Disc Brakes Service Manual
Contents
1. recommends the system to be re bled after the first 100 miles Rev 01 30 2015 DISC BRAKE SYSTEM FOR TRAILERS SERVICE MANUAL Troubleshooting For trailers with surge brake actuators What Is Happening Cannot back up surge braked 12 v solenoid valve is inoperative trailer This could be caused by a worn out shock absorber in the Surge Brake Actuator The linkage pivots on the brake Lubricate per manufacturer s actuator specifications i i np Inspect hitch ball and tighten or replace as required Loose hitch What Should Be Done Check tow vehicle back up light circuit Check 12 v solenoid Should be able to hear a click when 12 v DC is applied to lead wire Check connection to tow vehicle back up light circuit Check trailer ground connection do not depend on hitch ball connection to provide ground Trailer should have dedicated ground wire connected to grounding lug Replace per manufacturer s specifications Inspect hitch and tighten or repair as required Hitch ball worn or too small Replace with properly sized and rated ball A bent push rod in the shock ME Replace per manufacturer s specifications absorber ei master indera tating Replace per manufacturer s specifications Squeaking clatter or chucking A damaged coupler assembly Replace per manufacturer s specifications Replace rotor and check calipers Low brake fluid level in master Fill and bleed brakes cylinder2. vehicle transmission is in reverse When bleeding a system with a normally closed solenoid reversing valve bleed one cycle minimum with 12 VDC applied to the solenoid The possibility of trapping air at the valve will be eliminated Use only DOT3 brake fluid Bleeding the Brake System Pressurize the brake lines according to actuator manufacturer s recommendations Air bubbles rise to the highest point in any fluid power line Be sure the brake lines are level and avoid creating high points to hold air Make sure surge brake actuator calipers are as high as possible and actuator is as low as possible during bleeding process Use a small bleeder hose that will fit over the bleeder screw on one end and the other end in a clear container of brake fluid to observe bubbling Install bleeder hose on bleed screw on first caliper bled Bleeding process works best by starting with the caliper furthest from the actuator When pressure is applied to the system open the bleeder screw at the caliper one turn Any air and pressurized brake fluid will be vented through the orifice in the screw Bleeding operation is complete when trapped air is purged from system Be sure to close bleeder screw securely after each compression stroke of the master cylinder When bleeding is complete master cylinder reservoir should be full and all bleeder screws secured closed NOTES Bleeder screw should always point up Bleed brake system thoroughly LCI
3. DISC BRAKE SYSTEM FOR TRAILERS SERVICE MANUAL TABLE OF CONTENTS Disk Brakes for Trailers Introduction Safety Information Part Identification Brake System Attributes Reversing valves Bleeding the Brake System Troubleshooting w w Rev 01 30 2015 DISC BRAKE SYSTEM FOR TRAILERS SERVICE MANUAL Disk Brakes for Trailers Introduction Combining years of experience in the trailer frame and recreational vehicle industry with the newest and most innovative technology Lippert Components Inc steps up again with the addition of our new Disc Brake System for Trailers 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 Disc Brakes provide for the finest trailer brake systems in the industry Quality comes threefold in Lippert Components Inc e The finest quality materials The latest technology and design e The quality standards maintained from materials to final assembly Allthree 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 Disc Brake System When you speak of Lippert Components Inc our quality stands beside you Safety Information T
4. Replace or build actuator master cylinder Worn out caliper pads Replace caliper pads and check rotors Leaky caliper Leaky wheel bearing grease seal Replace or rebuild calipers Clean other hardware Replace grease seal and wheel bearings as required Pack wheel bearings Re bleed as necessary Clean other hardware Caliper Mounting bracket bolts Tighten to manufacturer s specifications may be loose and or replace as necessary Spindle nut may be loose Tighten to manufacturer s specifications and or replace as necessary Torque to manufacturer s specifications Lug nuts may be loose and or replace as necessary Rev 01 30 2015 DISC BRAKE SYSTEM FOR TRAILERS SERVICE MANUAL What Is Happening One brake overheating side pull poor brake performance All brakes overheating poor brake performance Preventive Maintenance What Should Be Done Check for foreign material in brake line Check for corrosion between caliper and Caliper piston not retracting piston Check and rebuild or replace caliper Bleed system A bent guide bolt caliper REDES en ed mounting bracket E q Selmi Check wheel bearings caliper rotor and replace as required Foreign materiallin brake line Flush and clean thoroughly Re bleed system Fill with new brake fluid per Low hydraulic fluid level manufacturer s specifications Bleed brakes to eliminate any trapped air Broken or pinched brake lines Replace
5. akes only This assembly uses a floating caliper Paint will inhibit caliper movement on guide bolt sleeves and on the caliper mounting bracket Reversing valves Utilizing surge brakes requires the use of a reversing valve Disc brakes work equally well in forward or reverse and the reversing valve allows for proper function Factory installed surge disc brake actuator is installed as standard equipment Surge brake actuators without a solenoid reversing valve installed as standard equipment will require the valve to be retro fit The solenoids are wired into the tow vehicle s back up light circuit These solenoids are found in two styles Normally Open This solenoid valve is installed near the master cylinder added inline Advantages e Ease of installation not time consuming Disadvantages e In a downhill disposition positive pressure will remain in the brake line When the tow vehicle is shifted into reverse and the reverse lights are energized the solenoid reversing valve traps the pressurized brake fluid and may result in failure to back up the trailer In the event the trailer abruptly contacts an obstruction such as a curb or speed bump while in the process of backing up force of this impact is transferred wholly to the master cylinder piston and can easily damage a seal Normally Closed This solenoid valve is installed into a T fitting from the master cylinder NOTE A three port valve is also available to eliminate t
6. ating properly after every hookup and before actual towing Know or at least be familiar with local and state laws regarding towed vehicle s brake system and any applicable laws and requirements Remember to allow for extra stopping distance needed when towing a trailer Disc brakes generally require more hydraulic pressure than drum brakes Verify that the hydraulic actuator will generate hydraulic pressure adequate to safely operate disc brakes Rev 01 30 2015 Page 3 DISC BRAKE SYSTEM FOR TRAILERS SERVICE MANUAL Scheduled inspections of the trailer s brake system should comprise the following Excessive or uneven wearing on the pads Excessive wear scoring excessive heat build up cracks in or warping of rotor Correct fluid level in master cylinder Bolts firmly tightened Any fluid leaks around calipers or brake lines NOTE Inspect all areas of the LCI Disc Brake System Excessive wear on pads or damage to the rotors due to excessive pad wear will not be covered by the Lippert Components Inc Limited Warranty Part Identification Inner Bearing Outer Bearing Rev 01 30 2015 DISC BRAKE SYSTEM FOR TRAILERS SERVICE MANUAL Brake System Attributes Do not use petroleum based grease Caliper seals o rings etc are installed using silicone lubricants Petroleum based lubricants are not compatible with these seals and o rings and will cause failure Do not paint solenoid reversing valves for trailers with surge br
7. he WARNING symbol is a sign that a service or maintenance procedure has a safety risk involved and may cause death or serious injury 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 is too high or the procedure is too difficult a certified technician should be consulted before performing the necessary service Failure to correctly service the vehicle may result in death or injury The owner s manual for your unit may have more procedures for service and maintenance Installation maintenance adjustment or repair of LCI Braking System should be performed by qualified technicians only Be sure to support trailer with jack stands to safely perform brake installation maintenance adjustment or repair Always test and confirm that trailer brakes are oper
8. he T fitting A return line from the valve MUST be installed to return brake fluid into the master cylinder Advantages e Eliminates the Disadvantages with Normally Open Valves Disadvantages e Needs additional fittings extra brake line and requires drilling and tapping an access hole in the master cylinder for the return line Some OEMs install the return line in the fill cap of the master cylinder This may allow a moisture to get into the brake fluid Rev 01 30 2015 DISC BRAKE SYSTEM FOR TRAILERS SERVICE MANUAL Solenoid valves may be one wire internally grounded case or two wires ungrounded case On a two wire model they are not polarity specific Solenoid valves will have an IN and OUT to specify fluid flow direction This configuration MUST be observed when plumbing a solenoid valve Older hydraulic drum brake systems needed a 10 12 psi residual pressure maintained to keep the wheel cylinder piston seals seated To accomplish this many surge brake actuators have a check valve with diaphragm installed just inside of master cylinder output port Disc brake systems subjected to residual brake line pressure will overheat the brakes and hubs Be sure surge brake actuator is designed specifically for disc brakes and the check valve is rendered inoperative Use an ice pick or awl to perforate the diaphragm Never tow a surge braked trailer if the tow vehicle s back up light circuit is ON at any time other than when the tow
9. n onto spindle install outer bearing Install spindle washer and thread on spindle nut with slots facing outward Tighten spindle nut with a pair of slip joint pliers to approx 50 ft lbs Back off torque usually turn so that you can finger tighten the spindle nut Finger tighten drop cotter pin through slot and hole in spindle If slot in nut does not align with hole in spindle back nut off until it does never tighten past finger tight 6 Bend legs over end of spindle and be sure legs do not interfere with oil cap upon reassembly Disc Brake Pads Disc brake pads are available through auto part stores You can ask for disc brake pad kit MD215 Brake pads are a consumable item so be sure to visually check pads every 3 000 miles Be sure to also check rotor surfaces visually when you are checking the brake pads Deep groves developing on one or both rotor surfaces can indicate a caliper piston slider bolt or residual pressure problem if this ever occurs Brake rotors should be turned when disc brake pads are replaced Disc Brake Caliper The proper mounting torque for the disc brake caliper mounting bolts is 40 50 ft lbs If these are removed for servicing the brake system add blue thread locking compound to the threaded area of the bolt at time of reassembly Also lubricate the inside of caliper bushings that the slider bolts go through Be sure to only use silicone based grease The rubber bushings are not compatible with petroleum based grea
10. on pressure cold before operation 2 Check lug nut torque On first trip tighten wheel lug nuts at start and at 10 25 and 50 miles and until no torque loss occurs and full torque is maintained Check lug nuts thereafter before each trip after any excessive braking and following winter storage Be sure to repeat procedure should a wheel ever be removed from the axle hub Oil level Before every trip check to see that the oil level is up to the level indicated on the oil cap A low level can indicate a seal or cap leak Bearing Lubrication Oil Your axle bearings are lubricated with a SAE 80 90W hypoid gear oil Periodically check and refill the hub as necessary to the level indicated on the clear plastic oil cap The oil can be filled through the cap by removing the rubber plug In order to check oil level do so after unit has been parked for a few minutes Recommended Oil Lube for axle bearings Oil designation SAE 90 SAE 80W 90 SAE 75W 90 Approved Sources Union Oil Co Unocal MP Gear Lube Exxon Co Gear Oil GX 80W 90 Mobil Oil Mobilube SHC 75W 90 Pennzoil Co Gear Plus 80W 90 GL 5 Gear Plus Super 75W 90 Oil Cap and Oil Seal The clear plastic oil cap should be tightened to 25 ft lbs Over tightening can damage the sealing o ring and cause an oil leak In order to remove hub rotor assembly a gear puller may be required The oil seal is a 2 part seal where the inside diameter of the seal presses onto the spindle journal and the out
11. or repair as required Brake actuator frame damaged Replace actuator Check Operating Manual for Electric Hydraulic Actuators Check wheel bearings caliper and rotor and replace as required Residual pressure in brake line Visually inspect brakes before each trip After each hook up check trailer brake operation before travel Follow manufacturer s recommendations for use and replacement of brake fluid Wash brake assembly immediately after exposure to salt water or other corrosives Occasionally check hub and assemblies to see they are within normal operating ranges 130 175 F Brake components may be much hotter than the hub or wheel use caution during inspection NOTE Refer to LCI s Trailer Axle Owners Manual for additional information regarding maintenance schedule suspensions bearing repack instructions and wheel torque recommendations Replacement Parts For Axle Service amp Warranty or a list of replacement parts please contact Lippert Components Inc Axle Division Plant 45 2703 College Ave Goshen IN 46528 574 971 4100 ext 4925 Rev 01 30 2015 DISC BRAKE SYSTEM FOR TRAILERS SERVICE MANUAL 8 000 Lb Disc Brakes With Oil Lubrication Operation amp Service Getting Started Set up and Adjustment For proper performance all new axles should have the following checked at the specified intervals 1 Check tire pressure Set to manufacturer s recommendations check weekly check inflati
12. ses Wheel Torque Specifications On first trip tighten wheel lug nuts at start and at 10 25 and 50 miles and until no torque loss is experienced Be sure to repeat procedure should a wheel ever be removed from the axle hub Procedure Make sure vehicle has been pulled or backed straight before re tightening to ensure tires wheels do not have significant side loads being applied as would occur if unit was turned sharply before coming to rest Use a clicker or digital style torque wrench and appropriate 6 point socket A short 3 or 6 extension maybe needed so that wrench and your hand will clear wheel Keep extension length to a minimum Remove nut covers or wheel covers to access wheel nuts if equipped Set torque wrench to vehicle manufacturers specifications to check wheel nuts If wheel has been removed and is being reassembled set torque to values listed below and torque wheel nuts in 2 stages Torque to value in criss cross pattern shown below Reapply decorative trim covers if equipped Rev 01 30 2015 DISC BRAKE SYSTEM FOR TRAILERS SERVICE MANUAL Torque Sequence Rev 01 30 2015 DISC BRAKE SYSTEM FOR TRAILERS SERVICE MANUAL LIPPERT COMPONENT S The contents of this manual are proprietary and copyright protected by Lippert Components Inc LCI LCI prohibits the copying or dissemination of portions of this manual unless prior written consent from an authorized LCI representative has been provided Any unauthori
13. side diameter of the seal presses into the hub bore Therefore a gear puller is the most efficient way to remove hub from spindle A new oil seal MUST be installed before reassembly or the old seal will leak upon reinstallation and use The National seal part number is W370219BG or Transcom part number is OB2233749 for reference When reinstalling a new oil seal be sure to correctly orientate the seal Most are marked AIR SIDE This side MUST not be placed towards the oil and bearing or it will fail in service Install new seal using a block of wood and hammer to drive the seal in the seal bore square until the outer face of the seal is flush with the seal bore face Do not use permatex on rubber encased oil seals Periodic Bearing Inspection A physical bearing inspection should be conducted every 15 000 miles An inspection of the bearing condition can detect early bearing issues Upon inspection bearings should look brand new and be able to be reassembled and used if in this condition If discoloration pitting corrosion flat spots or some abnormal condition is observed the bearing and race should be replaced at the same time Bearings are available at auto part stores Rev 01 30 2015 DISC BRAKE SYSTEM FOR TRAILERS SERVICE MANUAL Bearing Part Numbers Outer bearing cone Outer bearing race Inner bearing cone Inner bearing race Spindle nut adjustment The proper method to assemble the spindle nut is as follows After hub installatio
14. zed use shall void any applicable warranty The information contained in this manual is subject to change without notice and at the sole discretion of LCI Revised editions are available for free download from www lcil com Please recycle all obsolete materials For all concerns or questions please contact Lippert Components Inc Ph 574 537 8900 Web www IciT com Email warrantyelci1 com
Download Pdf Manuals
Related Search