levers in the direction the drums are turning 5 The actuating cam at the end of the shoe forces the primary shoe out to the drum surface 6 The force of the primary shoe actuates the secondary shoe to contact the drum 7 The force applied to the brake drum can be increased by elevating the current flow to the electromagnet Front of Brake Retracting Spring econdary Shoe 4 e Primary Shoe Electro Magnet Adjuster Adjusting Spring How to Use Your Electric Brakes Properly The Lippert Components Inc Electric Braking System is synchronized with your tow vehicle brakes WARNING 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 You may have to manually make small adjustments occasionally to accommodate changing loads and driving conditions Synchronization of tow vehicle to trailer braking can only be accomplished by road testing Locking up excessive grab or delayed application is quite often due to the lack of synchronization between the tow vehicle and the trailer being towed High voltage 2V Low voltage 2V or improperly adjusted brakes are the most common cause of these problems and can be easily remedied Prior to any adjustments your trailer brake
11. YATIVYL 3LIHM SLHOIT ONINNNY NYNL H1 dOLS MOTTI3A HE HH 5 4015 22 MAINTENANCE SCHEDULE Item Function Required Weekly 3 Months 3000 Miles 6 Months 6000 Miles 12 Months 12000 Miles Brakes Test that they are operational At Every Use Breakaway System Check battery charge and switch operation At Every Use Brake Adjustment Adjust to proper operating clearance Brake Magnets Inspect for wear and current draw Brake Linings Inspect for wear or contamination Brake Controller Check for correct amperage amp modulation Trailer Brake Wiring spots fray etc nspect wiring for bare Hub Drum nspect for abnormal wear or 6 Wheel Bearing nspect for corrosion or wear Seals nspect for leakage Replace if Springs nspect for wear loss of arch Suspension Parts nspect for bending loose fasteners wear Hangers nspect Welds Wheel Nuts and Bolts Tighten to specified torque values Wheels nspect for cracks dents or e distortion Tire Inflation Pressure nflate tires to mfg s specifications Tire Condition nspect for cuts wear bulging etc 23 Storage Storage Preparation If your trailer is to be stored for an extended period of time the
12. anks you for purchasing our Axles and Running Gear When you speak of Lippert Components Inc our quality stands beside you Safety Information The WARNING symbol above is a sign that a service or maintenance procedure has a safety risk involved and may cause serious injury or death if not performed safely and within the parameters set forth in this manual Always wear eye protection when performing service or maintenance to the vehicle Other safety equipment to consider would be hearing protection gloves and possibly a full face shield depending on the nature of the service This manual provides general service and maintenance procedures Many variables can change the circumstances of the service procedure i e the degree of difficulty involved in the service operation and the ability level of the individual performing the operation This manual cannot begin to plot out procedures for every possibility but will provide the general instructions for effectively servicing the vehicle In the event the skill level required or the procedure to difficult a certified technician should be consulted before performing the necessary service Failure to correctly service the vehicle may result in voiding the warranty inflicting injury or even death The owner s manual for your unit may have more procedures for service and maintenance IMPORTANT Break in period for electric drum brakes The break in period is a typical phenomenon with drum
13. asteners should be done in stages Follow the recommended sequence tighten fasteners per wheel torque requirements diagram see below 4 Wheel nuts bolts should be torqued before first road use and after each wheel removal Check and re torque after the 10 and 25 miles and again at 50 miles A periodic check during regular service is recommended Wheel Stud Torque Sequence Size Size 151 Stage 2nd Stage 3rd Stage 14 1 2 20 25 50 60 90 120 15 1 2 20 25 50 60 90 120 16 1 2 20 25 50 60 90 120 16 5 x 6 75 1 2 20 25 50 60 90 120 16 9 16 20 25 60 70 120 130 16 5 x 6 75 9 16 20 25 60 70 120 130 17 5 w long nut 5 8 50 60 100 120 190 210 17 5 w flange nut 5 8 50 60 150 200 275 325 14 5 Demount 1 2 tighten sequentially to 85 95 NOTE All torque in ft Ib 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 Tire inflation pressure is the most important factor in tire life Tire pressure should always be what is recommended by the manufacturer for the load Always check pressure cold before operat
14. available in single and multiple axle configurations In trailers with 2 or more axles the additional movement is maintained by an equalizer This feature allows for even load handling from axle to axle 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 The spindle is connected to a swing arm the swing arm is connected to a square inner bar that is sheathed in rubber and as the swing arm rotates and experiences the torque and resistance of driving conditions the characteristics of the rubber absorb and distribute the load providing benefit over leaf spring suspensions 3 The Lippert Components Inc Torsion Suspension system requires very little attention in regards to maintenance Normal inspection of the entire Lippert Components Inc Trailer Axle system can be applied to the Torsion Suspension system See inspection procedures for system components in this manual Shackle Link Center Hanger Rear Hanger Front Hanger I Fig 1 Tie Plate _ Equalizer Shackle Bolts Sprung Axle Torque Specifications AxleSize Axle Capacity Maximum ft Ib U Bolts 25 ft Ib 3 5k w 1 2 50 ft Ib 5 2k 65 ft Ib 6 8k 90 ft Ib Minimum 1 Maximum ft Ib 13 Ins
15. e completely flat If the magnet s coil is exposed in any way even if normal wear is evident the magnets should be replaced immediately If the electromagnets are replaced the drum armature surface should also be refaced If a magnet is replaced on one side of an axle it is recommended that the magnet on the opposite brake assembly also be replaced to ensure even braking capacity Omer dr t Fig 2 Figure 2 above shows an Electro Magnet with little or no wear If there are any pronounced gaps on the surface of the Electro Magnet the magnet should be replaced 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 After replacing shoes and linings your trailer brakes should be burnished in by applying the brakes 20 30 times with a 20 m p h decrease in speed e g 40 m p h to 20 m p h Allow ample time for brakes to cool between application This allows the brake shoes and magnets to begin seating to the brake drum Axle amp Suspension Installation The single most important portion of axle installation is parallel alignment of the trailer axle s
16. et on any brake Use the pin probes inserted through the insulation of the lead wires 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 Voltage in the system should begin at 0 volts and as the brake pedal of the tow vehicle is applied voltage will gradually increase to about 12 volts If the system does not indicate at least 12 volts problems may occur in the wiring of the system the battery or alternator of the tow vehicle When the brakes are applied a gradual increase in voltage is preferable to a quick increase to 12 volts A gradual increase in voltage ensures smooth and firm trailer braking A quick increase in voltage will cause the braking system to feel like the trailer is grabbing too quickly Taking a Voltage reading is usually done with probes inserted into the wire connector See Fig 3 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 Individual amperage draw can be measured by inser
17. ey are seated in NOTE Brakes should be manually adjusted after the first 200 miles of operation and periodically thereafter approx 3 000 mile intervals Hubs Drums Bearings Hub Removal remove the hub assembly for inspection maintenance or service follow the WARNING six 6 steps below Lift unit by the frame and never the axle or suspension Do not go under unit unless it is properly supported by jack stands Unsupported units can fall causing serious injury or death 1 Lift trailer and support it per manufacturer s requirements 2 Remove the wheel 3 Remove the grease cap by prying the edge out of the hub 4 Pull the cotter pin from the castle nut or if the hub is equipped with the Super Lube system bend the locking tang down and remove the outer spindle nut 5 Remove the spindle washer 6 Pull the hub off the spindle Do not let the outer bearing cone fall free of the assembly The inner bearing cone will be contained by the seal and will not fall out NOTE A gear puller may be necessary to remove hub from spindle 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 remachined if wear is more than 020 or out of round by more than 015 The drum should be replaced if scoring or wear is greater than 090 Drum Diameter 10 10 090 12 1
18. ion DO NOT bleed air from tires when they are hot Check inflation pressure weekly during use to insure maximum tire and tread life The following tire wear diagnostic chart will help you pinpoint the causes and solutions of tire wear problems NOTE Tire wear should be checked frequently because once a wear pattern becomes firmly established in a tire it is difficult to stop even if the underlying cause is corrected 16 PROBABLE CORRECTIVE CAUSE ACTION Over inflation Adjust pressure to particular load CENTER per tire catalog WEAR Under inflation Adjust pressure to particular load per tire catalog Loss of camber Make sure load doesn t SIDE or overloading exceed axle rating Call Lippert WEAR Service amp Warranty to advise TOE Incorrect toe in Call Lippert Service amp Warranty to WEAR advise Out of balance Check bearing adjustment and CUPPING balance tires FLAT SPOTS Wheel lockup amp Avoid sudden stops if possible and tire skidding adjust brakes Introduction to Troubleshootin 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 Mechanical failure is the most common form of malfunction h
19. ire and trailer max load ratings 3 Offset The relationship of the center line of the tire to the hub face of the axle should match any replacement Failure to match offset may result in reducing the carrying capacity of your axle 4 Rim Contour Replacement wheels should be direct replacements to match the rim contour WARNING Use only rim contours suggested by manufacturer Failure to use correct rim contour may cause dramatic separation of tire and wheel and could cause serious injury or death WARNING Attempting to modify or repair a wheel can cause unsafe conditions that may result in an explosion Air pressure on a weakened or cracked rim can cause serious injury or death 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 WARNING 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 serious injury or death Be sure to use only the fasteners matched to the cone angle of your wheel usually 60 or 90 The proper procedure for attaching your wheels is as follows 15 k Start all bolts or nuts by hand to prevent cross threading 2 Tighten bolts or nuts in the following sequence 3 Tightening f
20. lent time to check for parts that have become loose or worn WARNING POTENTIAL ASBESTOS DUST HAZARD Older brake linings have the potential to contain asbestos dust which has been linked to serious or fatal illnesses Certain precautions need to be taken when servicing brakes 1 Avoid creating and or breathing any brake dust 2 Do no machine file or grind the brake linings 3 Remove with a damp brush or cloth Dry brushing or compressed air will cause dust particles to be airborne Lubricate Brakes Prior to reassembling the brake drum assembly remember to apply a light film of white grease or an anti seize 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 11 Magnets This electric braking system utilizes an electromagnet to actuate the brake shoes These high quality magnets provide superior force and friction to safely and effectively stop the trailer These magnets should be inspected and serviced on the same schedule as the rest of the axle system at east once a year for normal use and more often if the trailer is used extensively Abnormal or uneven wear is a sign that the magnet needs to be replaced Check the surface of the magnet with a straight edge to check for uneven wear The surface of the magnet should b
21. of the new seal 3 Tap the new seal into place using a clean hard wood block See Fig 8 Bearing Adjustment Hub Replacement For adjusting bearings or replacement of removed hub follow procedures below 1 Place hub bearing washers and castle nut back on axle spindle in the reverse order from which they were removed Castle nut should be torqued to 50 ft lb Hub will rotate during this process Loosen castle nut to back off the torque Tighten castle nut finger tight until snug Insert cotter pin or locking tang if equipped with Super Lube If cotter pin or tang does not line up with hole back castle nut up slightly until pin or tang can be inserted Bend cotter pin over to lock nut in place or locking tang in the case of Super Lube Nut should be free to move with only the cotter pin keeping it in place ELECTRIC BRAKES The basic structure of the Electric Brakes on your trailer will resemble the brakes on your car 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 to follow along 1 Electric current is supplied to the trailer s braking system when the tow vehicle s brakes are applied 2 From the tow vehicle s battery the electricity flows to the brake s electromagnet 3
22. operly supported by jack stands Unsupported units can fall causing serious injury or death WARNING Always wear eye protection when servicing the axle brakes hubs springs and wheels Failure to wear eye protection may result in serious injury If the equalizer or equalizer bushings must be replaced follow the instructions above for lifting and supporting the trailer unit and then proceed as follows 1 With both axles blocked up remove the spring eyebolt keeper bolt and equalizer bolt from the equalizer to be repaired or replaced 2 Press the old nylon bushing out of the equalizer 3 Reassemble in reverse order 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 andspring eye nuts to a minimum of 55 ft Ib and a maximum of 70 ft lb 14 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 t
23. owever if the brake system fails and it s not mechanical it is usually electrical A Voltmeter and Ammeter are essential tools to diagnose these problems Mechanical problems are mostly self evident something is bent or broken Consult the following troubleshooting chart to determine the probable cause and corrective actions for a variety of issues with the braking system Please remember to use only Lippert Components Inc replacement parts on these systems Consult the Limited Warranty or call our Service Department for any other related issues 17 Troubleshooting Chart PROBABLE CAUSE BRAKES Open Circuits LLL Short Circuits CORRECTIVE ACTION Find amp Correct Test amp Correct Severe Underadjustment Adjust Brakes WEAK BRAKES Grease or Oil on Magnets or Linings Clean or Replace Corroded Connections Worn Linings or Magnets Clean amp Correct Cause of Corrosion Replace Scored or Grooved Brake Drums Improper Synchronization Machine or Replace Correct Underadjustment Adjust Brakes Glazed Linings Reburnish or Replace Overloaded Trailer Correct LOCKING BRAKES Underadjustment Adjust Improper Synchronization Correct Loose Bent or Broken Brake Components Test amp Correct Out of Round Brake Drums Machine or Replace Insufficient Wheel Load Broken Wires Adjust System Resistor and Synchronize INTERMITT
24. pection 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 16 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 Follow the trailer manufacturer s recommendations for lifting and supporting the unit 2 After the unit is properly supported place a suitable block under the axle tube near the end to be repaired This block is to support the weight of the axle only so that SUSPENSION COMPONENTS can be serviced or replaced Disassemble the U bolts nuts and tie plates Remove the spring eye bolts and the spring If the spring eye bushings are to be replaced press out the old bushing by hand or tapping out with a punch Free floating nylon bushing needs no lubrication Press the new bushing into the spring eye by hand or gently tapping it in with a bounceless rubber or plastic mallet 7 Reinstall repaired or replaced components in reverse order NOTE For multiple axle units the weight of each axle must be supported as outlined in Step 2 before disassembly of any component of the suspension system WARNING Lift unit by the frame and never the axle or suspension Do not go under unit unless it is pr
25. s should be burnished in by applying the brakes 20 30 times with a 20 m p h decrease in speed e g 40 m p h to 20 m p h Allow ample time for brakes to cool between application This allows the brake shoes and magnets to begin seating to the brake drum Trailer Wire Gauge Chart Gauge and Number Type of Wire of Axles Length of Run 16 gauge stranded copper 1 14 gauge stranded copper 2 Under 30 ft 9 1m from hitch to center of axles 12 gauge stranded copper 2073 Over 30 ft 9 1m hitch to center of axles General Maintenance Electric Brakes Brake Adjustment WARNING Prior to testing or adjusting brakes be sure area is clear of any pedestrians and vehicles Failure to perform test in a clear area may result in serious injury or death Lippert Components Inc Electric Brakes are manually adjustable only If manual adjusting is needed the following 6 step procedure can be utilized Initially brakes should be adjusted after the first 200 miles of operation when the brake shoes and drums have seated Next check and adjust brakes at 3 000 mile intervals or sooner if they are not performing as intended The brakes should be adjusted in the following manner 1 Jack up trailer and secure on adequate capacity jack stands Follow trailer manufacturer s recommendations for lifting and supporting the unit Make sure the wheel and drum rotates freely 10 WARNING Lift unit by the frame and never the axle or s
26. should check 3 2 ohms If shorted or worn excessively they must be replaced 6 Lubricate all brake moving parts using a high temperature brake lubricant 7 Remove any rust from braking surface and armature surface of drums with fine emery paper or crocus cloth Be sure to protect bearings from contaminating dust 8 Inspect oil or grease seals for wear or nicks Replace if necessary 9 Lubricate hub bearings 10 Reinstall hubs and adjust bearings 11 Mount and tighten wheels 24 WARNING Avoid getting any grease or oil on brake linings and pads or magnet surfaces 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 2 3 8 9 Maintenance schedule should current Inspect hitch for corrosion lubrication and wear Inspect safety chains for rust and wear Engage chains and breakaway Switch actuating chain securely Breakaway battery should be fully charged Electronic coupler must be secure Run check on all lights and break engagement and syncronization Load trailer with 1096 of total weight on the hitch end of trailer Smaller trailers front end
27. ting the ammeter in the line at the magnet you want to check Disconnect one of the magnet lead wire connectors and attach the ammeter between the two wires Consult Amperage Chart on the next page for normal amp readings Make sure that the wires are properly reconnected and sealed after testing is completed 19 Testing for Amperage can be done with probes See Fig 4 or alligator clips on the leads or an amp clamp See Fig 5 Amperage Chart Amps Two Four Six Magnet Brakes Brakes Brakes 3 0 6 0 12 0 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 Low quality electrical connections Open circuits Insufficient wire gauge Broken wires Blown fuses fusing of brakes is not recommended 6 Short circuits indicated by high amperage Possible causes of shorts are 1 Shorted magnet coils 2 Bare wires contacting a grounded object Finding the cause of short circuit the system is done by isolating one section at a time If the high amperage reading drops to zero by unplugging the trailer then the short is in the trailer If the amperage reading remains high with all the brake magnets disconnected the short is in the trailer wiring All electrical troubleshooting procedures should start at the controller Most complaints regarding brake harshness or
28. 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 Follow trailer manufacturer s guidelines to lift and support the trailer 3 Lubricate mechanical moving parts such as the hitch and suspension parts that are exposed to the weather 4 In the case of boat trailer axles that are subject to repeated immersion remove brake drums clean dry and re lubricate moving brake components inspect bearings clean and relubricate WARNING Lift unit by the frame and never the axle or suspension Do not go under unit unless it is properly supported by jack stands Unsupported units can fall causing serious injury or death Extended Storage Inspection Procedures Trailer should remain on jack stands during this procedure 1 Remove all wheels and hubs or brake drums Reinstall drum to same spindle and brake from which it was removed 2 Inspect suspension for wear 3 Check tightness of hanger bolt shackle bolt and U bolt nuts of the suspension for correct torque 4 Check brake linings brake drums and armature faces for excessive wear scoring damage or corrosion 5 Check brake magnets with an ohmmeter The magnets
29. ur 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 Recommended Wheel Bearing Lubrication Specifications Grease Thickener Type uere ient tea ceste no sce Lithium Complex Dropping POINT iiec canere 230 C 446 minimum CONSISTENCY 2 Po NERE EP Corrosion amp Oxidation Inhibitors Oil m Solvent Refined Petroleum Oil Base Oil Viscosity 40 C 104 F 150cSt 695 SUS Min Viscosity INdex 80 Minimum Pour Pont cete 10 C 14 F Minimum Approved Sources MOD II Oil EE Mobilgrease HP Exxon Standard ELE Ronex MP Keridall Refining CO Kendall L 427 Ashland Oil Go Valvoline Val plex EP Grease Pennzoil Prod Co Premium Wheel Bearing Grease 707L 7 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
30. uspension Do not go under unit unless it is properly supported by jack stands Unsupported units can fall causing serious injury or death 2 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 3 With a screwdriver or standard adjusting tool rotate the starwheel of the adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn 4 Then rotate the starwheel in the opposite direction until the wheel turns freely with a slight lining drag 5 Replace the adjusting hole cover and lower the wheel to the ground 6 Repeat the above procedure on all brakes For best results the brakes should all be set at the same clearance Clean and Inspect Brakes In the event the braking system encounters symptoms of improper application or failure immediate inspection and service must be implemented During normal use servicing the braking system once a year is considered normal Increased usage will require service on a regulated schedule based on 3000 6000 mile increments As magnets and shoes become worn they need to be changed to maintain maximum braking capability Be sure when disassembling brakes for cleaning to clean the backing plate magnet arm magnet and shoes Also make sure that any and all parts removed for cleaning are placed back into the same brake drum assembly This is also an excel
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