SAF-HOLLAND Tire Pilot Plus User manual

XL-AS20015BM-en-US Rev B
Installation and Operation Manual
SAF-HOLLAND®Tire Pilot™Plus System

2XL-AS20015BM-en-US Rev B · 2019-09-05 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,
and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Contents
Introduction
This manual provides information necessary for the installation
of the SAF-HOLLAND Tire Pilot Plus tire inflation system.
The Tire Pilot Plus uses air drawn from the tractor to pressurize
the system.
Read this manual in its entirety before installing this product.
Updates to this manual, which are published as necessary, are
available on the internet at www.safholland.us.
When replacement parts are required, SAF-HOLLAND highly
recommends the use of only SAF-HOLLAND Original Parts. A
list of technical support locations that supply SAF-HOLLAND
Original Parts and an Aftermarket Parts Catalog are available
on the internet at www.safholland.us or contact Customer
Service at 888-396-6501.
Warranty
Refer to the complete warranty for the country in which the product
will be used. A copy of the written warranty is included with the
product or available on the internet at www.safholland.com.
Notes, Cautions, and Warnings
Before starting any work on the unit, read and understand all
the safety procedures presented in this manual. This manual
contains the terms “NOTE”, “IMPORTANT”, “CAUTION”, and
“WARNING” followed by important product information. These
terms are defined as follows:
NOTE: Includes additional information to enable accurate
and easy performance of procedures.
IMPORTANT: Includes additional information that
if not followed could lead to hindered
product performance.
Used without the safety alert symbol,
indicates a potentially hazardous
situation which, if not avoided, could
result in property damage.
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury.
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
Contents Page
Introduction......................................................................... 2
Warranty.............................................................................. 2
Notes, Cautions, and Warnings ............................................. 2
Section 1 – General Safety Instructions ................................ 3
Section 2 – Tire Pilot Plus Identification................................ 4
Contents Page
Section 3 – Installation Instructions ..................................... 9
Section 4 – Multi-Axle Trailer Installation........................... 11
Section 5 – Performance Testing......................................... 11
Section 6 – Troubleshooting ............................................... 12

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XL-AS20015BM-en-US Rev B · 2019-09-05 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,
and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
General Safety Instructions
3
1. Safety Instructions
General and Servicing Safety Instructions
Read and observe all Warning and Caution hazard alert
messages. The alerts provide information that can help prevent
serious personal injury, damage to components, or both.
Failure to follow the instructions and safety
precautions in this manual could result in
improper servicing or operation leading to
component failure which, if not avoided,
could result in death or serious injury.
All maintenance should be performed by a properly
trained
technician using proper/special tools, and safe procedures.
NOTE: In the United States, workshop safety requirements
are defined by federal and/or state Occupational
Safety and Health Act (OSHA). Equivalent laws
could exist in other countries. This manual is
written based on the assumption that OSHA or
other applicable employee safety regulations are
followed by the location where work is performed.
Properly support and secure the vehicle from unexpected
movement when servicing the unit.
Failure to properly support and secure the
vehicle and axles prior to commencing work
could create a crush hazard which, if not
avoided, could result in death or serious injury.
Installation should be performed on an unloaded trailer if
possible.
Operational and Road Safety Instructions
Before operating vehicle, ensure that the maximum permissible
axle load is not exceeded and that the load is distributed
equally and uniformly.
Observe the operating recommendation of the trailer
manufacturer for off-road operation of the installed axles.
IMPORTANT: The definition of OFF-ROAD means driving
on non-asphalt/non-concrete routes, e.g.
gravel roads, agricultural and forestry tracks,
on construction sites and in gravel pits.
IMPORTANT: Off-road operation of axles beyond the
approved application design could result
in damage and impair suspension system
performance.
In the event of suspension component failure, quickly
reduce speed as safely as possible and remove the vehicle
from traffic. If unable to remove vehicle from traffic, follow
DOT safety requirements regarding emergency situations.
Contact a qualified towing and/or service company to
assist in repairing the vehicle or to move it to a qualified
repair facility.

4XL-AS20015BM-en-US Rev B · 2019-09-05 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,
and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Tire Pilot Plus Identification
2. Tire Pilot Plus Identification
In order to identify a parts list for your system the following
information is required:
Number of axles
Tire pressure setting
Single Tires or Dual Tires
Suspension Serial number(s)
Tapered or Parallel Spindle
2.1 Sliding Suspension Model Identification
The sliding suspension serial tag is located on the rear
crossmember (Figure 1).
NOTE: This manual applies to all suspension models.
However, determine your specific model number,
write that information below and refer to it
when obtaining information or replacement parts
(Figure 2).
2.2 Fixed Frame Model Identification
The fixed frame suspension serial tag is located on the frame
bracket (Figure 3).
NOTE: This manual applies to all suspension models.
However, determine your specific model number,
write that information below and refer to it
when obtaining information or replacement parts
(Figure 2).
Figure 2
Figure 1
TAG LOCATED ON
REAR CROSSMEMBER
H-SHAPED CROSS
SECTION
Figure 3
TAG LOCATED ON
THE FRAME BRACKET

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Installation Instructions
3. Installation Instructions
1. On the top dead center or 12 o’clock position of the axle
mark the centerline. At this centerline mark, use an ‘R’
drill bit to drill a hole using tap fluid or light cutting oil.
While drilling, periodically clean away metal shavings.
Use a telescoping magnet to go inside of the axle tube
and clear any remaining metal shavings (Figure 4).
NOTE: An axle drilling fixture is available if required
(Figure 1, page 4). Contact SAF-HOLLAND
customer service for details.
2. Using a 1/8" - 27 NPSF tap and cutting oil, tap the hole
drilled in step 1.
3. Insert 1/4" DOT tubing through the center hole in the
axle. Feed the air line through the axle and out of the
curbside spindle end. Leave approximately 6" of air line
outside the spindle (Figure 5 and 6).
NOTE: Leave enough air line out of the center hole to
reach desired location for the regulator assembly.
Protective loom (not shown) should be
used over the air line within the axle.
Failure to install a protective loom could
result in chaffing the air line which, if not
avoided could shut down the Tire Pilot
Plus system.
4. Insert 1/4" DOT tubing through from the curbside to
the roadside spindle. Leave approximately 6" of air line
outside of both spindles (Figure 7).
NOTE: Use of an 1/8" metal rod to assist in getting the
1/8" tubing across the axle could be necessary
(Figure 7).
continued
Figure 4
Figure 6
Figure 5
Figure 7

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Installation Instructions
3. Installation Instructions continued
Protective loom (not shown) should be
used over the air line within the axle.
Failure to install a protective loom could
result in chaffing the air line which, if not
avoided could shut down the Tire Pilot
Plus system.
5. Start on the curbside of the axle install the dual outlet
spindle plug assembly. Ensure that both pieces of 1/4"
tubing have been cut squarely. Trim off excess air line as
necessary. If spindle plug has compression fitting, remove
the brass nut and nylon sleeve from the compression
fitting. Slide the nut and nylon sleeve onto the air line.
Push the air line firmly into the compression fitting.
Hand tighten the compression nut and use a wrench to
tighten an additional 1/2 turn. If spindle plug has push-
to-connect fitting, push 1/4" air line into fitting until it
bottoms out in the fitting. Complete for both air lines and
fittings (Figure 8). Repeat this step for roadside single
fitting spindle plug.
6. Insert the cylinder plug assembly into the axle. Align the
vent holes or the vent notch to the 12 o’clock position
(Figure 9). Insert the spindle plug into the axle until
the shoulder contacts the spindle bore. Drive the spindle
plug into the axle unit fully seated against the face of the
spindle. Check for gaps with a 0.050" feeler gauge. Repeat
this step for the roadside spindle with the single fitting
spindle plug (Figure 10).
NOTE: If the axle is a parallel spindle with cross drilled
holes, take care to locate the cross drilled holes in
the windows of the spindle plug.
Figure 8
Figure 9
Figure 10
FEELER GAGE CHECK HERE BETWEEN
SPINDLE FACE AND SPINDLE PLUG

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Installation Instructions
Axle vents must be installed, due to the
Tire Pilot Plus system not venting through
the wheel end. Failure to do so could cause
build up of pressure which, if not avoided,
could create wheel end lube leaks.
7. Apply pipe thread compound to the vent fitting threads if
not present. Remove the compression brass nut and nylon
sleeve from the vent. Slide vent fitting, brass nut and nylon
sleeve over the air line coming out of the center hole in
the axle. Feed the excess air line through the vent. Thread
the vent fitting body into the axle hand tight plus two (2)
turns. Tighten the compression nut by hand and then use
a wrench to tighten an additional 1/2 turn (Figures 11
and 12).
Leave 12-18 inches of slack in the tube
coming through the vent assembly to allow
for suspension travel. Failure to do so could
cause excessive stress on the air lines
which, if not avoided, can damage air lines.
8. Install the pressure protection valve to the air tank as
illustrated in Figure 13. Take care to insure the ‘in’ side
of the valve is connected to the air tank.
9. Locate a secure location for mounting the regulator assembly.
Use the mounting holes provided. Recommended location
on sliding suspensions is the front or rear cross-members.
On fixed frame suspensions, the recommended location is
the main trailer beam either in front of the suspensions, or
just behind the suspensions (Figure 14).
10. Connect each axle air line together with a compression
or a push to connect (Figure 15, page 8)T-fitting.
Secure the compression fitting hand tight plus an
additional 1/2 turn (Figure 15, page 8).
continued
Figure 11
PRE-APPLIED
THREAD
COMPOUND
MOUNTING
HOLES
Figure 14Figure 13
Figure 12
COMPRESSION NUT

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Installation Instructions
3. Installation Instructions continued
11. Connect air tank pressure protection valve air line to the
regulator input in the control box (Figures 16 and 17).
12. Connect each axle T-fitting to the regulator output in the
control box (Figure 18).
13. Secure air lines between axles, air tank, and regulator
control box with 6" cable ties. Securing the air lines to
the brake hoses is recommended.
NOTE: Wire loom is recommend to protect air line from
sharp corners on the trailer sub-frame.
Protective loom (not shown) should be
used over the air line. Failure to install a
protective loom could result in chaffing
the air line which, if not avoided could
shut down the Tire Pilot Plus system.
14. Locate the ABS power cable and disconnect as illustrated
in Figure 19.
Figure 17
Figure 16
INPUT
Figure 18
OUTPUT
Figure 19
POWER CABLE
Figure 15

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XL-AS20015BM-en-US Rev B · 2019-09-05 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,
and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Installation Instructions
15. Install power adapter as illustrated in Figure 20.
16. Secure the ABS power adapter using a cable tie as
illustrated in Figure 21.
17. Route the wiring harness through the trailer cross rails to
connect the wiring to the regulator control box.
If the regulator control box is located on
a sliding suspension, be sure to leave
enough wiring loose to route along the
factory coiled wires and hoses at the
stinger bracket.
18. Run the wires for the trailer mounted warning light
through the trailer cross members. Use cable ties to
secure the wiring (Figure 22).
continued
Figure 20
Figure 22
Figure 21

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Installation Instructions
3. Installation Instructions continued
19. Mount the warning light on the roadside approximately
six feet from the bottom of the trailer. Use appropriate
water proof sealant on warning light screw holes if surface
mounted. If a flush mount light is desired with hidden
wires, push the LED light out of the plastic housing. Use
the rubber grommet in a 3/4" diameter hole in the trailer
to install grommet and light. Surface mount illustrated.
(Figures 23 and 24).
20. Install the warning light decal directly above the warning
light (Figures 23 and 24).
21. Install hubcaps to hubs if not pre-installed to your axles.
Torque hubcap bolts in a opposing pattern to 12-16 ft-lbs.
22. Install tire hoses by connecting the tire side first. Fittings
only need to be hand tight. Over-tightening can cause
damage to the seals inside the fittings and possible leaks.
Figure 24
Figure 23

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XL-AS20015BM-en-US Rev B · 2019-09-05 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,
and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Multi-Axle Trailer Installation
4. Multi-Axle Installation
1. For trailers with more than 3 axles or for systems
that require 2 different tire pressure settings, multiple
regulator assemblies are required.
2. To install multiple regulators follow the steps in Section 3
with the following exceptions:
 Install ABS Y-adapter cables in series for each regulator
assembly (male connector on ABS adapter #1 to
female connector on ABS adapter #2. As illustrated in
Figure 25.
 Install Led light for each regulator assembly.
5. Performance Testing
1. Make sure air and power are being supplied to the Tire
Pilot Plus system. Voltage should be a minimum of 12 volts.
Air pressure needs to be greater than the Tire Pilot Plus
regulator setting. The minimum recommended air pressure is
10% above the regulator setting.
2. To check function of the light, verify air and power to
the system and shut the 1/4 turn valve at the inlet of the
regulator box assembly. The light should illuminate.
3. To leak check the system, verify air and power are
present and install a pressure gauge on the outlet of the
control box. Shut the 1/4 turn valve. Leak rate should be
less than 1 psi per minute.
4. To check the regulator setting, verify air and power to the
system. Install a pressure gauge on the Schrader valve
located on the side of the regulator body.
5. To verify air flow from system, first verify air and power
to the system. Check air flow by disconnecting the output
line from the regulator box assembly.
Refer to electrical diagram part number 42210013 and air
schematic part number 42210012 for further help with system
function or installation questions.
Figure 25

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Troubleshooting
6. Troubleshooting Chart
PROBLEM POSSIBLE CAUSE POSSIBLE REMEDY
Tire Pressure LOW
and Warning Light
ON
Damaged tire, rim, and/or valve stem Repair/replace tire, rim and/or valve stem
Air system valve closed Open valve
Inadequate supply pressure Supply pressure must be a minimum of 10psi greater than the desired tire pressure.
Correct as necessary.
Inadequate supply voltage Supply voltage must be a minimum of 12V DC. Correct as necessary.
Defective Pressure Protection Valve Replace pressure protection valve
Note: System cannot use the same PPV as the air suspension. A dedicated port on the
air tank is required with a dedicated pressure protection valve.
Defective pressure switch Replace pressure switch
Defective solenoid valve Replace control box assembly
Regulator out of adjustment Adjust regulator
Defective regulator Replace control box assembly
Corroded butt connectors at solenoid Replace butt connectors
Loose/leaking air lines or fittings Spray all air lines and fittings with soapy water and repair leaks as needed
Leaking rotary union Replace rotary union
Leaking tire hoses Replace tire hoses
Tire Pressure LOW
and Warning Light
is OFF
Regulator out of adjustment Adjust regulator
Inadequate supply pressure Supply pressure must be a minimum of 10psi greater than the desired tire pressure.
Correct as necessary.
Inadequate supply voltage Supply voltage must be a minimum of 12V DC. Correct as necessary
Leaking rotary union Replace rotary union
Leaking tire hoses Replace tire hoses
Tractor does not have constant
power to the center pin of the 7way
connector (constant blue)
Update tractor wiring to have constant power to the center pin of the 7way connector
(ABS constant blue)
Tire Pressure HIGH
and Warning Light
is ON
Low supply pressure Incoming pressure must be greater than 100psi, or desired tire pressure +10psi
(whichever value is higher). Correct as necessary.
Low supply voltage Incoming voltage must be greater than 12V DC. Correct as necessary.
Defective Pressure Protection Valve Replace pressure protection valve
Note: System cannot use the same PPV as the air suspension. A dedicated port on the
air tank is required with a dedicated pressure protection valve.
Regulator out of adjustment Adjust regulator
Defective pressure switch Replace pressure switch
Defective solenoid valve Replace control box assembly
Corroded butt connectors at solenoid Replace butt connectors
Loose and/or leaking air lines
and/or fittings
Spray all air lines and fittings with soapy water and repair leaks as needed
Leaking rotary union Replace rotary union
Leaking tire hoses Replace tire hoses

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XL-AS20015BM-en-US Rev B · 2019-09-05 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,
and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Troubleshooting
PROBLEM POSSIBLE CAUSE POSSIBLE REMEDY
Tire Pressure HIGH
and Warning Light
is OFF
Low supply pressure Incoming pressure must be greater than 100psi, or desired tire pressure +10psi
(whichever value is higher). Correct as necessary.
Above Mechanical Limits of system System is designed to relieve tire pressure up to a maximum of 4psi above the
regulator setting. If tire pressure is more than 4psi above regulator setting, excess tire
pressure must be manually relieved.
Tire Pressure in-spec
and Warning Light
is ON
Air system valve closed Open valve
Inadequate supply pressure Supply pressure must be a minimum of 10psi greater than the desired tire pressure.
Correct as necessary.
Inadequate supply voltage Supply voltage must be a minimum of 12V DC. Correct as necessary
Defective Pressure Protection Valve Replace pressure protection valve
Note: System cannot use the same PPV as the air suspension. A dedicated port on the
air tank is required with a dedicated pressure protection valve.
Defective pressure switch Replace pressure switch
Defective solenoid valve Replace control box assembly
Defective indicator light switch Replace indicator light switch
Note: If regulator setting is changed from the factory setting, a new indicator light
switch may be required for proper functionality. Reference installation manual for
additional details.
Regulator out of adjustment Adjust regulator
Defective regulator Replace control box assembly
Corroded butt connectors at solenoid Replace butt connectors
Loose/leaking air lines or fittings Spray all air lines and fittings with soapy water and repair leaks as needed
Leaking rotary union Replace rotary union
Tire Pressure in-spec
and Warning Light
is OFF
System is working as designed, no issue
Air Leak from axle
vent
Damaged/loose airlines or
connections inside the axle
Remove spindle plug assemblies, inspect air line connections and repair as necessary
Leaking rotary union Replace rotary union
Loose and/or leaking air lines
and/or fittings
Spray all air lines and fittings with soapy water and repair leaks as needed
Air Leak from Tire
Hose
Overtightened connections Tire hose fittings should be hand tightened. Over-tightened fittings can damage the
o-rings inside the fitting. Inspect o-rings for damage and replace as necessary.
Brake air tank
de-pressurized or low
pressure
Defective pressure protection valve Replace pressure protection valve
Note: System cannot use the same PPV as the air suspension. A dedicated port on the
air tank is required with a dedicated pressure protection valve.
Air leak between air tank and
pressure protection valve
Spray all air lines and fittings with soapy water and repair leaks as needed

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Notes

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Notes

SAF-HOLLAND USA · 888.396.6501 · Fax [phone]
www.safholland.us
SAF-HOLLAND CANADA · 519.537.3494 · Fax [phone]
WESTERN CANADA · 604.574.7491 · Fax [phone]
www.safholland.ca
SAF-HOLLAND MEXICO · 52.55.5362.8743 · Fax [phone]
www.safholland.com.mx
[email protected]
From fifth wheel rebuild kits to suspension bushing repair kits,
SAF-HOLLAND Original Parts are the same quality components used
in the original component assembly.
SAF-HOLLAND Original Parts are tested and designed to provide
maximum performance and durability. Will-fits, look-alikes or, worse
yet, counterfeit parts will only limit the performance potential and
could possibly void SAF-HOLLAND’s warranty. Always be sure to spec
SAF-HOLLAND Original Parts when servicing your
SAF-HOLLAND product.
SAF-HOLLAND USA, INC.
1950 Industrial Blvd., Muskegon, MI 49442
www.safholland.com
XL-AS20015BM-en-US Rev B · 2019-09-05 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF, and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.