SAF Tire Pilot Plus User manual

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

2XL-AS20015BM-en-US Rev E · 2022-10-05 · 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
Contents Page Contents Page
Introduction......................................................................... 2
Warranty.............................................................................. 2
Notes, Cautions, and Warnings............................................. 2
Section 1 – General Safety Instructions ................................ 3
Section 2 – Tire Pilot Plus Identification................................ 4
Section 3 – Installation Instructions ..................................... 5
Section 4 – Multi-Axle Trailer Installation........................... 11
Section 5 – System Inspection ........................................... 12
Section 6 – Performance Testing......................................... 12
Section 7 – Electronic Regulator Assembly Mobile APP....... 13
Section 8 – Troubleshooting ............................................... 14
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.

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
General Safety Instructions
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.

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Figure 1
Tire Pilot Plus Identification
Figure 2
Figure 4
Figure 3
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 2).
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 3).
2.2 Fixed Frame Model Identification
The fixed frame suspension serial tag is located on the frame
bracket (Figure 4).
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 3).
The Tire Pilot Plus Electronic Regulator Assembly also has a
serial number tag on the control box, and a part number tag
located on the outside as illustrated in Figure 1.
TAG LOCATED ON
REAR CROSSMEMBER
H-SHAPED CROSS
SECTION
TAG LOCATED ON
THE FRAME BRACKET
SERIAL TAG

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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
NOTE: If your axles are prepped from SAF-HOLLAND
with spindle plugs and vents skip to number 8. If
your axle does not have a tapped hole, one will
need to be drilled. If a tapped hole is present skip
to number 3.
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 5).
NOTE: An axle drilling fixture is available if required.
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. Alternatively, a weld liner, fish tape,
or other method can be used to pull the tubing from one
spindle end to the center hole (Figures 6 and 7).
NOTE: Leave enough air line out of the center hole to
reach desired location for the regulator assembly
and account for suspension travel.
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.
continued
Figure 5
Figure 7
Figure 6

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Figure 8
Figure 9
Installation Instructions
3. Installation Instructions continued
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 8).
NOTE: Use of an 1/8" metal rod to assist in getting the
1/4" tubing across the axle could be necessary
(Figure 8).
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. Push 1/4" air line into fitting until it bottoms
out in the push-to-connect fitting. Complete for both
air lines and fittings (Figure 9). Repeat this step for
roadside single fitting spindle plug. Pressurize air lines
and check for leaks with a non-corrosive solution (soap
and water) prior to installing axle plug.

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Installation Instructions
6. Insert the cylinder plug assembly into the axle. Align the
vent notch to the 12 o’clock position (Figure 10). 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 11).
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.
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
O-ring from the vent. Slide vent fitting, brass nut and
O-ring 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 additional rotation until the vent is parallel to the
axle (Figure 13). Tighten the compression nut by hand
and then use a wrench to tighten an additional 1/2 turn
(Figures 12 and 13).
Leave 12-18 inches of slack in the tube
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.
continued
Figure 10 Figure 13
Figure 12
Figure 11
VENT NOTCH
FEELER GAGE CHECK HERE BETWEEN
SPINDLE FACE AND SPINDLE PLUG
PRE-APPLIED
THREAD
COMPOUND
COMPRESSION NUT

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Figure 15
Figure 14
Figure 16
Installation Instructions
MOUNTING
SLOTS
INPUT (SUPPLY
PRESSURE)
3. Installation Instructions continued
8. Install the pressure protection valve to the air tank. Take
care to insure the ‘in’ side of the valve is connected to
the air tank.
9. Locate a secure location for mounting the electronic
regulator assembly. Mount the electronic regulator
assembly with hose and wiring connections facing down
or to the side. Use the mounting slots provided on the
bracket with included hardware. Recommended location
on sliding suspensions is the front or rear crossmembers.
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 push to
connect (Figure 15) T-fitting.
11. Connect air tank pressure protection valve air line to the
electronic regulator input in the control box (Figure 16).
If connections are mounted facing up,
water and debris in the connections can
cause trouble over time, especially in
colder climates. Also, do not mount the
electronic regulator assembly upside
down. Internal components are sensitive
to the mounting orientation. If not
properly mounted the electronic
regulator assembly can fail prematurely,
shutting down the Tire Pilot Plus system.

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Installation Instructions
Figure 17
12. Connect each axle T-fitting to the electronic regulator
output in the control box (Figure 17).
13. Secure air lines between axles, air tank, and electronic
regulator control box with 6" cable ties. Securing the air
lines to the brake hoses is recommended.
NOTE: Wire loom is recommended 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 18.
15. Install power adapter as illustrated in Figure 19. Use
dielectric grease in the connections if not already present.
16. Secure the ABS power adapter using a cable tie as
illustrated in Figure 20.
17. Route the wiring harness through the trailer cross rails to
connect the wiring to the electronic regulator control box.
If the electronic regulator 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.
continued
Figure 18
Figure 20
Figure 19
POWER CABLE
OUTPUT
(TO TIRES)

10 XL-AS20015BM-en-US Rev E · 2022-10-05 · 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
Figure 21
Figure 23
Figure 22
3. Installation Instructions continued
18. Run the wires for the trailer mounted warning light
through the trailer crossmembers. Use cable ties to
secure the wiring (Figure 21).
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. Flush mount
illustrated. (Figures 22 and 23). Connect wiring
harness to light matching the wire colors. Use dielectric
grease in the connectors. Connect the other end of the
harness to the ABS adapter connector as illustrated in
Figure 19.
20. Install the warning light decal directly above the warning
light (Figures 22 and 23).

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Multi-Axle Trailer Installation
Figure 27Figure 26
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.
Be certain to pay attention to the
orientation of the hubcap, rim, and valve
stem locations. If the orientation of the
rim to hubcap is incorrect, premature
failure of the tire hoses and/or damage
to the rims can occur. Figure 24 shows
the proper orientation for a dual steel
wheel application with 5 hand hole rims.
Figure 25 shows the proper orientation
for an aluminum wide base single
application. The hubcap fitting position is
90 degrees relative to the valve stem in
Figure 25. Figure 26 shows the
proper orientation for dual steel wheels
with 2 hand hole rims.
4. Multi-Axle Trailer 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, Figure 27).
 Install Led light for each regulator assembly.
Figure 24
Figure 25

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Performance Testing
5. System Inspection
1. Confirm 12 volt power supply and air supply to trailer.
ABS system cycles with key to confirm power to the
trailer.
2. Confirm electrical connector on the electronic regulator
assembly is connected to the wiring harness.
3. Confirm air line input and output are connected to the
electronic regulator assembly and input air pressure from
the tank has a pressure protection valve installed.
4. Confirm system warning light is off.
5. Check for air leaks with a non-corrosive (soap/water)
leak test solution at the following areas:
 Pressure Protection valve
 Air input to electronic regulator assembly
 Air output from electronic regulator assembly
 Tire hose connections
 Axle inlet/vent assembly
6. Be certain to regularly drain the air tank of moisture.
Build up of moisture in the air system can cause
premature failure of the Tire Pilot Plus system. A water
separator or other moisture control measures may be
necessary in excessively humid or moist locations.
IMPORTANT: Tire pressure should be at or below
regulator setting prior to system start-up.
Failure to correctly set tire pressure prior
to system start-up will result in reduced
product performance.
6. 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 pressure setting. The minimum recommended air
pressure is 10% above the pressure setting.
2. To check function of the light, verify air and power to the
system. The light should illuminate when power and air
are first applied.
3. To leak check the system, install a pressure gauge with a
shutoff valve up stream of it at the outlet of the control
box. Verify air and power are present. Shut the valve.
Leak rate should be less than 1 psi per minute.
4. To check the pressure setting, verify air and power to
the system. WIth the same pressure gauge as in step 3,
turn the valve so it is down stream of the gauge. Shut
the valve. Control pressure should be within +/- 5psi of the
indicated setpoint.
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 electronic regulator assembly. Alternatively,
remove the tire hose from the hubcap. Depress the check
valve at the hubcap fitting with a small screwdriver to
confirm air flow. Light may illuminate during this test.
Refer to electrical diagram part number 42210013 and air
schematic part number 42210012 for further help with system
function or installation questions.

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Electronic Regulator Assembly Mobile APP
7. Electronic Regulator Assembly
Mobile APP
1. Download the mobile application by visiting the Play
store or Apple store.
2. Install the APP to your device.
3. Open the APP and select the device tab on the top
(Figure 28).
4. Scan for the nearby device you would like to connect to
and select it in the list.
5. Once connected, select the status tab on the top.
6. In the status tab you can review the following
(Figure 29):
a. Leak Status
b. Low Supply Status
c. System Mode
d. Tire SetPoint
e. Tire Pressure
f. Supply Pressure
g. Historic Faults
Figure 28
Figure 29

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.
Troubleshooting
8. 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
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 electronic regulator
assembly
Replace electronic regulator assembly
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
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.
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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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
Tire over-inflation Let system function with power and air, the system will relieve the tire pressure to the
current setpoint.
Tire Pressure in-spec
and Warning Light
is ON
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 electronic regulator
assembly
Replace electronic regulator assembly
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
LED warning light
flashing SOS
Electronic regulator assembly error Reset the module by cycling the power off then back on or clear the faults within
the mobile app. If this doesn't eliminate the light flashing, replace the module.

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.
XL-AS20015BM-en-US Rev E · 2022-10-05 · 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.
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]
SAF-HOLLAND, INC.
1950 Industrial Blvd., Muskegon, MI 49442
www.safholland.com