Dexter Axle E/H 1000 & 16000 Brake Actuators Service Manual
Contents
1. 9 Testing and Adjustment of Controller Unit 11 Troubleshooting rdr 12 Warranty ited ii irene 15 This is the safety alert symbol It is used to alert you to potential injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Actuator Installation Instructions Getting Started The following materials are required to properly install the Dexter E H unit If your trailer is not already equipped with brake lines you will need enough 16 diameter automotive brake line to SUOIJINASU uonejjejsu connect the trailer brakes to the unit Where possible steel tubing is preferred Four 1 4 threaded fasteners to mount the unit to the trailer One quart of DOT 3 or DOT 4 brake fluid from a new sealed container One emergency breakaway kit must include a 12 volt 10 amp hour minimum battery Wire see Electrical Installation Requirements for proper wire size Location of the Dexter E H actuator is at the discretion of the vehicle owner When selecting the location the following items should be considered 1 The shorter the wiring between the unit and the electrical power source the smaller the voltage drop 2 The unit should be located so that the electrical wiring and brake lines can be neatly routed directly to the towing vehic2. axles and components are available nationwide from our plant locations listed below orthrough our network of distributors Check our website for the distributor nearest you Visit us at our website www dexteraxle com Dexter Axle Dexter Axle 11870 650 East Road 75 East Dexter Axle N Manchester IN 46962 Albion IN 46701 222 Collins Rd Fax 260 982 7511 Fax 260 636 3030 Ph 260 636 2195 Elkhart IN 46516 Ph 260 982 4047 Dexter Axle West Pearl St Fremont IN 46737 Fax 260 495 1701 Ph 260 495 5100 Fax 574 295 8094 Ph 574 295 1900 Dexter Axle 1 Municipal Dr Dexter Axle 2700 S Yates Ave Carrollton MO 64633 Los Angeles 90040 Fax 660 542 1133 Ph 660 542 2232 Fax 323 724 8193 323 726 3157 Dexter Axle 500 S E 27th St El Reno OK 73036 Fax 405 262 9089 Ph 405 262 6700 Dexter Axle Perimeter Rd Monticello GA 31064 Fax 706 468 2966 Ph 706 468 6495 Company Headquarters 2900 Industrial Parkway East Elkhart IN 46516 Fax 574 295 8666 Ph 574 295 7888 DEXTER AXLE NO PART OF THIS CATALOG MAY BE REPRODUCED WITHOUT DEXTER AXLE S PERMISSION ALL PART NUMBERS DIMENSIONS AND SPECIFICATIONS IN THIS CATALOG ARE SUBJECT TO CHANGE WITHOUT NOTICE 5 05 Dexter Axle 2005 LIT 608 00
3. running clearances are properly adjusted consistent with the trailer manufacturer s recommendations Failure to properly adjust the brakes on trailers equipped with drum brakes can result in slower response time of the Dexter E H unit juaujsnipy ayeig Hupaajg 5 Remove the dust cap from the bleed screw on the Dexter E H unit and install plastic tubing onto the bleeder 6 Immerse the free end of the plastic tubing in a clean container partially filled with brake fluid 7 With eye protection on open the bleeder screw one half turn on the Dexter E H unit Take care to protect you and the trailer from brake fluid expelled from the bleeder 8 Activate the Dexter E H unit by turning on the ignition switch and pressing on the brake pedal or the manual control on the in cab controller 9 Watch the free end of the bleeder hose for air bubbles escaping into the container 10 Continue to bleed until the fluid becomes clear and free of bubbles 11 Tighten the bleeder screw turn off the Dexter E H unit and remove the plastic tubing from the bleeder screw Bleeding of the actuator is now complete Mad 12 Install plastic tubing onto the bleeder screw of the wheel cylinder caliper 13 Immerse the free end of the plastic tube in a clean container partially filled with brake fluid 14 Open the bleeder screw one half turn on the wheel cylinder caliper farthest from the Dexter E H unit If towed vehicle has multipl
4. A dedicated ground connection between the tow vehicle and trailer is also required Breakaway Battery Requirement To comply with federal requirements the trailer must be equipped with a breakaway switch and battery The breakaway battery needs to have a minimum capacity of 10 amp hours and needs to be maintained in a fully charged condition at all times The breakaway battery should be checked for proper charge level before every use Charging the Breakaway Battery The breakaway battery must be kept fully charged at all times in order to function properly Use only those breakaway battery kits that include a charging device Do not attempt to charge the breakaway battery directly from the tow vehicle without the appropriate charging device Note The Dexter E H actuator does not draw power from the tow vehicle accessory lead unless the brakes on the tow vehicle are actuated or manual control applied sjuawaunbay 22112913 Il Test Electrical Operation 1 Attach the trailer to the towing vehicle Do not connect trailer plug to tow vehicle until step 2 is completed 2 Pull the breakaway switch The Dexter E H unit should run If the unit does not run check breakaway battery condition and system wiring Reset the breakaway switch which will turn the unit off Note When the unitis running the motor will generate a hum that changes pitch as the unit builds pressure This is normal 3 Connect trailer plug to to
5. IT E H 1000 E H 1600 COMMON GROUND TRAILER AND tow VEHICLE It is critical that the BLACK power lead WHITE ground lead from the tow vehicle to the input of the actuator are sized and properly terminated i e dedicated 25 40 amp circuit on the tow vehicle 12 gauge wire minimum 10 gauge wire is recommended to optimize performance Consult the SAE wiring guidelines for proper trailer electrical harness design Low temperature applications below 0 F require 40 amp circuit Electrical Requirements The blue wire from the in cab electronic brake control is connected to the blue wire on the actuator The yellow wire from the actuator is connected to the cold side of the trailer emergency breakaway switch Under no circumstances should the blue wire and the yellow wire be connected together Requires an In Cab Electronic Control The Dexter E H actuator is intended to be used with an in cab electronic brake controller The unit will operate with a wide variety of controllers but provides optimum performance when used with a Dexter electronic brake controller The in cab controller must have an output capacity of at least 5 amps for proper operation of the Dexter E H actuator Electrical Connections Make sure all electrical connections are clean dry weather tight and secure to prevent damage to the wiring from dragging or becoming entangled with foreign objects
6. SERVICE MANUAL DEXTER AXLE E H 1000 amp 1600 BRAKE ACTUATORS 4 DEXTER AXLE www dexteraxle com Introduction This manual has been provided to guide you through the process of installing operating and maintaining your Dexter E H 1000 or E H 1600 hydraulic brake system actuator This electrically powered unit has been designed and manufactured to give safe reliable power to your hydraulic trailer brakes Before proceeding make sure that the unit is appropriate for your particular brakes The E H 1000 produces 1000 psi pressure for hydraulic drum brakes while the E H 1600 produces 1600 psi pressure for hydraulic disc brakes This new Dexter actuator is compatible with any electric brake controller but the best performance will be achieved using an inertial type controller such as the Dexter Predator DX2 The electronic timer type of controller is not recommended because these units use a fixed control that does not sense varying brake requirements For all your running gear needs Look fost toDenter Now visit us at our web site www dexteraxle com Il Table of Contents Contents Installation INStrUCTIONS sses 3 Getting Started 3 Electrical Installation Requirement 6 Wire Colors and Function smmmeserssessrrsrersssrrssnsrssrn rr nr rr nanna 6 Test Electrical Operation 22222 rager etaper reden kande 8 Bleeding and Brake
7. connected pull the breakaway switch on the trailer a b If the unit runs and builds pressure the breakaway system is functioning properly If the unit runs and builds pressure when the breakaway switch is pulled but will not function under normal operating conditions the problem most likely is a defective in cab controller or defective wiring between the tow vehicle and Dexter E H actuator If the unit runs but will not build pressure when the breakaway switch is pulled the problem most likely is a defective valve in the Dexter E H unit If the unit does not run measure the DC voltage between the white wire and the yellow wire If the voltage is less than 12 volts either the breakaway switch or the breakaway wiring is defective 2 After completing the above steps reset the breakaway switch and reconnect the trailer plug Trailer brakes too aggressive 1 Reduce the gain setting on the in cab electronic brake controller 2 Check brake adjustment Huljooysajqnoiy Il Troubleshoooting Trailer brakes not aggressive enough 1 Increase the gain setting on the in cab electronic brake controller Dexter Axle Limited Warranty WHAT PRODUCTS ARE COVERED All Dexter trailer axles suspensions and brake control systems excluding Dexter 6000 series Manufactured Housing Axles uenem LIMITED 2 YEAR WARRANTY Dexter Axle warrants to the original purchaser that its axles suspension systems and E H hydraulic bra
8. e axles always start with the rear axle first 15 To activate the Dexter E H unit turn the ignition switch on and press on the brake pedal 16 Watch the free end of the bleeder hose for air bubbles escaping into the clear container Continue to bleed the wheel cylinder caliper until the fluid becomes clear and free of bubbles Do not run the Dexter E H actuator without adequate brake fluid in the reservoir as it will damage the unit and void the warranty Check all bleeder screws to ensure Bleeding and Brake Adjustment that they are securely closed and do not leak 17 Tighten the bleeder screw turn off the Dexter E H unit and remove plastic tubing from the bleeder screw Bleeding of the wheel cylinder caliper is now complete 18 Refill the Dexter E H unit with brake fluid 19 Continue the above process steps 12 through 18 on the next farthest brake away from the actuator 20 Repeat these steps until all the brakes have been bled Testing and Adjustment of Electronic Controller Unit 1 Adjust the gain setting on the in cab controller to a mid range setting 2 Drive vehicle at 10 to 15 m p h 3 Apply the brakes If braking is too severe adjust the gain setting down to decrease pressure and retest If braking is inadequate increase the gain setting on the in cab electronic controller and retest 4 Repeat this process until the brakes respond appropriately The appropriate pressure setting will var
9. early comparable current product 2 Dexter Axle reserves the right to furnish a substitute or replacement component or product in the event an axle or any component of the axle is discontinued or is otherwise unavailable 3 These warranties are nontransferable GENERAL THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXCEPT THAT OF TITLE WHETHER WRITTEN ORAL OR IMPLIED IN FACT OR IN LAW INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE These warranties give you specific legal rights and you may also have other rights which vary from state to state THE DURATION OF ANY IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE DURATION OF THE EXPRESS WARRANTIES HEREIN DEXTER AXLE HEREBY EXCLUDES INCIDENTAL AND CONSEQUENTIAL DAMAGES INCLUDING LOSS OF TIME INCONVENIENCE LOSS OF USE TOWING FEES TELEPHONE CALLS OR COST OF MEALS FOR ANY BREACH OF ANY EXPRESS OR IMPLIED WARRANTY INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above exclusion or limitation may not apply to you uenem Inquiries regarding these warranties should be sent to Dexter Axle P O Box 250 Elkhart Indiana 46515 Genuine Dexter
10. emove the red plastic plug from the 16 inverted flare brake port 2 Brake line must be compatible with DOT 3 amp DOT 4 brake fluid Flush existing brake system and lines with DOT or DOT 4 brake fluid prior to connecting to the Dexter E H unit 4 Connect the brake line from the trailer brakes to the 3 1 inverted flare fitting on the actuator Installation Instructions Fill the unit with DOT 3 or DOT 4 brake fluid to the bottom of the reservoir filler neck When putting the filler cap back on it should be turned clockwise until snug Always use new DOT 3 or DOT 4 brake fluid froma sealed container Never attempt to reuse old or dirty fluid Do not overfill the unit Take care to protect painted surfaces from contact with the brake fluid Wash off any spilled brake fluid Mount the emergency breakaway switch and emergency breakaway battery on the trailer as detailed in the instruction sheets provided with the emergency breakaway kit SUOIJINASU lad Electrical Installation Requirements Undersized wire will increase electrical resistance and will prevent proper operation of this unit Wire Colors and Function BLACK 30 amp 12 volt Supply From Tow Vehicle BLUE Output From In Cab Electronic Brake Controller WHITE Trailer and Tow Vehicle Ground YELLOW Cold side of breakaway switch ELECTRICAL SCHEMATIC 12 VOLT 40 AMP CIRCUIT FROM TOW VEHICLE BREAKAWAY K
11. ke actuators shall be free from defects in material and workmanship for a period of two 2 years from the date of first sale of the trailer incorporating such components LIMITED 5 YEAR WARRANTY Dexter Axle warrants to the original purchaser that its Nev R Lube bearings and the suspension components only of its Torflex axles shall be free from defects in material and workmanship for a period of five years from the date of first sale of the trailer incorporating such components LIMITED 7 YEAR WARRANTY Dexter Axle warrants to the original purchaser that its Predator Series electric brake controllers shall be free from defects in material and workmanship for a period of seven 7 years from the date of purchase EXCLUSIVE REMEDY Dexter Axle will at its option repair or replace the affected components of any defective axle repair or replace the entire defective axle or refund the then current list price of the axle In all cases a reasonable time period must be allowed for warranty repairs to be completed Allowance will only be made for installation costs specifically approved by Dexter Axle WHAT YOU MUST DO In order to make a claim under these warranties 1 You must be the original purchaser of the vehicle in which the Spring Suspension Axles or Torflex Axles were originally installed 2 You must promptly notify us within the warranty period of any defect and provide us with any substantiation that we ma
12. le and trailer brakes Special care should be taken to minimize the number of bends and fittings in the brake line circuits 3 An emergency breakaway kit must be located on the trailer so that the trailer breakaway cable can be easily attached to the towing vehicle Il 4 The Dexter E H actuator is powered from the electrical system on the tow vehicle In order for the unit to function properly it must have adequate electrical power see Electrical Installation Requirements 5 The Dexter E H unit should not be placed in an area where it is susceptible to damage from trailer loads road debris or from being stepped on Failure to protect the actuator from damage can cause the unit to malfunction and void the Dexter Axle warranty Mounting consideration should be given to the following 1 The unit must be level with the filler neck up 2 It is the responsibility of the customer to provide necessary fasteners for attachment of the actuator to the trailer The Dexter E H actuator contains sensitive electronics that must be protected Drilling additional holes in the housing or electrostatically painting the Dexter Axle E H or welding anywhere on the unit will damage the unit making it inoperable and will void the manufacturer s warranty Always remove the unit from the trailer before doing any welding repair or modifications to the trailer structure Connect the trailer brake lines to the actuator as follows 1 R
13. the Dexter Axle E H unit leaving only the blue black white and yellow wires It is important that the unit is disconnected from any other wires going to the towing vehicle or breakaway switch and breakaway battery Failure to do so may result in a faulty test 8 Using a 12 volt battery connect the white wire to the negative terminal of the battery 9 Connect the black wire to the positive terminal of the battery The motor should not run If the motor runs the unit may be defective 10 Leave the white wire connected to the negative terminal of the battery 11 Connect the blue and black wires together to the positive terminal of the battery 12 The motor should run and the unit should pressurize 13 If this does not occur the unit needs repaired 14 Leave the white wire connected to the negative terminal of the battery 15 Connect only the yellow wire to the positive terminal of the battery 16 motor should run and the unit should pressurize 17 If this does not occur the unit needs repaired 18 If the unit checks OK reconnect the wires leading to the trailer plug and repeat steps 9 through 14 at the trailer plug If you do not get the same results as before the problem is in the trailer wiring or the electronic brake controller Using the breakaway system to troubleshoot a unit that is not operating correctly 1 With a fully charged breakaway battery and trailer plug dis
14. w vehicle 4 Turn the ignition switch on and turn the in cab electronic brake controller on The Dexter E H unit should run whenever the brake pedal is depressed If the unit does not run check system wiring 5 Apply the controller manual slide The Dexter E H unit should run and brake lights come on Testing the Dexter E H unit confirms that it is operating It DOES NOT confirm that the brakes are operating properly Regular inspection adjustment and maintenance of the brakes lines hoses drums discs fluid and other associated components is necessary to ensure proper brake operation 6 Some brake controllers will not produce a high enough signal voltage to actuate the trailer brakes when the vehicle is at a standstill Minimal trailer brake force is produced when the voltage output to the E H actuator is at least 3 VDC Maximum trailer brake force is achieved at 12 VDC 7 Breakaway circuit will not function if voltage is still present at the black wire lead Test Electrical Operation Bleeding and Brake Adjustment 1 It typically is much easier to bleed the brakes with two people working together or use of a power bleeding device 2 Special care must be taken to insure that the Dexter E H unit does not run out of brake fluid Check the fluid level frequently during the bleeding process 3 Block the wheels on the trailer and towing vehicle 4 If the trailer is equipped with drum brakes check that the brake
15. y reasonably request 3 The axles or suspensions must have been installed and maintained in accordance with good industry practice and any specific Dexter Axle recommendations including those specified Il Il Warranty in Dexter Axle s publication Operation Maintenance Service Manual EXCLUSIONS These warranties do not extend to or do not cover defects caused by 1 The connecting of brake wiring to the trailer wiring or trailer wiring to the towing vehicle wiring 2 The attachment of the running gear to the frame 3 Hub imbalance or any damage caused thereby 4 Parts not supplied by Dexter Axle 5 Any damage whatever caused by or related to any alteration of the axle including welding supplemental brackets to the axle 6 Use of an axle on a unit other than the unit to which it was originally mounted Normal wear and tear Alignment Improper installation 10 Unreasonable use including failure to provide reasonable and necessary maintenance as specified in Dexter Axle s publication Operation Maintenance Service Manual including required maintenance after Prolonged Storage 12 Improper wheel nut torque 13 Cosmetic finish or corrosion LIMITATIONS 1 In all cases Dexter Axle reserves the right to fully satisfy its obligations under the Limited Warranties by refunding the then current list price of the defective axle or if the axle has been discontinued of the most n
16. y depending on the weight of the load being transported on the trailer weather conditions and road conditions The Testing and Adjustment of Electronic Controller Unit procedure should be repeated each time the trailer is used Failure to properly adjust the Dexter E H actuator may result in poor brake performance and could result in serious or 1uawjsnipy pue unsal fatal injuries and or property damage Il Troubleshooting Troubleshooting Guide Unit will not run or brakes are slow to respond To determine if the unit is functioning properly perform the checks outlined below 1 Verify that the trailer and tow vehicle are wired according to the electrical schematic shown in Electrical Requirements 2 Re bleed the trailer brakes and actuator 3 If the trailer is equipped with drum brakes re adjust the drum brakes to the trailer manufacture s recommended running clearance 4 Trailer wiring that is too small can cause slow response see section on Electrical Installation Requirements 5 Slow response can be caused by brake line restrictions The trailer brake lines must be at least 3 6 in diameter Steel tubing is preferred over flexible hoses 6 Check to see if the white ground wire runs directly to the tow vehicle ground IT MUST NOT BE GROUNDED TO THE TRAILER ONLY IT IS IMPORTANT THAT THIS GROUND WIRE RUNS DIRECTLY TO THE TOW VEHICLE S BATTERY GROUND NO EXCEPTIONS 7 Detach all wires from
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