Owner's Manual - Trailer Parts from TrailerPart.com

1 1 Owner's ManualAxles, Brakes, Hubs, and Drums2000 lbs. to 7000 of Brake The First & , Races and Manual contains information about axle assemblies, attachingparts, electric brakes and hub/drum Spring axle AssembliesRubber Torsion axle AssemblyAttaching Parts ForLeaf Spring AxlesAL-KO Kober Corporation and Hayes axle Inc. are major suppliers tothe light Trailer industry. Our axles, brakes, hubs and drums are inoperation around the world, helping trailers tow smoothly and stopsafely. Our product line is the result of years of advanced engineeringin the United States as well as Germany, where vehicular technology isunsurpassed. AL-KO and Hayes products have undergone years ofexhaustive testing and we continue to strive for superior reliability,safety and and Electric BrakeAdhering to the recommended service schedule on page 11 will ensurethe finest towing and stopping action Manual describes service and repair procedures for AL-KO Koberand Hayes axle Trailer axles.

2 Technicians must follow their employer sprocedures and these procedures when servicing or repairing equipmentor components. Before performing any service or maintenance, reviewthe Trailer manufacturer s recommendation for procedures and First!AFasteners must be tightened to aspecific torque value. The technicianmust use the proper torque wrench to perform these torque can result in product failure which could causeproperty damage, serious injury, or loss of prevent serious eye injury, always wearsafety eye protection when you perform vehiclemaintenance or AL-KO and Hayes brake liningsare asbestos free. Other brake liningsmay contain asbestos fibers, a cancer and lung disease brake linings contain non-asbestos fibers, whose long-termeffects to health are unknown. You must use caution when youhandle both asbestos and non-asbestos materials. (See page 38.)

3 This indicates a procedure that youmust follow exactly to avoid damaging equipment or componentsand to avoid serious personal injury, or loss of service and maintenance procedures are provided for use byqualified service technicians. Do not attempt to service, repair orwork on brakes or axles unless you have appropriate mechanicalknowledge and skills. You must understand all procedures andinstructions before you begin to work on a unit. Some proceduresrequire the use of special tools for safe and correct service. Failureto use special tools when required can cause damage to equipmentand components. Lack of proper training, failure to follow properprocedures, or not using proper tools or safety equipment, canresult in property damage, serious personal injury, or loss of following symbols are used to warn the user of potential dangersthat could cause serious damage to equipment or cause personal injuryor !

4 FASTENER TORQUE!WARNINGASBESTOS FIBER!WARNING6 Electric Brake Assembly(10" Left Hand Shown) Primary Shoe(Shorter Lining) MagnetAdjusterScrewSecondary ShoeTrailer FrontShoe HoldDownAssemblySlipperBlockLever ArmAL-KO and Hayes electric brakes are cam actuated, self energizingdrum brakes. Their operation is similar to automotive drum brakes butthe actuation system is different. Electric brakes are actuatedelectrically through a magnet rather than hydraulically through a wheelcylinder. The magnet is positioned so its poles are close to an armaturesurface, which is machined or bolted inside the brake drum. When themagnet is energized, it is attracted to the armature surface causing africtional force that pivots the lever arm and slipper block. This forcesthe primary shoe against the drum which energizes the secondary shoe.(Visit for animation.)Electric Brake OperationRetractSpring7 Typical Brake SystemAL-KO Kober and Hayes axle supply electric brake assemblies asshown on the opposite page.

5 Many components make up the entire braking system . Several components are not supplied by AL-KOKober or Hayes axle including:Brake ControllerResistorsConnectorsBreak-away SwitchBatteryFusesWire specific components on your braking system may vary at thediscretion of the Trailer manufacturer or dealer. Below is a schematicshowing possible components and general this total system, AL-KO and Hayes supply the brake proper function of your brakes depends on many components,please follow the vehicle or component manufacturer srecommendations when installing, using or servicing these BrakeAssembliesBreak-awaySwitch8 Before The First TripTorque wheel nuts now and thenevery fifty miles for the first 200miles and then according to theschedule on page 11. Over or under torqued wheel nuts cancause the wheel to separate from the wheel mounting surfaceduring operation.

6 Wheel separation can result in propertydamage, serious personal injury, or loss of life. (See page 24 fortorque specifications.)Adjust brakes after the first 200 miles and then asoutlined on page 11. A green brake is an unburnished manufacturing tolerances dictate that there is a break-inperiod required after which the lining will seat and become perfectlyconcentric with the drum. During this break-in period, the user mustbe aware that additional brake adjustments are mandatory to achieveoptimum braking performance. Failure to adjust brakes can result inbrake lockup, reduced brake performance, or total loss of brakeswhich can lead to serious personal injury or loss of wheel nut torque as it may loosen several timesbefore the wheel is properly seated to the wheel mounting nut torque must be checked with a torque wrench and adjustedif necessary. Do not overtighten.

7 Be sure to follow the instructions onpage the hitch or pin height of the tow vehicle so thatthe Trailer is being pulled in a horizontal position. Trailers must betowed as level as possible. If the Trailer leans down in the front it willdistribute too much weight to the front axle . If the hitch or pin heightis too high, the rear axle will receive too much of the load. Eithercondition can overload an axle even if the Trailer is not overloaded. Improper Trailer position can causetow vehicle handling problems resulting in property damage,serious personal injury, or loss of !WARNING!FASTENER TORQUE!WARNING9 Synchronize the Trailer brakes with the tow vehiclebrakes. Trailer brakes are designed to stop the Trailer . They cannotstop both the tow vehicle and Trailer . Improper synchronizationbetween the Trailer and tow vehicle brakes can overload the brakesand generate excessive heat, causing brake fade or failure.

8 Propersynchronization is achieved when the Trailer s brakes have a slightlead over the tow vehicle s brakes. This is accomplished by adjustingthe brake controller. There are several types of brake controllersavailable. See the manufacturer s recommendation for adjusting thecontroller. When done properly, there should be no sensation of thetrailer pushing or pulling the tow test before using. Be sure area isclear of traffic and pedestrians. Do notexceed 30 Follow procedures outlined by the controllermanufacturer. Failure to do so could result in property damage,serious personal injury, or loss of the Trailer after it is fully loaded and ready for , brakes, wheels, tires, frames and suspension components aredesigned to carry a specific maximum weight. Locate the VIN(Vehicle Identification Number) plate on the Trailer . It will show theGVWR (Gross Vehicle Weight Rating).

9 The GVWR is the totalamount your Trailer (including tongue weight) can weigh when it iscompletely loaded including holding tanks, propane etc. The GAWR(Gross axle Weight Rating) is the maximum load that the axles willcarry and the maximum load the brakes will stop. Follow theinstructions on page 10 for weighing the Trailer and determining the GVWR (Gross VehicleWeight Rating), the GAWR (GrossAxle Weight Rating) or having improper weight distribution canresult in reduced performance or failure of the axle (s), brakes,and other suspension components. This failure can lead toproperty damage, serious personal injury, or loss of The First Trip45 WARNING!WARNING!10 Weighing The TrailerFind a scale large enough to weigh the Trailer . They are generallyavailable at truck stops, concrete yards, grain elevators, , weigh the Trailer in its entirety (including the tongue weight)while detached from the tow vehicle.

10 This weight must be less than theGVWR (Gross Vehicle Weight Rating) on the VIN plate. If overweight,contents must be unloaded until it is within the GVWR the Trailer to the tow vehicle. Weigh the total of all trailerwheels making sure the tow vehicle is off of the scale. If this readingexceeds the GAWR, contents must be is equally important that the load is distributed evenly among all of theaxles and wheels. One axle or wheel may be overloaded even ifthe GVWR and GAWR weights are within the Trailer forward until the front axle is off of the scale. Ontandem axle trailers, both axles should be carrying about the same not, level the Trailer orredistribute the triple axle trailers, pull the Trailer forward again until thefront two axles are off the scale. Calculate the weight of each axleand balance , check weightdistribution at each the above techniqueweighing only the right orleft side.