Lippert Components Trailer Axle User Manual
Rev: 03.18.2014
Page 1
Trailer Axle Owners Manual FULL
TABLE OF CONTENTS
Introduction 3
Safety Information 3
Break-in Period for Electric Drum Brakes 4
Hubs/Drums/Bearings 4
Hub Removal 4
Brake Drum Inspection 5
Bearing Inspection 5
Bearing Lubrication - Oil 6
Bearing Lubrication - Grease 6
Seal Inspection and Replacement 7
Bearing Adjustment/Hub Replacement 7
Electric Brakes 8
How to Use Lippert Electric Brakes Properly 9
General Maintenance - Electric Brakes 9
Brake Adjustment 9
Lubricate Brakes 10
Clean and Inspect Brakes 10
Magnets 10
Shoes and Linings 11
Axle and Suspension Installation 11
Suspension Systems 11
Double-Eye Leaf Springs 12
Torsion Suspension System 13
Inspection 14
Suspension Replacement 14
Wheels 15
Wheel Selection 15
Torque Requirements 16
Tires 17
Introduction to Troubleshooting 18
Troubleshooting 18
Measuring Voltage 18
Troubleshooting Chart 19
Measuring Amperage 20
Amperage Chart 21
Maintenance Schedule 22
Wiring Diagram 23
Pigtail and Coupler Wiring Color Codes 24
3,500LB AXLE WHEEL END COMPONENTS 25
5,200LB AXLE WHEEL END COMPONENTS 30
6,000LB AXLE WHEEL END COMPONENTS 34
7,000LB AXLE WHEEL END COMPONENTS 37
Storage 41
Storage Preparation 41
Extended Storage Inspection Procedures 41
Trip Preparation Checklist 42
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Trailer Axle Owners Manual FULL
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.
1. The finest quality materials.
2. The latest technology and design.
3. 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. thanks 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.
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Trailer Axle Owners Manual FULL
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.
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 100% 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 they 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
To remove the hub assembly for inspection, maintenance or service, follow the 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 death or serious injury.
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. If equipped with oil lubrication, unscrew oil
cap using a 2½” socket. Let oil drain into pan.
4. Pull the cotter pin from the castle nut 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: Brakes may need to be adjusted or backed off to remove drum from spindle.
NOTE: A gear puller may be necessary to remove hub from spindle.
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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. 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: Ensure 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.
Drum Maximum Re-bore Diameter
7" 7.09"
10" 10.09"
12" 12.09"
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.
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 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.
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. If the old grease is not removed completely, chemical compatability may result in
component failure or damage.
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Trailer Axle Owners Manual FULL
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. 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. 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 (Fig. 2).
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.
Fig. 1
Fig. 2
Recommended Wheel Bearing Grease Specifications
Thickener Type Lithium Complex
Dropping Point 230°C (446°F) Minimum
Consistency NLGI No. 2
Additives EP, Corrosion, & Oxidation Inhibitors
Base Oil Solvent Refined Petroleum Oil
Base Oil Viscosity @40°C (104°F) 150cSt (695 SUS) Minimum
Viscosity Index 80 Minimum
Pour Point -10°C (14°F) Minimum
Rev: 03.18.2014
Approved Sources
Mobil Oil Mobilgrease HP
Exxon/Standard Ronex MP
Kendal Refining Co. Kendall L-427
Ashland Oil Co. Valvoline Val-plex EP Grease
Pennzoil Prod. Co. Premium Wheel Bearing Grease 707L
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Trailer Axle Owners Manual FULL
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. Tap the new seal into place using a clean, hardwood block (Fig. 3).
NOTE: When installing a new oil seal, be sure side marked “AIR SIDE” is away from bearing cone.
Fig. 3 Fig. 4
Bearing Adjustment/Hub Replacement
To adjust bearings or replace 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.
2. Loosen castle nut to back off the torque.
3. Tighten castle nut finger tight until snug.
4. Insert cotter pin. If cotter pin does not line up with hole, back castle nut up slightly until pin can be
inserted (Fig. 4).
5. Bend cotter pin over to lock nut in place. Nut should be free to move with only the cotter pin keeping
it in place.
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Trailer Axle Owners Manual FULL
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. Electric current is supplied to the trailer’s braking system when the tow vehicle’s brakes are applied.
7. From the tow vehicle’s battery, the electricity flows to the brake’s electromagnet.
8. When energized the magnets are attracted to the rotating surface of the drums.
9. This moves the actuating levers in the direction the drums are turning.
10. The actuating cam at the end of the shoe forces the primary shoe out to the drum surface.
11. The force of the primary shoe actuates the secondary shoe to contact the drum.
12. The force applied to the brake drum can be increased by elevating the current flow to the magnet.
Fig. 5
A
B
C
Callout Description
A Primary Shoe
G
F
E
D
Rev: 03.18.2014
B Actuating Lever
C Adjuster
D Magnet
E Adjusting Spring
F Secondary Shoe
G Retracting Spring
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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. 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 causes of these problems and can be easily remedied.
Prior to any adjustments, 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.
Trailer Wire Gauge Chart
Wire Gauge and Type Number of Axles Length of Run
16 Ga Stranded Copper 1 N/A
14 Ga Stranded Copper 2
12 Ga Stranded Copper 2 or 3
Under 30ft. (9.1m) from
hitch to center of axles
Over 30ft. (9.1m) from
hitch to center of axles
General Maintenance - Electric Brakes
Brake Adjustment
Prior to testing or adjusting brakes, be sure area is clear of any persons and vehicles. Failure to perform
test in a clear area may result in death or serious injury.
Lippert Components, Inc. Electric Brakes are automatic adjust only. If manual adjusting is needed, the
following 6-step procedure can be utilized. 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.
Lift unit by 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 death or serious injury.
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.
NOTE: A second screwdriver will be needed to push the auto adjusting lever away from the adjuster
starwheel so that the starwheel can be rotated backwards.
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.
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Trailer Axle Owners Manual FULL
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.
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 excellent time to check for parts that have become loose or worn.
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 must be taken when servicing brakes:
1. Avoid creating and/or breathing any brake dust.
2. Do not machine, file, or grind the brake linings.
3. Remove with a damp brush or cloth. Dry brushing or compressed air will cause the dust particles to
become airborne.
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 least 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 be 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.
Figure 6 (Page 11) 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.
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Trailer Axle Owners Manual FULL
Shoes and Linings
Linings should be replaced if the material is worn to ⁄” 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.
Fig. 6
Axle and Suspension Installation
The single most important portion of axle installation is parallel alignment of the trailer axle(s) 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.
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.
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Trailer Axle Owners Manual FULL
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. This feature allows
for even load handling from axle to axle.
Double-eye suspension systems are available on 8,000 lb. axles. Tandem and triple axle mounting kits are
available for both 33” and 35” axle spacing.
Front Hanger
Shackle Link Center Hanger
Fig. 7
Shackle Bolts
Tie Plate
Equalizer
Spring Axle Torque Specifications
Bolt Type Axle Capacity Maximum Torque
2K 25 ft-lb
Rear Hanger
Rev: 03.18.2014
U-Bolts
3.5K with ½ " 50 ft-lb
5.2K 65 ft-lb
6-8K 90 ft-lb
Minimum Torque Maximum Torque
Shackle Bolts 30 ft-lb 50 ft-lb
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Trailer Axle Owners Manual FULL
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.
Fig. 8
Outside Frame
Outside
Bracket
Dimension
NOTE: For Torsion installation, mount axle bracket to
frame bracket (Fig. 8) and torque fasteners
as specified in the chart below.
NOTE: Washer(s) must be placed against the slotted
hole in the axle bracket (Fig. 8A).
NOTE: Low profile brackets have plain round holes.
A
Rev: 03.18.2014
Torsion Axle Torque Specifications
Axle Size Bolt Size Torque Range
#8 - #9 ½ " 70-90 ft-lb
#10 - #13 ⁄" 120-150 ft-lb
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Trailer Axle Owners Manual FULL
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