Axle Service Manual
Contents
1. To measure voltage connect the voltmeter to both magnet wire leads while the towing vehicle is connected and the engine is running to insure accurate readings The voltage should begin at O asthe controller is increased slowly to approximately 12 volts If the controller does not produce this voltage control refer to your brake controller trouble shoot ing and information manual The lower reading will provide smoother braking while the higher may produce sharp or severe braking AMPERAGE MEASUREMENT PROCEDURE Amperage is the electrical current flowing in the brake system while the magnets are energized Make sure of your ammeter s rating to prevent damage to meter An easy place to check the amperage is at the output wire from the brake controller to the brakes Disconnect this blue wire and put the ammeter in series into this line Please refer to the following chart merican Electrical 7 Individual amperage draw can be measured at the magnet by inserting the ammeter in the line of the magnet you wish to check Disconnect one of the wire leads from the wire magnet and attach the ammeter between the two wires Reconnect the wires when completed BRAKE SIZE AMPS TO MAGNET 2 BRAKES 4 BRAKES 6 BRAKES 7 x 1 1 4 2 5 5 0 10 0 15 0 10 x 2 1 4 3 0 6 0 12 0 18 0 12x2 3 0 6 0 12 0 18 0 12 x 3 1 2 3 0 6 0 12 0 18 0 There are several possible reasons that may cause voltage variations Listed below are the most proba2. or open or shorted circuit or properly wired system including a good between towing vehicle and trailer heck brake adjustment or worn or defective magnet s or a damaged or worn connector between vehicle trailer hat controller is installed correctly and functioning correctly Intermittent or Surging Brakes C C C C heck heck ground heck heck or out of round brake drums or properly wired system including a good between towing vehicle and trailer or defective magnet or wiring or loose worn wheel bearings D Rockwell x American 6 Electrical TROUBLESHOOTING GUIDE FOR ELECTRIC BRAKES Ensure trailer is not overloaded Check for loose or corroded connections Check for properly wired system Check for a shorted circuit Check for worn or defective magnet Check brake adjustment Check for bent backing plate flange Check for contaminated brake linings Check brake system wiring Check for worn damaged brake linings Check for weak or broken brake shoe return spring Check for worn brake drums Check that correct controller is installed Check for improper controller installation Ineffective or Weak Brakes Check for contaminated brake linings Check for weak or broken brake shoe return spring Check for rust on armature plate or brake drum Check for improper controller installation Grabbing or Locking Brakes ELECTRICAL VOLTAGE MEASUREMENT PROCEDURE
3. They must be maintained at the appropriate torque rec ommendations to prevent loose wheels potentially broken studs and to prevent the wheel from separating from the axle TIRE PRESSURE Tire pressure should be checked frequently and inflated to the tire manu facturer s recommendations CAUTION Wheel torque must be maintained to insure that damage is not incurred to the wheel wheel studs and or attaching parts mi Wheel and Tire Safety 15 REQUIRED WHEEL TORQUES ft Ibs 1st Setting 2nd Setting Final Setting 8 12 13 Wheel 20 25 35 40 50 75 14 15 16 Wheel 20 25 50 60 90 120 16 Wheel 20 25 70 80 130 150 9 16 studs BOLT TIGHTENING SEQUENCE 5 Hole Pattern 6 Hole Pattern 8 Hole Pattern A 3 2 e 9 e WARNING Modifications of the tire 8 wheel assembly can result in damage to the trailer or personal injury if not used according to the manufacturer s specifications D Rockwell x American 16 Replacement Parts REPLACEMENT PARTS MAGNET REPLACEMENT KITS BRAKE SIZE MAGNET KIT NUMBER WIRE COLOR BRAKE MTG NUT TORQUE FT LBS 7x 11 4 K71 57 White 45 70 10 x 2 1 4 PPBM10E Green 45 70 12x2 PPBM12E White 25 50 12x3 1 2 4738 23 Orange 60 90 BRAKE SHOE REPLACEMENT KITS BRAKE SIZE SINGLE KIT 1 BRAKE 7x11 4 K71 45 10 x 2 1 4 PPDSL10E 12x2 PPBSL12E 1
4. 5 Now move the star wheel in the opposite direction until you can feel a little resistance from the brake and replace the hole cover 6 Carefully lower the tire to the ground 7 Repeat this procedure for all wheels making sure to adjust all brakes at the same time D Rockwell x American Aieugpg dll Kemeyeaiq Sg i Zb du is EE E R lkuel Brake Troubleshooting 5 TROUBLESHOOTING GUIDE FOR ELECTRIC BRAKES Dragging Brakes C C C C heck heck heck heck magne C heck or defective controller or corroded brake assembly or weak or broken brake shoe return spring or worn or damaged lever arm between and brake shoe or improper controller installation Noisy Brakes 000909000900 C heck heck heck heck heck heck heck brake adjustment or worn brake shoes or contaminated brake linings or weak or broken brake shoe return springs or bent backing plate heck wheel bearing adjustment or worn or damaged wheel bearings or worn or damaged magnets Inoperative Breakaway System C heck or dead or weak 12 volt battery on trailer Check all wiring and connections C If heck breakaway switch only one brake is operating check other magnets No Brakes C C C C C C C heck heck heck ground heck heck towing heck or defective circuit breaker
5. Double eye leaf springs have eyes at both ends of the spring and have special bushings to protect them from wear They do not need lubricating Slipper leaf springs have an eye at only one end which is also fitted with a special bushing to protect them from wear The trailing end of the spring is designed to slide against the rear hangers Either of these suspensions will provide you with comfortable trouble free towing but as with any mechanical parts they should be inspected periodically depending on usage at recommended intervals of 6 months or 5 000 miles whichever comes first Should you find excessive wear in the hanger components you should have them replaced by a qualified technician Should you find excess wear in any of the attaching parts bolts nuts bushings broken or worn out springs you should replace them and torque attaching bolts to the following standards as shown below D Rockwell x American 12 Suspensions CAUTION Make sure the trailer is raised and supported according to the manfacturers reguirements before beginning any repairs of the trailer SUSPENSION TOROUE REOUIREMENTS U Bolt Torgue 3 8 30 50 ft Ibs 7 16 45 70 ft Ibs 1 2 45 70 ft Ibs 9 16 60 85 ft Ibs Shackle Bolt Torque 7 16 45 70 ft Ibs 9 16 not torqued snug fit to allow parts to move easily The lock nut is used to position parts USE CAUTION If the above maintenance pro
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9. 2x3 1 2 right side 4737 3 left side 4737 4 BEARING REPLACEMENT CUPS amp CONES BRAKE SIZE HUB CUP CONE 7x11 4 4 or 5 Bolt L 44610 Inner L 44649 Inner and Outer and Outer 10 x 2 1 4 5 or 6 Bolt L 68111 Inner and L 68149 Inner and L 44610 Outer L 44649 Outer 12x2 6 Bolt 25520 Inner and 25580 Inner and 15245 Outer 15123 Outer 12x2 8 Bolt 25520 Inner and 25580 Inner and 14276 Outer 14125A Outer 12 x 3 1 2 8 Bolt 25520 Inner and 25580 Inner and 02420 Outer 02475 Outer SEAL REPLACEMENT BRAKE SIZE HUB SEAL 7x1 1 47 4 or 5 Bolt 12192TB 10 x 2 1 4 5 or 6 Bolt 171255TB 12x 2 6 or 8 Bolt 22333TBN 12 x 3 1 2 8 Bolt 22333TBN Grease 370219A Oil E Rockwell American sa xe ay UO AJUBLIEM paljdu Jo ssaidxa Aue jo 49291G 10 sje w PUB sjjeo auoudala ig 9104 sea Bulmo Aue Buipnjoui seBewep jenuanbasuo2 10 Je1uaplouI Aue JO 8 Gel aq JOU EYS UBDIISUUYZ JEMADOY JOLUOJSND SUT 104 Apawal anisnjoxa y SI AUEUEM siy Japun 1uawadejdai 10 aeda 7 BOUEUS1UIPUI Alesseoeu pue jqeuose apinod 0 eunjle Buipnjoui asn ajqeuosesiun 3 JeUJOJSN9 au jo uoIssessod au Ul ajiym UuONSUNHELUU 10 JOSJep wo Dumpsa Jou afeuieg g UOneljsisui Jadoiduuy vw A0 pasned s199jap 19409 JOU Sop AJUBLUEM SL E steuBew pue sulu 231219 GUIPNJIUI 1E8M BUUON 5 pe runouw AISUIDUO sem ll YOIUM 0 42y ey 19470 HUN uo AjquUasse ajxe Jo asn 4 a xe y jo UOI e19 e Au
10. OPERATION SERVICE MANUAL FOR American AXLES TABLE OF CONTENTS Safety Notice LL 1 Brakes a dina tana ra tawon adt e aaa 1 2 Electric Brake Maintenance 3 Trailer Connection e 4 Brake Troubleshocoting 5 6 Electrical ee a a 6 7 Hubs Drums and Bearings ss ss ss 8 9 Posi Lube LL 10 Suspension Systems 11 12 Torsion Ales 13 Tire and Wheel Safety 4 4 14 15 Replacement Parts 16 MADE IN USA Safety Notice 1 SAFETY NOTICE Providing safe dependable operation of your axle s and related compo nents is important This manual provides basic procedures for service and repair using established industry standards There are many varia tions in procedures to repair and maintain the axle and its related parts however it is not possible to provide you with all the detail for various service procedures Refer to your trailer manufacturer s owners manual for any specific warnings and procedures that may relate to the safety and maintenance of your trailer If these procedures are not clear to you or if you are unsure you should contact a trailer repair facility who has a trained axle repair technician for advice or repair NEW AXLE SETUP AND ADJUSTMENTS Wheels Re torque wheel nut torque requirements on new trailers at 50 miles See page 16 for torque rates Brakes Adjust at 3 000 miles Tire Pressure See tire manufacturers recommendations Brake Contr
11. ble e Poor electrical connections e Open circuits e Broken wires or incorrect wire size e Brake controller malfunction Electrical problems can also be caused by bare wires defective con trollers or shorts in the magnet coil Locating the source of a short circuit should be done by checking indi vidual sections Should you find the amperage reading drops to zero after disconnecting the trailer then the short is in the trailer If the amperage is highafter all of the magnets are disconnected the short is somewhere in the trailer wiring Please note that the majority of electrical brake complaints can be traced to the controller Refer to your brake controller manual to insure your con troller is correctly adjusted and that the connections are in compliance with the manufacturer s specifications D Rockwell x American 8 Hubs Drums and Bearings HUBS DRUMS AND BEARINGS Rockwell American bearing configuration uses industry standards for bearing sets bearings amp cones and hubs This standard of using tapered roller bearings helps to reduce the axial end play provided at assembly and is essential to performance of the bearings life The bearings are packed with lithium base grease Your axles may be equipped with the Rockwell American Posi lube system which provides for lubricating the hubs at a special grease fit ting This option allows grease to flow through specially machined axle spindles which have been dril
12. cedures are not applied there could be serious damage to the components possibly resulting in physical injury and or damage to property To perform undercarriage modifications please carefully follow the rec ommendations as follows 1 Raise and support the trailer until it is clear of the ground 2 When the trailer is securely supported place a block under the axle close to the end which will be repaired You need to secure only the axle tube in order to remove and replace the part you want to replace If your trailer has two axles you will need to support both axle tubes 3 Disassemble the attaching parts u bolts nuts and the links 4 Remove the eye bolts and the springs and place them clear of your working area 5 If needed remove the spring bushings and replace with new ones 6 Use the reverse order to reinstall your components Special note The fittings that attach the springs to the chassis mounts are designed specially to be wear resistant and should not be lubri cated merican Torsion Axle 13 JA JUNUB THE EQUALIZER TORSION AXLE Your trailer may be equipped with our Equalizer axle s The Trailer manufacturer specifies their use according to individual engineering requirements Each spindle is attached to a trailing arm which rocks up and down during road shock This movement is transferred to a steel inner bar within the axle beam Rubber cords then absorb the shock from the twisting i
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14. led to allow the grease to be passed from the fitting tothe inner bearing and back out through the outer bearing BRAKE DRUM INSPECTION The brake drum surface should be inspected for scoring or excessive wear If the wear is greater than 020 oversized it should be resurfaced If the drum has worn out of round by more than 015 it should be re ma chined If wear or scoring is more than 090 the hub and drum assembly will have to be replaced The armature surface which contacts the magnet needs to be inspected for uneven wear or scoring Drums can be resurfaced removing no more than 030 and should be to 120 micro inch finish In the event you need to turn the drums or resurface the armature it is recommended that you replace the magnets at the same time Special notes Make sure the inside of the hub cavity is carefully cleaned and free of any contamination following turning and before re assembly merican Hubs Drums and Bearings g HUB INSPECTION REMOVAL REPLACEMENT AND ADJUSTMENTS A Removal of Hub 1 Remove wheel 2 Remove grease cap 3 Remove cotter pin or bend tang washer on Posi Lube 4 Unscrew the spindle nut counter clockwise 5 Remove spindle washer 6 Remove hub from spindle B Seal Inspection and Replacement 1 Seals should be replaced each time the hub is removed 2 Pry the seal out ofthe hub with a screwdriver 3 Tap new seal into place C Bearing Maintenance Adjustments and Re
15. necessary loosen never tighten nut to align slot with the hole in the spindle Bend one leg of cotter pin over the end of the spindle and the other leg over the nut Tap legs slightly to set Cotter pin must be tight POSI LUBE LUBRICATION PROCEDURE Posi Lube Lubrication Procedure 1 Remove the rubber cap at end of the grease cap 2 Using a standard grease gun place the tip onto the grease fitting at the end of the spindle 3 Pump the grease into the fitting as you continue pressure you will notice the old grease coming out at the cap When you begin to see the new grease remove the gun and clean off any excess and replace the rubber cap merican Suspensions 11 ROCKWELL AMERICAN SUSPENSION SYSTEMS Single Axle Tandem Axle Double Eye Spring Double Eye Spring DO I a A a Q _ alli A 3 n See Single Axle Tandem Axle Slipper Spring Slipper Spring We also provide your suspension systems as well as the axle assemblies These components are designed to perform a number of tasks to provide your trailer with the best and smoothest towing possible The above drawings offer a view of single and tandem axle assemblies in both the double eyed and slipper spring versions Your axle undercarriage may be equipped with double eye leaf springs or slipper leaf springs depending on the manufacturer s specification
16. nner bar THE BENEFITS Superior Performance The independent action provides greater control and stability which makes towing the trailer much easier Wheel vibration is absorbed by the rubber cords SIDE MOUNT INSTALLATION OUTSIDE FRAME OUTSIDE BRACKET DIMENSION Washer s must be placed against the slotted hole in the axle bracket NOTE Low profile brackets have plain round holes Side mount hangers should be welded to frame with three 3 1 4 fillet welds 2 1 2 long on each side of the hanger and a fillet weld on each end Welds should be meet the quality standards of the Amercan Welding Society D1 1 Structural Welding Code 14 Wheel and Tire Safety WHEEL AND TIRE SAFETY Your trailer manufacturer has specified the wheel and tires to be used It is very important that you do not make any changes that may alter the recommended size or load capacities Any deviations however slight or unnoticeable may cause damage or be dangerous to operate TIGHTENING PROCEDURE 1 After mounting a wheel over the studs start all lug nuts by hand to prevent cross threading 2 After all the lug nuts have been snugged tighten the nuts to the recommended torgues using the seguence and progressive values provided on page 16 Re torgue after first 50 miles of use and periodically re check the torgue TOROUE REOUIREMENTS It is a necessary procedure to periodically check the torque levels of your wheel lug nuts
17. oller Settings Refer to Brake Controller manufacturers recommendations BRAKES Your trailer electric brakes are actuated by an electric magnet which is modified by an electrical impulse from the brake controller The trailer brakes will apply smoothly and slightly ahead of the truck brakes if all the brake components are installed and connected properly The brakes are activated with the electrical impulse from the controller to the magnets which when in contact with the armature plate will apply the pressure to the primary shoe and will engage the secondary shoe much like hydraulic brakes on a passenger vehicle As brake pres sure applied by the driver is increased the electrical flow to the magnets increases the pressure between the brakes and drums to meet the braking requirements of the driver D Rockwell x American 2 Brakes Electric brakes have been used on a variety of trailers for many years and offer many benefits to the driver Please refer to the brake controller infor mation provided by the installer of your towing vehicle for procedure and operation of the controller DOUBLE CHECK e Make sure your controller is installed according to the manufac turer s recommendations Make sure that the proper brake controller adjustments have been made to correctly engage the tow vehicle brakes and the trailer brakes to work together to providing safe and comfortable braking e Make sure that the brakes have been prope
18. placement 1 Inspect for corrosion and wear 2 If any rust or wear exists on the bearing then remove and replace 3 If bearings are found to be in good condition then cleaning and repacking the grease is all that is needed Note Do not spin bearings with compressed air 4 Hand pack each bearing individually using a premium lithium base wheel bearing grease 5 Reinstall the hub reversing the procedure above using the bearing adjustment procedures below 6 If you have the Posi Lube system refer to the Posi Lube Lubrication Procedure D Bearing Adjustment 1 Feel and Drag Method Tighten slotted nut until hub drags slightly when rotated Rotating the hub while tightening the nut seats the bearing Loosen the slotted nut 1 6 turn 1 hex to align nut slot with the cotter pin hole Wheel should turn freely Insert new cotter pin through nut and spindle If necessary loosen never tighten nut to align slot with the hole in the spindle Bend one leg of cotter pin over the end of the spindle and the other leg over the nut Tap legs slightly to set Cotter pin must be tight If equipped with Posi Lube bend tang back into position D Rockwell x American 10 Posi Lube 2 Torque Wrench Method Make sure nut is loose Tighten nut with torque wrench to an initial torque of 50 ft Ibs Loosen nut from initial torque and finger tighten Insert new cotter pin through nut and spindle If equipped with Posi Lube reset tang If
19. rly seated by applying the brakes repeatedly and lightly for about 20 to 25 times at a low speed under 25 miles per hour to begin the seating in of the brake to the brake drum components Do this in a safe and low traffic area for everyone s safety Below is a view of the 10 and 12 brakes used on your trailers axle s depending on your trailer and manufacturer s specifications Right Hand 10 Electric Brake Left Hand 12 Electric Brake merican Electric Brake Maintenance 3 ELECTRIC BRAKE MAINTENANCE Your trailer brakes should be adjusted between 250 to 300 miles after all of the brake components have seated Since driving conditions and areas vary you should re check brakes adjustments at a minimum of 3 000 miles CAUTION Do not place jack on axle or springs Use jack stands to secure trailer ADJUSTMENT PROCEDURE 1 Make sure your trailer is on a level surface and is free of any potentially dangerous items Jack up the trailer and secure with jack stands Make sure you are using the trailer manufacturer s procedure for jacking and safely supporting the trailer until the tire and wheel are clear of the ground surface Find the adjusting hole cover and remove it from the backing plate Use a brake adjusting tool to adjust the star wheel of the adjuster and expand the brakes until the brake shoes are sufficiently expanded so that the tire and wheel will not easily rotate
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