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Electric to Hydraulic Disc Brake Conversion Installation and Owner’S Manual (For Aftermarket Application)

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Electric to Hydraulic Disc Brake Conversion Installation and Owner’S Manual (For Aftermarket Application) Electric to Hydraulic Disc Brake Conversion Installation and Owner’s Manual (For Aftermarket Application) Electric to Hydraulic Disc Brake Conversion Installation and Owner’s Manual (For Aftermarket Applications) Table of Contents Introduction Introduction �������������������������������������������� 1 Document Information ................................. 1 Document Information Trailer Axle Brake Inspection .......................... 1 The hydraulic disc brake assembly and kits are an Safety Information ..................................... 2 additional option for replacement brakes or the installation Resources Required ................................... 2 of current industry standards in braking. Parts List ................................................ 3 Trailer Axle Brake Inspection Installation .............................................. 3 In general, based on normal activity, trailer brakes should Mount Hydraulic Brake Actuator ....................... 3 be checked annually or every 36,000 miles, whichever Electric Brake Hubs Removal .......................... 4 comes first. If above normal trailer activity is experienced, Brake Hub Removal ................................... 4 then more frequent brake component inspections are Hydraulic Disc Brake Preparation ...................... 6 Disc Brake Assembly Installation ...................... 6 recommended. In the event the braking system encounters Inner Bearing Cone and Grease Seal Installation ..... 7 symptoms of improper application or failure, immediate New Seal Installation .................................. 7 inspection and service MUST be performed. Bearing Lubrication ������������������������������������ 7 Installing The Brake Lines ����������������������������� 8 Bleeding The System .................................. 9 Post Disc Brake Installation ........................... 9 Disc Brake Rotor and Pad Inspection ������������������ 9 Disc Brake Caliper ..................................... 9 Recommended Wheel Bearing Lubrication ���������� 9 Approved Sources: ������������������������������������ 9 Wiring Diagram ....................................... 10 Notes .................................................. 11 lci1.com 574-537-8900 1 CCD-0001284 Rev: 02.05.19 Electric to Hydraulic Disc Brake Conversion Installation and Owner’s Manual (For Aftermarket Application) Resources Required Component Inspection Periods • Cordless or Electric Drill or Screw Gun Periodic Bearing Inspection - Should be performed • Appropriate Drive Bits annually or every 36,000 miles, whichever comes first. • Flaring Tool Bearing Inspection - Should be performed annually or every 36,000 miles, whichever comes first, under normal • Reamer/De-burring Tool use, or every 3,000 - 6,000 mile increments above normal • 2 1/2” Wrench use. • 7/16” Wrench Brake Cleaning and inspection - Should be performed • 3/8” Wrench annually under normal use or every 3,000 - 6,000 mile increments above normal use. • 1/2” Wrench Bearing Lubrication Inspection - Should be performed • Torque Wrench annually unless periodic brake inspection reveals abnormal • “P” Fasteners braking performance. • Self-Tapping Screws • Screw Clips Safety Information • Metal Hydraulic Brake Line 1/4” and 3/16” • Pre-made Soft Line Extensions THE “WARNING” SYMBOL ABOVE IS A SIGN THAT • 3/16” Flaring Fittings — T’s, Barrels, Plugs and Fittings AN INSTALLATION PROCEDURE HAS A SAFETY RISK • Department of Transportation (DOT) 3 or 4 Brake Fluid INVOLVED AND MAY CAUSE DEATH OR SERIOUS • Zip Ties INJURY IF NOT PERFORMED SAFELY AND WITHIN THE PARAMETERS SET FORTH IN THIS MANUAL. ALWAYS • Wire Nuts WEAR EYE PROTECTION WHEN PERFORMING • Heat Shrink Butt Connectors THIS INSTALLATION PROCEDURE. OTHER SAFETY • 12 AWG Wire EQUIPMENT TO CONSIDER WOULD BE HEARING PROTECTION, GLOVES, AND POSSIBLY A FULL • Hard-line Brake Pipe Cutter FACE SHIELD, DEPENDING ON THE NATURE OF THE INSTALLATION PROCEDURE. PERFORMING SERVICE, REPAIR OR ROUTINE MAINTENANCE WORK CAN CAUSE PERSONAL INJURY OR DEATH. USE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHENEVER PERFORMING SERVICE WORK OR ROUTINE MAINTENANCE. MAKE SURE WORK SPACE IS CLEAN AND FREE OF SLIP OR TRIP HAZARDS. lci1.com 574-537-8900 2 CCD-0001284 Rev: 02.05.19 Electric to Hydraulic Disc Brake Conversion Installation and Owner’s Manual (For Aftermarket Application) Parts List Installation Part# Description Qty Mount Hydraulic Brake Actuator 1. Locate wiring for the brake system near the coupler of 688768 5.2-6k Disc Brake Conversion Kit (Tandem axle) 4 6 Lug 1/2” Studs the trailer. 688789 5.2-6k Disc Brake Conversion Kit (Triple axle) 6 6 2. Mark the 12 volt wire, the ground wire, the control wire Lug 1/2” Studs and the breakaway wire. 688835 5.2-8k HYBRID disc brake conversion kit (Tan- 4 dem axle) – 5 bolt brake flange 1/2” studs 3. Determine pump location. Ensure the location gives access to run wires and brake lines. 688836 5.2-8k HYBRID disc brake conversion kit (Triple 6 axle) – 5 bolt brake flange 1/2” studs 4. Using the provided “L” bracket and self-tapping screws, 689017 5.2-8k HYBRID disc brake conversion kit (Tan- 4 mount the pump on a compartment sidewall or to the floor. dem axle) – 5 bolt brake flange 5/8” studs 689018 5.2-8k HYBRID disc brake conversion kit (Triple 6 NOTE: A dampening material may be used under the axle) – 5 bolt brake flange 5/8” studs pump to reduce vibrations when the pump is running. 689156 5.2-8k HYBRID disc brake conversion kit (Tan- 4 dem axle) – 5 bolt brake flange 9/16” studs 5. Mount the control (resistor) in the same compartment near the pump. 689159 5.2-8k HYBRID disc brake conversion kit (Triple 6 axle) – 5 bolt brake flange 9/16” studs 6. Using wire nuts, connect the marked wires to the pump. 689389 5.2-8k HYBRID disc brake conversion kit (Tan- 4 dem axle) – 5 bolt brake flange 5/8” studs – OIL NOTE: The pump requires four wires to function properly: BATH Black is 12 volts of constant power, blue is to the tow 689391 5.2-8k HYBRID disc brake conversion kit (Triple 6 vehicle brake controller wire, white is the ground and axle) – 5 bolt brake flange 5/8” studs – OIL BATH yellow is for the emergency breakaway system. 689410 8k Disc Brake Conversion Kit (Tandem Axle) – 4 4 Bolt Flange 9/16” Stud NOTE: Make sure all four wires are a minimum of 12 AWG. 689413 8k Disc Brake Conversion Kit (Triple Axle) – 4 6 7. Connect the blue and white wires from the control to the Bolt Flange 9/16” Stud blue and white wires of the pump. 689421 8k Disc Brake Conversion Kit (Tandem Axle) – 4 4 Bolt Flange 5/8” Stud 689423 8k Disc Brake Conversion Kit (Triple Axle) – 4 6 Bolt Flange 5/8” Stud 689464 8k Disc Brake Conversion Kit (Tandem Axle) – 4 4 Bolt Flange 5/8” Stud – OIL BATH 689466 8k Disc Brake Conversion Kit (Triple Axle) – 4 6 Bolt Flange 5/8” Stud – OIL BATH lci1.com 574-537-8900 3 CCD-0001284 Rev: 02.05.19 Electric to Hydraulic Disc Brake Conversion Installation and Owner’s Manual (For Aftermarket Application) Electric Brake Hubs Removal Disassemble the brake hub assembly for inspection, maintenance or service as follows: NOTE: It is normal to have a small residual amount of grease on the exterior of a new hub. Most of the time, 1. Make sure unit is on level ground. simply wiping off the residual grease is an appropriate solution. However, if there is noticeable diminished braking 2. Chock tires before beginning wheel disassembly. capability or grease continues to weep, the hub should be NOTE: Chocked tires will prevent trailer from rolling while checked by a qualified service provider. It is not normal for brakes are disengaged during disassembly, cleaning, a hub to continue to weep grease after its initial installation. inspection and assembly operations. Excess grease can coat the brake pads, magnets and braking surfaces inside of the hub. 3. Loosen wheel lug nuts before raising the trailer to prevent tire from spinning during lug nut removal. 4. After lug nuts have been loosened, raise the unit until THE UNIT MUST BE SUPPORTED PER the tire spins freely. MANUFACTURER’S RECOMMENDATIONS BEFORE A. Continue to lift and support trailer per manufacturer’s WORKING UNDERNEATH. FAILURE TO DO SO MAY recommendations. RESULT IN DEATH OR SERIOUS INJURY. B. Use appropriately rated jack stands. Brake Hub Removal C. Place jack stands under the unit’s frame only. 5. Remove all lug nuts from wheel, then remove wheel from brake hub (Fig.1). ALWAYS LIFT THE UNIT BY ITS FRAME AND NEVER BY A. Set wheel and lug nuts aside for later re-assembly. ITS AXLE OR SUSPENSION. AXLE AND SUSPENSION COMPONENTS ARE NOT DESIGNED, OR RATED, B. Do not lean removed tire against unit or any jacks. FOR THE DEAD-WEIGHT, POINT-OF-CONTACT Leaning a heavy tire against a suspended trailer could LOADS THAT THE TRAILER’S FRAME IS. DO NOT GO cause damage to the outside of the unit or place undue UNDER THE TRAILER UNLESS IT IS SUPPORTED BY side pressure against a jack, possibly causing the unit to APPROPRIATELY RATED JACK STANDS. IMPROPERLY become unstable. SUPPORTED UNIT CAN COLLAPSE, CAUSING POSSIBLE SERIOUS PERSONAL INJURY OR DEATH. Wheel WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN PERFORMING SERVICE OR MAINTENANCE OPERATIONS. ALWAYS WEAR EYE PROTECTION WHEN SERVICING TRAILER AXLES, BRAKES, HUBS, SPRINGS AND WHEELS. NOT USING Axle Hub PPE MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH. Lug Nuts Fig.1 lci1.com 574-537-8900 4 CCD-0001284 Rev: 02.05.19 Electric to Hydraulic Disc Brake Conversion Installation and Owner’s Manual (For Aftermarket Application) 6. Prior to brake hub disassembly, create a clean area to 11. Pull brake or idler hub off of spindle as follows (Fig.3): place removed parts to prevent possible contamination or A. Make sure brakes have been disengaged. damage to removed parts. B. To prevent outer bearing cone falling freely from the 7. Remove dust cover from hub by prying its edge out of assembly, place one hand on the backside outer rim of the hub (Fig.1). the hub and the other hand over the outside of the hub A. If servicing a brake drum, remove the lubed dust cap bore to cover the bearing cone. with the installed lubed rubber plug. B. If brake assembly is equipped with oil lubrication, place a drip pan underneath the hub. I. Unscrew oil cap using a 2 1/2” socket wrench.
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