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9,000 - 15,000 LBS. CAPACITY
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1. LT Connect To The Trailer Ground Circuit Note Either an onboard or breakaway battery may be used Brakes are slow to respond 1 2 Braking Systems Hydraulic Re bleed the trailer brakes and actuator If the trailer is equipped with drum brakes readjust the drum brakes to the brake manufacture s recommended running clearance Slow response can be caused by trailer wiring that is too small For trailers where the E H unit is located less than 10 feet from the tow vehicle 12 gage wire is recommended for the black and white wires between the tow vehicle and the E H unit All other wires should be a minimum of 16 gauge For trailers where the E H unit is located more than 10 feet from the tow vehicle 10 gage wire is recommended for the black and white wires between the tow vehicle and the E H unit All other wires should be a minimum of 16 gauge Slow response can be caused by improper adjustment of the brake controller On inertia based electronic brake controls adjust the pendulum inertia sensor to a more aggressive setting and or increase the gain setting 34 Unit will not run when the ignition is on and the brake pedal is depressed 1 Verify that the trailer and tow vehicle are wired as detailed on the electrical schematic With the ignition switch on and the brakes not applied you should have 12 13 volts between the black and white
2. Complete Hub Kits Brake Assemblies amp Kits 4 Brake Controllers amp Actuators CE MEN S Ready for Immediate Shipment Direct to Your Door Visit us online at www dexteraxle com 89 Dexter Video Gallery In keeping with our continual commitment to industry safety and the development of innovative products please feel free to view our ongoing video gallery at www dexteraxle com video_gallery or scan the following QR codes We are confident these videos will help educate and promote the Dexter product line that you as our customer are investing in ORADI me s Bearing Genuine Torflex Maintenance Replacement Parts Suspension Axles GERD ofo s Leaf Spring Axles E H Actuator Installation AO opao m E Z Flex Suspension DENO n Genuine Brakes Nev R Adjust Brakes n ofi Removable Spindle Sway Control 90 Service Record Date Service Performed Mileage 91 Service Record Date Service Performed Mileage 92 Genuine Dexter axles and components are available nationwide from our plant locations listed below or through our network of distributors Check our web site for the distributor nearest you Visit us online at www dexteraxle com Dexter Axle Dexter Axle 301 West Pearl Street 500 South 7th Street Fremont IN 46737 Albion IN 46701 Fax 260 495 1701 Fax 260 636 3030 Ph 260
3. eeneneeneneee Warranty Dexter Axle Limited Warranty 85 Axle Identification Axle IdentifiCatioriz s to eee Ert nere ire ak drag 88 Video Gallery Dexter Video Gallery sseeeetettttette tentes 90 1091007 Jo Maintenance Schedule 3Months or 6Monthsor 12 Months or Item Function Required Weekly 3 000 Miles 6 000 Miles 12 000 Miles Brakes 1881 At Every Use operational Brake Adjust to proper operating Adjustment clearance not required with Nev R Adj brakes diu e de draw Brake Linings Inspec for wear or contamination Brakacontrolen Check for correct amperage and modulation nee 0 Inspec for cracks leaks kinks Camshaft Check for wear and Bushings breakage Anchor Pins Lubricate with approved and Rollers grease Slack Adjuster Lubricate with approved Lubrication grease Inspect wiring for bare spots fray etc Breakaway Check battery charge and At Every Use System switch operation ee or sor uses E a E oe or scoring Wheel Bearing Inspect for corrosion or and Cups wear Clean and repack Inspect for leakage Replace if removed Springs Inspect for wear loss of pring arch Suspension Inspect for bending loose Parts fasteners and wear Extreme Duty Grease Bushings cire aS ees Wheel Nuts Tighten to specified torque and Bolts values Wheels Inspect for cr
4. eese rennen 70 MeasUrilig iiir rr eret thence reperi eter eee eee 71 Adjusting Precautions seeseeeeeeeenenennen enm 72 Additional Suspension Maintenance 72 Heavy Duty Suspension Torque 73 Wheels andTires Wh els eterni eerte re A 74 Wheel Selection cetera re tat e ee tee dte a 74 Torque Requirements eese ener nnne enne nnne nn 75 Wheel Torque Sequence eene 76 Acc MM LER 77 Tire Wear Diagnostic Chart seen 78 Replacement Parts Kits Fastener Torque Specifications sneeee 79 Bearing Replacement Chart essen 80 Seal Replacement 80 Electric Brake 1 80 Brake Shoe Replacement Kits sese 8 Air Brake Shoe amp Linings needed 81 Air Brake Repair Kils encre rer eec reno tree dns 81 Disc Brake Pad Kit essere rennen nennen 81 Disc Brake Caliper Repair Kit 81 Storage Storage Preparatiofi eere ere ep dedico After Prolonged Storage Inspection Procedure Trip Preparation Checklist
5. DEXTER AXLE www dexteraxle com 9 000 15 000 LBS CAPACITY OPERATION MAINTENANCE SERVICE MANUAL Introduction This manual is designed to provide information for you to understand use maintain and service your trailer running gear system Your axles are manufactured by Dexter Axle Since 1960 Dexter s experience in the design testing and manufacturing of trailer axles has resulted in the most complete product line in the industry The Dexter running gear system consists of axles suspensions and braking systems which are engineered to provide you the finest towing and stopping performance available today Two Dexter philosophies are at work to provide you the best product available and have enabled us to maintain our position of leadership First we operate on the theory that there is always a better way for a product to operate to be manufactured and or to be serviced We are constantly striving to find that better way Secondly we maintain wall to wall production control so that all the major components of your running gear system are manufactured in Dexter facilities under our strict quality control standards These manufactured components include axle beams hubs drums spindles and braking systems as well as the components used in the attachment of the axle to the chassis Dexter has the most complete state of the art manufacturing facilities which enable us to provide you the trailer owner
6. Citgo Lithoplex MP 2 Lithoplex CM 2 Mystik JT 6 Hi Temp Grease 2 ConocoPhillips 76 Lubricants Kendall Multiplex RED 2 L427 Super Blu Grease Dexter Axle Company Lithoplex Red MP 2 Exxon Mobil Company Ronex MP Mobilith AW 2 Mobil Synthetic Grease Fuchs Renolit Uniwrl 2 Great Plains Lubricants Lithium Complex EP 2 Oil Center Research of Oklahoma Liquid O Ring No 167L Pennzoil Quaker State Company Synthetic Red Grease Royal Mfg Company Royal 98 Lithium Complex EP 2 Shell Valvoline Gadus 53 V220C Gadus S5 V220 Rotella Heavy Duty Lithium Complex 2 Valvoline Multi Purpose GM Valvoline Durablend 59 Hubs Drums Bearings Oil SAE 90 SAE 80W 90 SAE 75W 90 Approved Oil Sources Ashland Oil Valvoline Dura Blend Valvoline Power Lube CITGO Petroleum Co CITGO Premium Gear Oil MP Mystik JT 7 Mystik Power Lube Conoco Universal Gear Lubricant 80W 90 Exxon Company USA Gear Oil GX 80W 90 Industrial Oils Unlimited Super MP Gear Oil 80W 90 Kendall Refining Co Kendall NS MP Hypoid Gear Lube Lubriplate Division Fiske Brothers Refining Lubriplate APG 90 MFA Oil Company Multi Purpose Gear Oil 80W 90 Mobil Oil Corporation Mobilube SHC Mobil 1 Synthetic Gear Lube Phillips 66 Petroleum Superior Multi Purpose Gear Oil Philguard Gear Oil Philsyn Gear Oil
7. How to Measure Amperage System amperage is the current flowing in the system when all the magnets are energized The amperage will vary in proportion to the voltage The engine of the tow vehicle should be running with the trailer connected when checking the trailer braking system One place to measure system amperage is at the BLUE wire of the controller which is the output to the brakes The BLUE wire must be disconnected and the ammeter put in series into the line System amperage draw should be as noted in the following table Make sure your ammeter has sufficient capacity and note polarity to prevent damaging your ammeter With new ammeters that have inductive pickup clamps it is not necessary to cut the blue wire 311 29 3 suiejs S Bunjeig lud 21 Braking Systems Electric Magnet Amperes Chart Size Magnet Brakes Brakes Brakes 0 60 120 180 If a resistor is used in the brake system it must be set at zero or bypassed completely to obtain the maximum amperage reading Individual amperage draw can be measured by inserting the ammeter in the line at the magnet you want to check Disconnect one of the magnet lead wire connectors and attach the ammeter between the two wires Make sure that the wires are properly reconnected and sealed after testing is completed 30o 30 AMMETER The most common electrical problem is low or no voltage and amperage at the brakes Co
8. Pennzoil Products Co Gear Plus 80W 90 GL 5 Gear Plus Super 75W 90 Gear Plus Super EW 80W 90 Multi Purpose 4092 Gear Lube Oil Center Research Liquid O Ring 750 GX Sun Refining and Marketing Company Shell Oil Company Sonoco Ultra Sonoco Dura Gear Spirax A Spirax G Spirax HD Spirax S Texaco Oil Company Multigear EP Multigear SS Troco Division Royal Manufacturing Multigear Select Gear Oil Union Oil Company Unocal MP Gear Lube 76 Triton Syn Lube EP Seal Inspection and Replacement Whenever the hub is removed inspect the seal to assure that it ee is not nicked or torn and is still capable of properly sealing the bearing cavity If there is any question of condition replace the seal Use only the seals specified in the Seal Replacement Chart Bad Seal Nicks and Tears REPLACE SEAL To replace the seal 1 Pry the seal out of the hub with a seal removal tool or a screwdriver Never drive the seal out with the inner bearing as you may damage the bearing Apply a sealant similar to PERMATEX High Temp Red RTV Silicone Gasket to the outside of the seal Use only enough to provide a thin coat to prevent any excess from contaminating the rubber lip s of the seal It is okay to apply a slight amount of lube to the inner rubber lip s to aid with installing onto the spindle Note No sealant should be used if the outside of the seal is rubber coat
9. Plastic Oil Cap 7 e 20 Hex Nut Application 9 15K 9 15K Cam Bushing Spider 12 15K Air Brake Shoe Hold Down 006 086 00 9K 10K U Bolt 006 038 00 10 15K 10K GD 12K 15K U Bolt 10K 12 15K 006 1 12 00 Spring Eye Rubber Bushed 10K 12 15K 006 072 00 Equalizer Rubber Bushed Oil Hubs 021 035 00 021 036 00 021 088 00 Brake Mounting 006 017 00 79 SHy sueg juaura3e day Bearing Replacement Chart Inner Bearing Outer Bearing Dx No Industry No Dx No Industry No 9K 10K GD 031 019 014 382A 031 030 11 25520 031 019 02 387A 031 030 12 25580 10K HD 031 022 01 394A 031 019 01 382A 031 022 02 395S 031 019 02 387A 12K 031 020 01 3920 031 021 01 28622 031 020 02 3984 031 021 02 28682 15K 031 020 01 3920 031 021 01 28622 031 020 02 3984 031 021 02 28682 Seal Replacement Reference ramener LN 12 010 056 00 71 388 00 15 010 056 00 71 388 00 Electric Brake Magnets Magnet Kit Number Brake Size one magnet per kit Wire Color 124 x 3 10K K71 376 00 Replacement Parts Kits 80 Brake Shoe Replacement Kits 1274 x 396 Electric Cast Back Plate K71 499 00 LH K71 498 00 RH Electric Stamped Back Plate K71 049 00 LH K71 050 00 RH Hydraulic K71 165 00 LH K71 166 00 RH 1214 x 4 Electric Cast Back Plate K71 501 00 LH K71 500 00 RH Electric Stamped Back Plate K71 051 00 LH K71 052 00 RH Hydraulic K71 167 00 LH K71
10. 010 zi e e FAILURE TO BACK OFF THE INNER ADJUSTING NUT COULD CAUSE BEARING AND AXLE SPINDLE OVERHEATING OR DAMAGE WHICH COULD RESULT CD IN THE WHEEL LOCKING UP OR COMING OFF DURING e VEHICLE OPERATION AND LEAD TO AN ACCIDENT INJURIES OR DEATH D FAILURE TO TORQUE THE OUTER LOCKNUT PROPERLY COULD CAUSE THE WHEEL END TO COME OFF DURING VEHICLE OPERATION WHICH COULD RESULT IN AN ACCIDENT INJURIES OR DEATH 63 Axle Installation Axle amp Suspension Installation Responsibility for proper axle alignment lies with the axle installer The axle must be installed so that it will be parallel to the drive axle s of the tractor This will allow good vehicle control when cornering longer tire wear and it will eliminate dog tracking Alignment can be determined by measuring from the center of the trailer king pin to the center of each end of the axles The difference should not vary by more than 1 6 In the case of multiple axles the axles must also be in line with each other The difference between the centers of one axle and end centers of the other axle must not vary more than 78 Safety glasses should be worn at all times when assembling or disassembling axles and their components Dexter tubular axles are made of high strength steel for better fatigue life and superior welding qualities The round tubular axles provide a uniform section modulus no matter how the beam is rot
11. Dexter E H actuator Dexter Axle attempts to provide compatibility with most controllers available but is unable to anticipate design changes that might be introduced by the various controller manufacturers The E H 1000 will supply 1 000 psi for your drum brakes and the E H 1600 will generate 1 600 psi for maximum output for your Dexter disc brakes The sealed weather tight housing contains the electronics necessary to control the high pressure piston pump and proportioning valve for smooth efficient braking Vacuum Hydraulic The basic actuation system consists of a vacuum booster synchronizing valve check valve and a plumbing kit which includes all lines and fittings A vacuum supply from the engine manifold is routed to the front of the booster and the top chamber of the synchronizing valve through flexible hoses The rear of the booster and the lower chamber of the synchronizing valve are connected by a separate line The vacuum from the engine must pass through a normally closed check valve The check valve keeps gas vapor out of the system and insures that the highest vacuum available will be kept in the system With the engine running and with no brake pedal pressure a vacuum exists throughout the system The synchronizing valve is connected to the master cylinder hydraulic supply When the brake pedal is applied the hydraulic pressure in the synchronizing valve forces a poppet to open which allows atmospheric air to enter the
12. disc This action converts the kinetic energy motion into heat The heat is dissipated rapidly by the ventilated disc The floating caliper brake uses piston s situated on one side of the brake rotor Hydraulic fluid pressure pushes against the piston s to apply the inboard brake pad As the inboard pad exerts force against the rotating rotor surface the caliper moves laterally towards the trailer frame and in turn applies an equivalent force to the outboard brake pad against the rotor surface As the lining material wears the caliper will automatically maintain the proper lining to rotor clearance The floating caliper design is used on Dexter 10 000 and 12 000 Ib axle models Disc brake effectiveness is the same going either in a forward or reverse direction All Dexter disc brakes should be actuated with a braking system that is capable of providing a maximum hydraulic pressure of 1 600 psi 28 Electric Hydraulic Actuation Systems To effectively operate your hydraulic trailer brakes we recommend the Dexter E H electro hydraulic actuator controlled by the Predator DX2 electronic brake controller These high performance hydraulic power modules will supply pressurized brake fluid to your trailer brakes in proportion to the amount of braking effort called for by the towing vehicles deceleration rate It is the responsibility of the end user to ensure that their in cab electronic controller is compatible with the
13. 0 1 degree of each other A B 1 4 Ensure the lateral tension pulling force applied to the measuring tape is the same for both A and B measurements Use a tensioning device scale or optical laser to ensure accuracy Scrub Angle C D Measure distances C curbside then D roadside between axles measuring from front of axle extension to front of axle extension or axle center to center Adjust the rear axle so it aligns to the front axle These also must be equal to within of each other C D e This measurement should be as close to zero as possible The smaller the offset the lower the rolling resistance and the better the fuel economy 71 C 4 B E m d d E i c int D Figure 2 Adjusting 1 Loosen the adjustable track rod clamp bolts Figure 1 and turn the center rod to adjust as necessary per above 2 After adjusting tighten the adjustable track rod clamp nuts Figure 1 to proper torque Recheck measurements and readjust as needed Precautions 1 Always measure to the front axle ends for accurate alignment 2 Avoid measuring to rims suspension brackets hub cap vent holes brake drums etc This can result in improper alignment For accurate measurements use axle extenders 3 Always align any succeeding axles with the front axle not to the kingpin or coupler Additional
14. 3 Disassemble the U bolts nuts and tie plates 4 Remove the spring eye bolts and remove the spring and place on a suitable work surface 5 f the spring eye bushings are to be replaced press out the old bushing using a hydraulic shop press Suspensions 66 Be sure to wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious injury 6 Lubricate the rubber bushing with liquid soap not petroleum Press the new bushing into the spring eye using a hydraulic press 7 Reinstall repaired or replaced components in reverse order Note For multiple axle units the weight of each axle must be supported as outlined in Step 2 before disassembly of any component of the suspension system If the equalizer or equalizer bushings must be replaced follow the instructions above for lifting and supporting the trailer unit and then proceed as follows 1 With both axles blocked up remove the spring eyebolt keeper bolt and equalizer bolt from the equalizer to be repaired or replaced 2 Press the old rubber bushing out of the equalizer using a hydraulic press 3 Lubricate the replacement bushing with liquid soap and press into the equalizer 4 Reassemble in reverse order Be sure to wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious injury 67 suoisuadsn Suspensions Suspension Replacem
15. Adjustment Mounting and adjustment procedure If available use installation template per manufacturer s directions If template is not available use the following procedure 1 Install air chamber with proper push rod length 2 Install the slack onto the camshaft 3 Adjust the slack arm up to the point where the slack arm starts to engage into the clevis slot 4 Take the diameter pivot pin and place it into the clevis slot Hold in place at this point the pin is like a shim Aly suigjs S Buryjeig 5 Continue adjusting the slack arm back against the pin 6 When the slack arm touches the pin the slack rotation will stop The camshaft will start to rotate as you keep adjusting the slack with the wrench 7 Continue adjusting with the wrench which is now bringing the shoes into closer contact with the drum 8 As you continue to adjust spin the drum by hand to get a feel for the brake drag 9 Adjust until the drum stops 10 Adjust an additional 1 4 to 1 2 turn of the wrench 11 Pull slack away by hand from the pin 12 Remove the pin from the clevis slot 13 Align 1 2 holes 14 Insert 1 2 pin 15 Make sure the drum rotates one 1 full revolution If it did proceed to step sixteen 16 If it did not rotate one revolution remove the air chamber and slack Start over at step one 1 Do not tighten the adjuster hex nut as tight as previously done 16 Insert the pin 17 Install and
16. Manual Slack Adjustment sese 50 Introduction to Troubleshooting esseeeeenennenn 52 Troubleshooting Chart Air 53 Hubs Drums Bearings Hubs Drums Bearings 1 1 tet rete tli teet poete 55 H b Removal srh rrt ree 55 Brake Drum 55 Beating Inspection 1 rire rnnt nennen tette 56 Bearing Lubrication Grease 57 Bearing Lubrication Oil sess 58 Recommended Wheel Bearing Lubrication Specs 59 Seal Inspection and 61 62 Axle Installation Axle amp Suspension Installation 64 Suspensions SUSPENSION SySteMS marn i andi deel 65 Slipper Leaf 65 Inspection and 66 Suspension Replacement ssssssssssssssseeeeeenenee 68 Torflex Suspension sesessseseeeneeeneenennn re nemenens 68 Heavy Duty Suspension Axle 70 Alignment Procedure
17. Tire Pressure Inflate Evenly on Both Sides to Req Pressures Pulls to One Side Unmatched Tires on Same Axle Match Tires on Axle Restricted Brake Lines or Hoses Repair or Replace Malfunctioning Cylinder Check for Stuck or Sluggish Pistons Assembly Defective or Damaged Shoe and Lining Install New Shoe and Lining Complete Axle One Side Out of Adjustment Adjust Improper Fluid Replace Rubber Parts Fill with DOT4 Fluid Dragging Blocked Master Cylinder Open with Compressed Air or Replace Cylinder Braking Systems Hydraulic Parking Brake Cable Frozen Free Cable and Lubricate Improper Lining Thickness or Location Install New Shoes and Linings 32 SYMPTOM Troubleshooting CAUSES REMEDIES Broken or Kinked Brake Line Repair or Replace No Brakes Severe Underadjustment Adjust Brakes Malfunctioning Actuation System Troubleshoot System Brake Adjustment Not Correct Manual Adjust Brakes Automatic Make Several Reverse Stops Excessively Worn Brake Linings Replace Shoe and Lining Incorrect Lining Install Correct Shoe and Lining Grease or Fluid Soaked Lining Repair Grease S
18. are actuated In an emergency situation they can provide some braking independent of the tow vehicle Retractor Spring Secondary Shoe Primary Shoe WY EN Self Adjusting Cable Actuating Lever Centering Springs 2 Backing Plate Adjuster Spring hidden Adjuster Assembly Adjuster Lever Left Hand or Road Side Brake Shown Note Actuating lever should always wrap around front side of axle magnet wires should exit brake backing plate on rear side of axle Self Adjusting Feature 12 Brake Series Only Forward self adjust electric brakes were introduced in October of 1996 This feature adjusts the brakes on both forward and reverse stops Brake adjustment occurs when lining wear results in enough gap between the shoes and the brake drum surface This added clearance will allow the adjuster mechanism to rotate the screw assembly at the bottom of the brake That action expands the distance between the shoes and thus closes the gap to the drum surface Brake Controllers Electric brake controllers provide power to the magnets to actuate the trailer brakes Dexter Axle offers a state of the art inertial controller called the Predator DX29 This controller features an accelerometer design which senses the deceleration of the towing vehicle and sends a proportional voltage to the electric trailer brakes Other features include a visual gain setting for quick and eas
19. make small adjustments occasionally to accommodate changing loads and driving conditions Proper synchronization of tow vehicle to trailer braking can only be accomplished by road testing Brake lockup grabbiness or harshness is quite often due to the lack of synchronization between the tow vehicle and the trailer being towed too high of a threshold voltage over 2 volts or under adjusted brakes Before any synchronization adjustments are made your trailer brakes should be burnished in by applying the brakes 20 30 times with approximately a 20 m p h decrease in speed e g 40 m p h to 20 m p h Allow ample time for brakes to cool between application This allows the brake shoes and magnets to slightly wear in to the drum surfaces Trailer Wire Size Chart Recommended Number Hitch to Axle Minimum Hookup of Brakes Distance in Feet Wire Size Copper 30 12 AWG 30 10 AWG 30 50 8 AWG 30 50 10 AWG Braking Systems Electric Synchronizing Your Trailer Brakes To insure safe brake performance and synchronization read the brake controller manufacturer s instructions completely before attempting any synchronization procedure Before road testing make sure the area is clear of vehicular and pedestrian traffic Failure to brake safely could result in an accident and personal injury to yourself and or others Make several hard stops from 20 m p h on a dry paved road free of sand
20. of brake shoes and linings the brakes must be re burnished to seat in the new components This should be done by applying the brakes 20 to 30 times from an initial speed of 40 m p h slowing the vehicle to 20 m p h Allow ample time for brakes to cool between applications This procedure allows the brake shoes to seat in to the drum surface Hardware Check all hardware Check shoe return spring hold down springs and adjuster springs for stretch or wear Replace as required Service kits are available Instructions for 10 12K Hydraulic Disc Brakes Notice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance Preparation 1 Jack up trailer and secure on adequate capacity jack stands Follow trailer manufacturers recommendations for lifting and supporting the unit Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 Remove the wheel from the hub leaving the brake exposed Removal of Old Brake Caliper 1 With tire wheel assembly s removed from hub and zero pressure in hydraulic system remove hex nuts from slider bolts and withdraw bolts from brake assembly Note orientation of anti rattle springs Lift calipers from assembly and secure to
21. often controlled by a series of control valves and servos to insure proper braking under all conditions 30 Introduction to Troubleshooting Proper brake function is critical to the safe operation of any vehicle A properly installed vacuum hydraulic electric hydraulic or air hydraulic system should not require any special attention with the exception of routine maintenance as defined by the manufacturer If problems occur the entire tow vehicle trailer braking system should be analyzed by a qualified mechanic Typical problems in a hydraulic braking system are Air or vacuum leaks Hydraulic system leaks Air in brake lines Water or other impurity in brake fluid Rusted or corroded master or wheel cylinders Actuation system malfunction Please consult the following troubleshooting charts to determine the causes and solutions for common problems found in trailer braking systems 31 9iine1jp H suia s S Burjeig SYMPTOM Troubleshooting Noisy Brakes CAUSES REMEDIES Underadjustment Adjust Lack of Lubrication Lubricate Broken Brake Components Replace Components Incorrect Brake Components Correct Loose Bent or Broken Brake Components Replace Components Locking Brakes Underadjustment Adjust Out of Round Drums Machine or Replace Incorrect
22. spring is held in the off position by the air diaphragm When the air is exhausted the spring provides the braking force to the air chamber pushrod thus actuating the brakes Do not disassemble the spring brake It contains a compressed spring that may cause injury if removed The spring brake must be caged before servicing and should only be performed by qualified personnel 43 Aly swaysks Buryjeig Braking Systems Air Slack Adjusters The air brake slack adjusters perform two functions 1 The slack adjuster acts as a lever arm to convert the linear pushrod force to rotational camshaft torque The length of the slack adjuster determines the amount of torque multiplication provided from the pushrod 2 Allows a simple external adjustment of the lining to drum clearance to compensate for shoe lining wear There are two types of slack adjusters manual and automatic Manual slack adjusters The manual slack adjusters require manual adjustment to compensate for the brake lining wear and the associated drum to lining gap that results Adjustment is usually performed by rotating the hex adjusting nut on the slack adjuster body to set a lining to drum clearance of about 020 030 See instructions for manual slack adjustment procedure Automatic slack adjuster The automatic slack adjuster ASA maintains an optimum clearance between the brake lining and the drum by automatically adjusting on the return stroke d
23. tas 26 Self Adjusting Mechanism for 12 Brakes 26 Hydraulic Parking Brake Option eee 26 Hydraulic Disc Brakes sse 28 Electric Hydraulic Actuation Systems 29 Vacuum Hydraulic 29 Air Hydraulic 90 Introduction to Troubleshooting 91 Troubleshooting Chart Hydraulic 32 Electric Hydraulic Troubleshooting Guide 94 General Maintenance Hydraulic Brakes 36 Drum Brake Adjustment 36 Wheel Cylinders 37 e Brake Lines 497 t Shoes and Linings 37 d Hardware eiecit eee coerente 38 Instructions for 10 12K Hydraulic Disc Brakes 38 em Hydraulic Disc Brake Parts nennen 41 C Braking Systems Air e S GCami Air Brakes oe e cp eC edi lum Operation e Air Brake Components Air Chambers a Spring Brake 5 Slack Adjusters S Cams Brake vus General Maintenance Adjustment sse Brake Component Lubrication 1274 Quick Change Brakes PQ T Recommended Recommended 47 Air Brake Automatic Slack 49 Air Brake
24. with the finest product possible For all your running gear needs Look fost toDenter Visit us online at www dexteraxle com Introduction Maintenance Schedule seen Important Safety Notice Getting Started Setup and Adjustment sse 5 Answers to Commonly Asked Questions seeeee 6 Braking Systems Electric Electric Brakes err rere nere etr reri n ees 8 AECT T 10 Self Adjusting Feature Brake Controllers ell How To Use Your Electric Brakes Properly 12 Trailer Wire Size Chart 12 Synchronizing Your Trailer Brakes General Maintenance Electric Brakes 24 Brake Adjustment 14 Brake Cleaning and Inspection ats Brake Lubrication 15 16 6 17 Introduction to Troubleshooting 18 Troubleshooting 18 Troubleshooting Chart Electric 19 How to Measure Voltage 21 How to Measure Amperage 21 Magnet Amperes Chart 22 Braking Systems Hydraulic Hydraulic Brakes 24 Hydraulic Drum Brake Operation 25 Duo Servo 25 Uni SerVO isle a earch
25. 168 00 RH 1214 x 5 Electric Cast Back Plate K71 503 00 LH K71 502 00 RH Electric Stamped Back Plate K71 053 00 LH K71 054 00 RH Hydraulic K71 169 00 LH K71 170 00 RH Air Brake Shoe amp Linings Shoe amp Lining No ma e Model EHEDIDMEN Size Required per Brake OKHD HD o dqmwxa 4 040 321 01 321 01 Air Brake Repair Kits Description AxeMode Kit Number SHy sueg u3waLjd y Camshaft PQ Style Repair Kit 10 15K K71 101 00 Brake Shoe PQ Style Hardware Kit 10 27K K71 460 00 Disc Brake Pad Kit 10K or 12K K71 180 00 Disc Brake Caliper Repair Kit 10K or 12K K71 181 00 lad 81 Storage Storage Storage Preparation If your trailer is to be stored for an extended period of time or over the winter it is important that the trailer be prepared properly 1 Remove the emergency breakaway battery and store inside out of the weather Charge the battery at least every 90 days 2 Jack up the trailer and place jack stands under the trailer frame so that the weight will be off the tires Follow trailer manufacturer s guidelines to lift and support the unit Never jack up or place jack stands on the axle tube or on the equalizers Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedl
26. 495 5100 Ph 260 636 2195 Company Headquarters 2900 Industrial Parkway East Elkhart IN 46516 Fax 574 295 8666 Ph 574 295 7888 Dexter Axle 500 Southeast 27th Street El Reno OK 73036 Fax 405 262 9089 Ph 405 262 6700 Dexter Axle 199 Perimeter Road Monticello GA 31064 Fax 706 468 2966 Ph 706 468 6495 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 GEARED FOR INNOVATION SINCE 1960 www dexteraxle com 2900 Industrial Parkway East m Elkhart IN 46516 Phone 574 295 7888 m Fax 574 295 8666 ISO 9001 Certified Front cover photo courtesy of Lehigh Career amp Technical Institute
27. Broken Brake Components Replace Components Out of Round Brake Drums Machine or Replace Insufficient Wheel Load Adjust System Resistor and Synchronize Faulty Controller Test amp Correct Intermittent Brakes Broken Wires Repair or Replace Loose Connections Find amp Repair Faulty Ground Find amp Repair 19 311129 3 suiejs S Hulyesg SYMPTOM CAUSES Troubleshooting REMEDIES Wrong Magnet Lead Wire Color Correct Incorrect Adjustment Adjust Brakes Pull to One Side Grease or Oil on Linings or Magnets Clean or Replace Harsh Brakes Broken Wires Find amp Repair Bad Connections Find amp Repair Underadjustment Adjust Correct Improper Controller Change Faulty Controller Test amp Correct Underadjustment Adjust Noisy Brake Lack of Lubrication Lubricate Broken Brake Components Replace Component Incorrect Brake Components Correct Grease or Oil on Linings or Magnet Clean or Replace Surging Brakes Out of Round or Cracked Bra
28. Shoe If the brakes are applied while the vehicle is backing the shoes rotate in the direction of the drum rotation This causes the secondary shoe to leave the anchor and causes the primary shoe to move against the anchor Action of the brake is the same in reverse as forward 25 9iine1jp H suiajs S Burjeig Braking Systems Hydraulic Uni Servo This type of hydraulic brake utilizes a single acting cylinder Upon actuation the primary shoe is pressed against the brake drum which causes the shoe to move in the direction of rotation This movement in turn actuates the secondary shoe through the adjuster link assembly Braking in reverse is significantly less Aduster Spring Adjuster Assembly effective than in the forward direction Uni servo brakes are normally used with surge type actuators Anchor Post Hydraulic Wheel Cylinder Actuating Pin Primary Shoe Self Adjusting Mechanism for 1214 Hydraulic Brakes Forward self adjust hydraulic brakes were introduced in March 1997 This feature adjusts the brakes on both forward and reverse stops Brake adjustment occurs only when lining wear results in enough gap between the shoes and the drum surface This added clearance will allow the adjuster mechanism to rotate the screw assembly at the bottom of the brake That action expands the distance between the shoes and thus closes the gap to the drum surface Hydraulic Parking Bra
29. Suspension Maintenance Check Track arms should be checked for clearance If slack is found it should be repaired immediately since this indicates that there is wear in the rubber bushing or track arm parts Check the adjustable track arm clamps for proper torque Loose clamps will Suspensions 72 cause wear on the adjusting threads and the suspension cannot be kept in alignment On leaf spring type suspensions have the trailer checked for axle alignment after two to three thousand miles Check leaf springs for broken leaves Replace broken leaves immediately to prevent the other leaves from being overloaded On taper leaf springs be sure the plastic liner is serviceable and on top of the spring The liners between leaves should be in place and serviceable suoisuadsn Heavy Duty Suspension Torque Requirements Before torquing equalizer bolts level equalizers parallel to main frame members After initial break in period up to 1 000 miles and at least every 4 months thereafter all bolts and nuts should be checked to ensure recommended torque is being maintained Minimum Torque Values for Bolts With Clean Dry Threads Torque Min Torque Max Description Ft Lbs Ft Lbs 18 7 UNC Nut Oiled 565 615 Dry 765 815 1 8 UNC Nut 275 325 Spring Keeper Nut 18 UNF 35 50 Track Rod Clamp Nut 56 18 UNF 130 170 73 Wheels Wheel Selection Wheels are a very important and critical component of your ru
30. Y BREACH OF ANY EXPRESS OR IMPLIED WARRANTY 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 AuegeueMw Inquiries regarding these warranties should be sent to Dexter Axle Company P O Box 250 Elkhart Indiana 46515 Note Current publication Operation Maintenance Service Manual can be found at www dexteraxle com lud 87 1 Axle Identification In the unlikely event that you should require service assistance from Dexter Axle please have the lot number of the axle available when you call On all axles produced after April 2001 this nine digit number can be found on the rear side of the axle beam approximately 18 from the curb side of the vehicle Look for the words DEXTER AXLE and the lot number will be located directly under the name Axle Identification 88 Dexter Online Parts Store From magnets and seals to complete brake and hub kits Dexter offers a complete line of genuine replacement parts for your trailer Most products are available in stock and ready to ship within 24 hours direct to you from the factory With dedicated customer support quick turnaround and a 30 day money back guarantee the Dexter Online Parts Store helps keep your trailer going Hub Components Brake Components Suspension Components GENUI TE Neg
31. acks dents or distortion Tire Inflation Inflate tires to mfg s Pressure specifications Tire Condition Inspect for cuts wear bulging etc Seals Introduction Important Safety Notice Appropriate service methods and repair procedures are essential for the safe reliable operation of all running gear as well as the personal safety of the individual doing the work This manual provides general directions for performing service and repair work with tested effective techniques Following these guidelines will help assure reliability There are numerous variations in procedures techniques tools parts for servicing axles as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Anyone who departs from the instructions provided in this manual must first establish that they neither compromise their personal safety nor the vehicle integrity by their choice of methods tools or parts Refer to your vehicle manufacturer s owners manual for additional procedures techniques and warnings prior to performing any maintenance or repairs 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 Getting Started Setup and Adjustment For proper performance all new axles should have the fol
32. aft Bushings Brake Adjustment 3 Adjust Not Correct Harsh Brakes Oil on Linings Replace Linings Wrong Brake Use Only Approved Component Dexter Components 53 SYMPTOM Troubleshooting CAUSES REMEDIES Cams Froze in Replace Camshaft Park Position Bushings Wrong Size Air Chamber Use Correct Size Air Chamber Brake Lock Up Incorrect Slack Adjuster Length Use Correct Length Slack Adjuster Air System Timing Malfunction Too Low Relay Valve Crack Pressure Quick Release Valve Malfunction Troubleshoot per System Mfgr s Directions S Cam Flipped Due to Brake Lining Wear Replace Linings Adjust Broken Return Determine Cause of Surging Brakes Springs Breakage and Replace Grease or Oil nen on Linings Replace Linings Out of Round Turn or Replace or Cracked Drums Drums Linings Dragging Due to Weak or Broken Return Spring Replace Return Springs Wrong Component in Brake Use Only Dexter Approved COmponents Overheating Brakes Braking Systems Air Bearing Adjustment Re adjust Air System Malfunction Sticky Valves Dirt etc Troubleshoot per System Mfgr s Directions Improp
33. and gravel If the trailer brakes lock and slide decrease the gain setting on the controller If they do not slide slightly increase the gain setting Adjust the controller just to the point of impending brake lockup and wheel skid 311 29 3 suiejs S Bunjeig Note Not all trailer brakes are capable of wheel lockup Loading conditions brake type wheel and tire size can all affect whether a brake can lock It is not generally considered desirable to lock up the brakes and slide the tires This can cause unwanted flat spotting of the tires and could also result in a loss of control If the controller is applying the trailer brakes before the tow vehicle brakes then the controller adjustments should be made so the trailer brakes come on in synchronization with the tow vehicle brakes For proper braking performance it is recommended that the controller be adjusted to allow the trailer brakes to come on just slightly ahead of the tow vehicle brakes When proper synchronization is achieved there will be no sensation of the trailer jerking or pushing the tow vehicle during braking General Maintenance Electric Brakes Brake Adjustment Most Dexter 1274 electric brakes have a self adjusting feature If manual adjusting is required use the following procedure Brakes should be adjusted 1 after the first 200 miles of operation when the brake shoes and drums have seated 2 at 3 000 mile intervals 3 or as use and pe
34. ated Brake spiders are positioned and welded to specific requirements at our factory Welding the spider directly to the axle beam provides a higher strength and more reliable brake attachment over bolt on versions In welding suspension components to a Dexter trailer axle extreme care must be exercised to obtain correct location and ensure the spring seat load bearing surfaces are parallel to each other Any welding of additional attachments to the axle should be approved by Dexter Axle s engineering department 64 Suspension Systems co N The suspension systems incorporated into Dexter axles are T designed to provide the trailer owner three basic functions 1 Attach the axle to the trailer a 2 Dampen the effects of road shock 3 Provide stability to the trailer ce All Dexter suspension systems are available in single and multiple axle configurations Slipper Leaf Springs Slipper springs have an eye formed in one end only with the other end formed into a reverse curve The attachment of these springs is as follows 1 The front eye is attached directly into the front hanger with a bolt and nut 2 The rear end of the spring is captured in the rear hanger or equalizer with a keeper bolt that prevents the spring from coming out when the trailer is jacked up for service Spring Eye Center Bolts U Bolt Hanger U Bolt Front Hanger Rear Hanger Spring Eye Bolts Tie Plate Equalizer Ti
35. bottom oijneapAy suia s S Burjeig 29 Braking Systems Hydraulic chamber of the valve Since this part of the valve is connected to the rear of the vacuum booster the vacuum on this side of the booster chamber is lost The vacuum on the front side of the booster chamber is maintained and this atmospheric vacuum pressure differential causes a piston to move in the booster s slave cylinder This piston applies the hydraulic pressure to the brakes through the connecting hydraulic line When the pedal is released the poppet in the synchronizing valve is closed and by internal passages the air in the rear of the booster chamber is removed This restores a vacuum which is equal to the vacuum in the front part of the booster chamber The pressure balance allows the slave cylinder piston to be pulled back to its original position and the hydraulic pressure to the brakes is released Air Hydraulic Air hydraulic braking systems are commonly used when the tow vehicle has a diesel engine which does not develop manifold vacuum The air hydraulic tow vehicle has an air compressor mounted on the engine to supply compressed air for the braking system and other needs required by the tow vehicle trailer combination This air is routed to a booster chamber attached to the trailer master cylinder The air pressure multiplies hydraulic output pressure which then sends fluid to the wheel cylinders The air over hydraulic systems are
36. d drums loose parts etc Replace defective parts with genuine Dexter replacements Please consult the following troubleshooting charts to determine the causes and solutions for common problems found in trailer braking systems Best braking performance is achieved with a controller setting that is just short of wheel lock up or slide Overly aggressive braking which results in wheel lock up and sliding can cause a dangerous loss of control and result in personal injury or death SYMPTOM CAUSES Open Circuits Troubleshooting REMEDIES Find amp Correct No Brakes Severe Underadjustment Adjust Brakes Faulty Controller Test amp Correct Short Circuits Find amp Correct Grease or Oil on Magnets or Linings Clean or Replace Corroded Connections Clean amp Correct Cause of Corrosion Worn Linings or Magnets Replace Weak Brakes Scored or Grooved Brake Drums Machine or Replace Improper Synchronization Correct Underadjustment Adjust Brakes Glazed Linings Reburnish or Replace Overloaded Trailer Correct Underadjustment Adjust Improper Correct Synchronization Locking Brakes Faulty Controller Test amp Correct Loose Bent or
37. dic inspection of the fasteners used to attach the Torflex axle to the vehicle frame no other suspension 68 maintenance is required on Torflex axles They are of course N subject to the maintenance and inspection procedures regarding brakes hubs bearings seals wheels and tires as outlined in this manual N DO NOT WELD ON THE TORFLEX BEAM It has rubber cords inside and the heat generated by welding could damage the cords 69 Suspensions Heavy Duty Suspension System Axle Alignment Alignment For safe and efficient trailer operation to prevent excessive tire wear off tracking and hard pulling it is recommended that after a short break in period you have a qualified trailer mechanic check the alignment To align a four 4 spring suspension the track arms need to be adjusted There is one adjustable track arm rod on each axle typically on the road left side Loosen the clamp nuts at each end of the adjusting bolt so the adjusting rod can rotate see Figure 1 Align front axle with the king pin or coupler and adjust rear axle parallel to the front axle Be sure to secure the clamps on the adjustable track arm after alignment see Figure 1 Alignment Procedure Figure 1 Before taking axle alignment measurements make sure the trailer is unloaded and free the suspension of any binds by pushing the trailer backwards and then pulling the trailer forward While pulli
38. e Plate The articulation of this suspension occurs when the rear end of each slipper spring slides against the wear surfaces provided in the rear hangers or equalizers This suspension is also available in single and multiple axle configurations Mad 65 Inspection and Replacement All the components of your suspension system should be visually inspected least every 6 000 miles for signs of excess wear elongation of bolt holes and loosening of fasteners Whenever loose or replaced the fasteners in your suspension system should be torqued as detailed in the charts at the end of this book Fastener Torque Values Worn spring eye bushings sagging springs or broken springs should be replaced using the following method Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 1 Support the trailer with the wheels just off the ground Follow the trailer manufacturer s recommendations for lifting and supporting the unit Do not lift or place supports on any part of the suspension system 2 After the unit is properly supported place a suitable block under the axle tube near the end to be repaired This block is to support the weight of the axle only so that suspension COMPONENTS can be removed
39. e emery paper or crocus cloth Protect bearings from contamination while so doing Inspect oil or grease seals for wear or nicks Replace if necessary Lubricate hub bearings Refer to procedure in manual Reinstall hubs and adjust bearings per instructions in manual Mount and tighten wheels per instructions in manual 83 01 Trip Preparation Checklist There are a number of simple rules to follow in caring for your trailer axle assembly that can add to its life and in the case of some of these rules you may be protecting your own life as well Using the following checklist before starting a trip with your trailer is highly recommended Some of these items should be checked 2 3 weeks prior to a planned trip to allow sufficient time to perform maintenance 1 Check your maintenance schedule and be sure you are up to date 2 Check hitch Is it showing wear Is it properly lubricated Storage Fasten safety chains and breakaway switch actuating chain securely Make certain the breakaway battery is fully charged Inspect towing hookup for secure attachment Load your trailer so that approximately 10 of the trailer s total weight is on the hitch For light trailers this should be increased to 15 Fifth wheel type trailer should have 15 25 weight on the hitch Do Not Overload Stay within your gross vehicle rated capacity consult your trailer s identification plate Inf
40. eal or Wheel Cylinder Install New Shoe and Lining Weak Brakes Frozen Master Cylinder lor Wheel Cylinder Pistons Recondition or Replace All Cylinders Brake Fluid Glazed Lining Reburnish or Replace Excessive Drum Wear Replace Trapped Air in Lines Bleed System Overloaded Trailer Correct Malfunctioning Actuating System Troubleshoot System Harsh Brakes Brake Adjustment Not Correct Manual Adjust Brakes Automatic Make Several Reverse Stops Grease or Fluid Replace Shoes Surging Brakes on Linings and Linings Grease or Oil on Linings Clean or Replace Out of Round Drums or Cracked Drums Machine or Replace 33 oijneapAy suia s S Buryjeig aD Electric Hydraulic Troubleshooting Guide Electrical Schematic Trailer From Tow Vehicle Controller Plug Typically Blue 12 Volt 40 Amp Circuit From LAM White Tow Vehicle Ground From Tow Vehicle Blue Lanyard BLACK WHITE Break Away Switch Minimum Yellow 9 Amp Hour Breakaway Battery Black Blue Hydraulic Line Light Blue Yellow White Charger
41. ed For these type of seals it is recommended to apply a thin coat of oil to the outside rubber Clean the seal journal of the spindle to inspect for nicks or roughness Use a file to remove any burrs from the leading edge or shoulder area Clean the journal area with very fine emery cloth Any presence of deep gouges or scratches in this area may cause seal failure allowing lubricant to leak out of the hub Clean the seal bore in the hub and inspect for any nicks gouges or scratches that may prevent the seal from retaining the bearing lubricant inside the hub Orient the seal properly Many oil bath seals will be marked AIR SIDE on the side of the seal to facing out of the hub after installation Install new seal into place using a seal driver or seal installation tool of proper size It is important that any seal g suwinig sqny shuies 61 Hubs Drums Bearings installation tool contact the outer ring of the seal casing If no seal driver is available use a clean block of wood It is critical that the seal be driven in evenly and straight NEVER hammer directly on the seal The seals will be pressed flush to the back surface of the hub in the 9K 10K General Duty axle product line The seals in the 10K through 15K axles need to be installed so that the airside face of the seal is approximately 11 6 from the inner bearing cone It is NEVER necessary to bottom out the seal for proper installation Driving the seal in
42. ed if worn unevenly or abnormally As indicated below a straightedge should be used to check magnet condition For best results the magnet should be flat Even if wear is normal as indicated by your straightedge the magnets should be replaced if any part of the magnet coil has become visible through the friction material facing of the magnet It is also recommended that the drum armature surface be refaced when replacing magnets see section on Brake Drum Inspection Magnets should also be replaced in pairs both sides of an axle Use only genuine Dexter replacement parts when replacing your magnets Straight Edge Gaps show ABNORMAL WEAR replace magnet NORMAL WEAR Braking Systems Electric Shoes and Linings A simple visual inspection of your brake linings will tell if they are usable Replacement is necessary if the lining is worn to Ye or less Shoes contaminated with grease or oil or abnormally scored or gouged should also be replaced Hairline heat cracks are normal in bonded linings and should not be cause for concern When replacement is necessary itis Acceptable Hairline Cracks important to replace both shoes on each brake and both brakes of the same axle This will help retain the balance of your brakes 311 29 3 suiejs S Bunjeig POTENTIAL ASBESTOS DUST HAZARD Some older brake linings may contain asbestos dust which has been linked to serious or fatal illnesses Certain preca
43. ent 1 Make sure springs are on straight Align spring eyes to front hanger Insert spring eye bolts but do not torque at this point 2 Assemble springs into equalizer 3 After leveling equalizer to frame torque equalizer nuts to values specified in Fastener Torque Specifications Replacement Parts Kits section 4 Torque spring eye bolts to values specified in Fastener Torque Specifications Replacement Parts Kits section for rubber bushed suspension Torque bronze bushed suspension to snug fit only Torflex Suspension The Torflex suspension system is a torsion arm type suspension which is completely self contained within the axle tube It attaches directly to the trailer frame using brackets which are an integral part of the axle assembly The Torflex axle provides improved suspension characteristics relative to leaf spring A gt axles through the unique 2 arrangement of a steel Torsion Arm torsion bar surrounded by four natural rubber cords encased in the main structural member of the axle beam Mounting Bracket Axle Tube The spindle is attached to a lever called the torsion arm which is fastened to the rubber encased bar As load is applied the bar rotates causing a rolling compressive resistance in the rubber cords This action provides the same functions as conventional sprung axles with several operating advantages including independent suspension Except for perio
44. er Mounting of Air Chamber and Slack Adjuster Mount per Recommended Procedure Camshaft or Shoes Frozen Replace Bushing 54 Hubs Drums Bearings cc Hub Removal e Whenever the hub equipment on your axle must be removed for inspection or maintenance the following procedure should be utilized N 1 Elevate and support the trailer unit per manufacturers co instructions D e o Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 Remove the wheel s 3 Remove the grease or oil cap by unscrewing it counterclockwise while holding the hub stationary 4 Bend the locking tang down from the outer spindle nut and remove spindle nut 5 Remove the tang washer and unscrew the inner spindle nut counterclockwise and remove the spindle washer 6 Remove the hub from the spindle being careful not to allow the outer bearing cone to fall out The inner bearing cone will be retained by the seal Note A gear puller may be necessary to remove hub from spindle Brake Drum Inspection There are two areas of the brake drum that are subject to wear and require periodic inspection These areas are the drum surface where the brake shoe
45. erous times to remove excess pad clearance prior to operation of vehicle Torque Specifications Rotor Mounting Bolts 14 Torflex 90 110 Ft Lbs Outer Spindle Nuts 100 175 Ft Lbs Hub Cap 20 30 Ft Lbs Wheel Mounting Nuts 200 Ft Lbs with clamp ring 40 Hydraulic Disc Brake Parts Qty Description Brake 1 Anchor Yoke Assembly 10K 12K 1 includes 6 of item 6 1 Anchor Yoke Assembly 14 Torflex 1 includes 6 of item 6 090 002 02 090 011 02 includes items 6 3 9 10 z z 7 7 Caliper Repair Kit contains 054 066 00 007 186 00 007 116 00 006 046 00 006 017 00 025 014 00 097 004 00 097 002 00 024 203 00 K71 181 00 010 062 00 054 069 00 054 067 00 054 068 00 K71 180 00 Brake Pad 091 003 00 Anti Rattle Spring 046 105 00 O Ring 010 062 00 Hex Locknut 006 125 00 Installation Tool 071 182 00 oijneapAy suia s S Burjeig O Ring Bleeder Screw Caliper Seal Dust Boot Disc Brake Replacement Pad Kit contains TOM Recommend hose with banjo fitting 7 e 20 threaded hole for fitting 1 S Cam Air Brakes Operation Trailer air brakes are operated by the tractor air supply through a series of relay and check valves When braking is desired the air is supplied to the axle air chamber which applies a force that is multiplied by the slack adjuster lever arm length This force is transmitted rotationally through the camshaft which through the geome
46. es should be adjusted 1 after the first 200 miles of operation when the brake shoes and drums have seated 2 at 3 000 mile intervals 3 or as use and performance requires The brakes should be adjusted in the following manner 1 Jack up trailer and secure on adequate capacity jack stands Follow trailer manufacturer s recommendations for lifting and supporting the unit Make sure the wheel and drum rotates freely Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 3 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn 4 Then rotate the star wheel in the opposite direction until the wheel turns freely with a slight lining drag 5 Replace the adjusting hole cover and lower the wheel to the ground 6 Repeat the above procedure on all brakes For best results the brakes should all be set at the same clearance Braking Systems Hydraulic 36 Most of the brake components are very similar to those used in e
47. f possible If a machine is unavailable packing by hand method is acceptable The method to pack bearing cones is as follows 1 Place a quantity of grease onto the palm of your hand 57 Repeat this while rotating the Continue this process until you Before reinstalling apply a light Press a section of the widest end of bearing into the outer edge of the grease pile closest to the thumb forcing grease into the interior of the bearing between two adjacent rollers bearing from roller to roller have the entire bearing completely filled with grease coat of grease onto the bearing cup mating surface Bearing Lubrication Oil If your axles are equipped with oil lubricated hubs then your lubrication procedure is to periodically fill the hub with a high quality hypoid gear oil to the level indicated on the clear plastic oil cap The oil can be filled through the rubber plug hole in the cap Oil should be replaced every 12 months or 12 000 miles Hubs Drums Bearings 58 Recommended Wheel Bearing Lubrication Specifications Grease Thickener Type Lithium Complex 215 C 419 F Minimum Dropping Point Consistency NLGI No 2 Additives EP Corrosion amp Oxidation Inhibitors g swinig sqny Viscosity Index 80 Minimum Approved Grease Sources Chem Arrow Arrow 2282 sfiuuea Chevron Texaco Chevron Ulti Plex Grease EP 2 Texaco Starplex Moly MPGM 2
48. hange Brakes PQ Block and secure trailer on adequate capacity jack stands Follow trailer manufacturers recommendations for lifting and supporting the unit Check that the wheel and drum rotate freely Release brake and back off slack adjuster Remove wheel equipment Aly swaysks Buryjeig anchor pin Remove anchor pin Repeat procedure 4 for the bottom shoe Remove brake keeper springs Unwrap bottom shoe by pivoting the shoe on the camshaft head and twisting the shoe 90 under the spindle Remove shoe assemblies from spider Remove slack adjuster lock ring disconnect slack clevis and then remove slack adjuster Remove camshaft lock ring spacer washer s and camshaft Completely inspect all brake components servicing as necessary Recommended Reassembly 1 Install new camshaft bushing Ream bushing to 1 505 1 515 if required Install camshaft seals into the spider Note When installing camshaft seals the seal on the slack adjuster side is installed with seal facing into spider This allows grease to purge outside the brake assembly when greasing the camshaft bushing It also aids to avoid damage of the seal lip when camshaft is installed Install new cam roller assemblies onto the brake shoes Note The head of roller pin should face the camshaft D washer once shoes are installed on spider aD 47 Braking Systems Air Install D shaped camshaft washer onto the camshaft 4 Ins
49. ions of tire wear problems Proper matching of the tire wheel combination is essential to proper function of your trailer running gear Some tires may call for a maximum inflation pressure above the rim or wheel capacity DO NOT EXCEED MAXIMUM INFLATION PRESSURES FOR RIMS OR WHEELS Catastrophic failure may result S775 Sail pue sjoauM Tire Wear Diagnostic Chart Center Wear Over Inflation Edge Wear Under Inflation Side Wear Loss of camber or overloading Incorrect toe in Cupping Out of balance Flat Spots Wheel lockup amp tire skidding Adjust pressure to particular load per tire catalog Adjust pressure to particular load per tire catalog Make sure load doesn t exceed axle rating Align at alignment shop Align at alignment shop Check bearing adjust ment and balance tires Avoid sudden stops when possible and adjust brakes Tire wear should be checked frequently Once a wear pattern becomes firmly established in a tire it is difficult to stop even if the underlying cause is corrected Wheels and Tires 78 Replacement Parts Kits Fastener Torque Specifications Description Spindle Nut Inner Outer Grease Zerk Cam Brackets Air Chamber 36 16 Self Locking Hex Nut 56 11 Hex Locknut 13 Hex Head Cap Screw 13 Hex Cap Screw 58 11 Hex Locknut 1 8 Hex Locknut 1 8 Hex Locknut 34 10 Hex Locknut 34 10 Hex Locknut 1 8 Hex Locknut 116 7 Hex Locknut
50. ke Drums Machine or Replace Faulty Controller Test amp Correct Overadjustment Readjust Out of Round Brake Drums Machine or Replace Dragging Brakes Braking Systems Electric Incorrect Brake Replace Components Loose Bent or Broken Replace Brake Components Faulty Breakaway Switch Repair or Replace Loose Wheel Bearing Adjustment Adjust Bent Spindle Replace Axle 20 How to Measure Voltage System voltage is measured at the magnets by connecting the voltmeter to the two magnet lead wires at any brake This may be accomplished by using a pin probe inserted through the insulation of the wires The engine of the towing vehicle should be running when checking the voltage so that a low battery will not affect the readings Voltage in the system should begin at 0 volts and as the controller bar is slowly actuated should gradually increase to about 12 volts If the controller does not produce this voltage control consult your controller manual VOLTMETER The threshold voltage of a controller is the voltage applied to the brakes when the controller first turns on Lower threshold voltage will provide for smoother braking If the threshold voltage is too high the brakes may feel grabby and harsh
51. ke Option The parking feature on Dexter hydraulic brakes is cable operated The cable end is attached to the internal parking brake lever to actuate the brake On Dexter 1274 brakes manufactured before February 2002 the parking cable body mounts to a support plate which is attached to the brake mounting flange The cable end is routed through the dust shield and the brake spider to attach to the internal parking brake lever For 1274 brakes produced after February 2002 a short cable is installed directly into the backing plate to provide a convenient means for the trailer manufacturer to attach an appropriate operating system 26 The internal parking brake lever of Dexter 12 brakes transfers the applied cable force through a cam mechanism The cam mechanism generates a spreading force between the primary and secondary shoes The shoes move toward the drum until contact is made Friction generated between the drum and lining contact surface results in parking brake capability Park Lever 9iineap g suiajs gs 9 Park Cable 27 Braking Systems Hydraulic Hydraulic Disc Brakes Dexter Axle manufactures two types of disc brakes the floating caliper and the fixed caliper brake With both styles the disc brake uses friction pads astride a ventilated rotor which is attached to the wheel hub When the brake is actuated the pads are pressed against the sides of the rotor causing drag to slow the rotating
52. late tires according to manufacturer s specifications inspect tires for cuts excessive wear etc Check wheel mounting nuts bolts with a torque wrench Torque in proper sequence to the levels specified in this manual Make certain the brakes are synchronized and functioning properly Check tightness of hanger bolt shackle bolt and U bolt nuts per torque values specified in manual Check operation of all lights Check that your trailer is towing in a level position and adjust hitch height if required 84 Dexter Axle Limited Warranty WHAT PRODUCTS ARE COVERED All Dexter Axle Company Dexter Axle trailer axles suspensions and brake control systems excluding Dexter 6000 series Manufactured Housing Axles LIMITED 1 YEAR WARRANTY As specified in Dexter Axle s current publication Operation Maintenance Service Manual grease and oil seals FOR ALL PRODUCTS have a one 1 year limited warranty from the date of first sale of the trailer incorporating such components Except as to grease and oil seals the following four other warranties are available LIMITED 2 YEAR WARRANTY Dexter Axle warrants to the original purchaser that its axles suspension systems and E H hydraulic brake 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 AuegeueMw Dexter Axle warran
53. lectric brakes and maintenance is comparable for the hub and drum shoes and linings and bearings Specific maintenance activities are as follows Wheel Cylinders Inspect for leaks and smooth operation Clean with brake cleaner and flush with fresh brake fluid Hone or replace as necessary Brake Lines Check for cracks kinks or blockage Flush with fresh brake fluid Bleed system to remove all air Use DOT3 or DOT4 brake fluid and replace as necessary Shoes and Linings A simple visual inspection of your brake linings will tell if they are usable Replacement is necessary if the lining is worn to within or less contaminated with grease or oil or abnormally scored or gouged Hairline heat cracks are normal in bonded linings and should not be cause for concern When replacement is necessary it is important to replace both shoes on each brake and both brakes of the same axle This will help retain the balance of your brakes oijneapAy suia s S Burjeig POTENTIAL ASBESTOS DUST HAZARD Some older brake linings may contain asbestos dust which has been linked to serious or fatal illnesses Certain precautions need to be taken when servicing brakes 1 Avoid creating or breathing dust 2 Avoid machining filing or grinding the brake linings 3 Do not use compressed air or dry brushing for cleaning dust can be removed with a damp brush 37 Braking Systems Hydraulic After replacement
54. lectromagnets are energized and are attracted to the rotating armature surface of the drums which moves the actuating levers in the direction that the drums are turning Braking Systems Electric Brake Controller Breakaway Switch Stoplight Wire Battery Brake Wire Power Wire Ground Wire The resulting force causes the actuating cam block at the shoe end of the lever to push the primary shoe out against the inside surface of the brake drum The force generated by the primary shoe acting through the adjuster link then moves the secondary shoe out into contact with the brake drum Increasing the current flow to the electromagnet causes the magnet to grip the armature surface of the brake drum more firmly This results in increasing the pressure against the shoes and brake drums until the desired stop is accomplished 311 29 3 suiejs S Bunjeig 12V Battery for Breakaway Switch Towing Vehicle Trailer Connection Braking Systems Electric Features Electrically actuated brakes have several advantages over other brake actuation systems 1 They can be manually adjusted at the controller to provide the correct braking capability for varying road and load conditions They can be modulated to provide more or less braking force thus easing the brake load on the towing vehicle They have very little lag time from the moment the tow vehicle s brakes are actuated until the trailer brakes
55. lowing checked at the specified intervals Wheel Nut Torque at 10 25 and 50 miles Brake Adjustment at 200 and 3 000 miles Tire pressure to manufacturer s requirements Brake synchronization set brake controller per controller manufacturer s directions Answers to Commonly Asked Questions Q Why do my brakes and hubs get so hot A Braking systems use friction to slow the vehicle and the Introduction energy used to retard the trailer is converted to heat Dexter brakes are designed to operate up to extremely high temperatures during hard braking application This heat is noticeable on the hub and drums and is to be normally expected on a properly functioning brake If a brake is malfunctioning and running excessively hot this can be noticed by smoking brakes or the paint burning off of the brake drum If this occurs refer to the brake troubleshooting diagram for your type of brake Why do have to adjust my brakes Brakes must be adjusted to compensate for the lining and drum wear that occurs during use of the braking system Some brakes require manual adjustment to move the linings closer to the drum Refer to the brake adjustment section for your style of brakes Other brakes may have an automatic brake adjuster such as the automatic slack adjusters for air brakes Note Prior to 10 96 electric and hydraulic self adjusting brakes adjust only during hard reverse stops If your driving does not inc
56. lude these types of stops you will have to manually adjust your brakes Designs after 10 96 adjust both in forward and in reverse Adjustment in reverse still requires hard stops while adjustment in forward motion will occur through normal driving My brake linings are cracked do have to replace them Usually light cracking of the surface of a brake lining can be expected under normal use This is not cause for replacement However if the lining is missing chunks your brake linings or shoes will require replacement Q Why do have to torque the wheel nuts on my trailer and do not have to do so in my car A The main reason is wheel capacity Your entire car may weigh 3 000 Ibs which is spread over four wheels while a 6 000 Ib trailer axle has 3 000 Ibs on a single tire and wheel This places greater stress on the wheel tire combination The second reason is loading Your car is designed to have the wheels track the arc of a turn reducing side load on the tire and wheel Trailers are subjected to harsh side loads especially in double and triple axle configurations These side loads work to flex the wheel which may cause the wheel to lose torque over time Please follow the wheel usage instructions located later in this manual Q Why can t lock and slide my electric brakes A On an unloaded trailer you may be able to lock up your brakes if your electric brake controller is supplying full amperage to the brake
57. mmon causes of this condition are Poor electrical connections Open circuits Insufficient wire size Broken wires Blown fuses fusing of brakes is not recommended Improperly functioning controllers or resistors An ken gt Another common electrical problem is shorted or partially shorted circuits indicated by abnormally high system amperage Possible causes are 1 Shorted magnet coils 2 Defective controllers 3 Bare wires contacting a grounded object 22 Finding the cause of a short circuit in the system is done by isolating one section at a time If the high amperage reading drops to zero by unplugging the trailer then the short is in the trailer If the amperage reading remains high with all the brake magnets disconnected the short is in the trailer wiring All electrical troubleshooting procedures should start at the controller Most complaints regarding brake harshness or malfunction are traceable to improperly adjusted or non functioning controllers See your controller manufacturer s data for proper adjustment and testing procedures For best results all the connection points in the brake wiring should be sealed to prevent corrosion Loose or corroded connectors will cause an increase in resistance which reduces the voltage available for the brake magnets 23 311 29 3 suiejs S bulyesg Hydraulic Brakes The hydraulic brakes on your trailer are much like those on your automobile or light tr
58. n and cause loss of braking and or wheel lockup Loss of braking can cause an accident resulting in injuries or death 45 Aly swajshs Buryjeig General Maintenance Adjustment Brake Component Lubrication Camshaft bushings Lubricate with approved grease through the grease fittings at the spider and camshaft support bracket locations Apply just enough grease so grease is visible flowing past camshaft bushing seals During this process it is advisable to grab the camshaft and shake the camshaft to see if there is excessive clearance in the camshaft bushings due to wear Camshaft roller journals and brake anchor pins These components are to be lubricated with a high temperature anti seize grease upon disassembly maintenance and reassembly Manual and automatic slack adjusters Lubricate with Lithium base NLGI Grade 1 anti wear grease with rust and oxidizer additives applied at intervals of 3 to 6 months or 50 000 miles or per slack adjuster manufacturer s recommendations For Manual Slack Adjusters Lubricate with NLGI Grade 2 For Automatic Slack Adjusters Lubricate with ASA manufacturers recommended lubricant ASA C Anchor Pins a and Roller Journals Spider and Support Bushings Lubricate with NLGI Grade 2 Lubricate with high temperature anti seize grease Braking Systems Air 46 Recommended Disassembly 1 4 Lift top shoe upward to disengage the shoe webs from the 1214 Quick C
59. ng the trailer forward on a level floor apply the brakes and release This will ensure that an adjustable undercarriage is in its rearmost lock position The trailer MUST be level from side to side as well as from front to rear Note Neither service nor parking brakes should be applied during the measurement procedure Ensure the king pin or coupler is at the correct height Use axle end extenders or remove outer wheels and any obstructions to achieve a straight line for measuring from king pin to the axle ends or axle centers Proper tools for axle alignment inspection are Spring loaded kingpin extender with level or plum bob Axle end extenders 50 foot steel tape Optional adjustable tram 70 A means to measure axle center to axle center Optional Extra adjustable track arm rod clamp bolts if c i ec required t5 E o e N Adjust Clamp Bolt Nut Tighten to 130 170 Ft Lbs Adjust Clamp Bolt Nut Tighten to 130 170 Ft Lbs Adjustable Track Arm Rod Figure 1 Measuring Figure 2 1 Lateral Centerline E Determine lateral centerline of trailer body and axles by measuring distance E between trailer and axle centerlines first and correct so that distance E is 1 4 or less for each axle Thrust Angle A B Measure distances A curbside then B roadside from the king pin or coupler to the front of the axle extension or axle centers These must be equal to within
60. ng cone using a suitable solvent Dry the bearing with a clean lint free cloth and inspect each roller completely If any pitting spalling or corrosion is present then the bearing must be replaced The bearing cup inside the hub must be inspected IMPORTANT Bearings must always be replaced in sets of a cone and a cup Be sure to wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious eye injury 56 When replacing the bearing cup proceed as follows 1 Place the hub on a flat work surface with the cup to be replaced on the bottom side 2 Using a brass drift punch carefully tap around the small diameter end of the cup to drive out a UJ 3 After cleaning the hub bore area replace the D cup by tapping in with 5 the brass drift punch Be eo sure the cup is seated all o the way up against the retaining shoulder in the hub Replace only with bearings as specified in the Bearing Replacement Chart Bearing Lubrication Grease Do not mix Lithium calcium sodium or barium complex greases due to possible compatibility problems When changing from one type of grease to another it is necessary to insure all the old grease has been removed Grease should be replaced every 12 000 miles or 12 months Prior to repacking bearings all old grease should be removed from the wheel hub cavity and bearings Bearings should be packed by machine i
61. nning gear system When specifying or replacing your trailer wheels it is important that the wheels tires and axle are properly matched The following characteristics are extremely important and should be thoroughly checked when replacement wheels are considered 1 Bolt Circle Many bolt circle dimensions are available and some vary by so little that it might be possible to attach an improper wheel that does not match the axle hub Be sure to match your wheel to the axle hub 2 Capacity Make sure that the wheels have enough load carrying capacity and pressure rating to match the maximum load of the tire and trailer 3 Offset This refers to the relationship of the center line of the tire to the hub face of the axle Care should be taken to match any replacement wheel with the same offset wheel as originally equipped Failure to match offset can result in reducing the load carrying capacity of your axle 4 Rim Contour Replacement tires must meet the same specifications as the originals Mismatched tires and rims may come apart with explosive force and cause personal injury to yourself or others Mismatched tires and rims can also blow out and cause you to lose control and have an accident which can result in serious injury or death Wheels and Tires 74 Do not attempt to repair or modify a wheel Even minor modifications can have a great effect Do not install a tube to correct a leak through the rim If the rim is c
62. nted 7 Normal wear and tear Alignment 9 Improper installation D 86 10 Unreasonable use including failure to provide reasonable and necessary maintenance as specified in Dexter Axle s current publication Operation Maintenance Service Manual including required maintenance after Prolonged Storage 11 Improper wheel nut torque 12 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 nearly 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 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 AN
63. ork should be done more frequently as required Magnets and shoes must be changed when they become excessively worn or scored a condition which can reduce vehicle braking Clean the backing plate magnet arm magnet and brake shoes Make certain that all the parts removed are replaced in the same brake and drum assembly Inspect for any loose or worn parts stretched or deformed springs and replace as necessary 311 29 3 suiejs S Bunjeig POTENTIAL ASBESTOS DUST HAZARD Some older brake linings may contain asbestos dust which has been linked to serious or fatal illnesses Certain precautions need to be taken when servicing brakes 1 Avoid creating or breathing dust 2 Avoid machining filing or grinding the brake linings 3 Do not use compressed air or dry brushing for cleaning dust can be removed with a damp brush Brake Lubrication Before reassembling apply a light film of grease or anti seize compound on the brake anchor pin the actuating arm bushing and pin and the areas on the backing plate that are in contact with the brake shoes and magnet lever arm Apply a light film of grease on the actuating block mounted on the actuating arm Do not get grease or oil on the brake linings drums or magnets Magnets Your electric brakes are equipped with high quality electromagnets that are designed to provide the proper input force and friction characteristics Your magnets should be inspected and replac
64. prevent damage to brake hose Do not allow caliper to hang from the hose Remove anti rattle springs and brake pad 38 Inspection 1 3 Rotor Specifications Rotor Thickness 1 185 New 1 12 Min Service Limit 10 12K Rotor Thickness 2 15 New 2 09 Service Limit 14 Torflex Slider bolts must be straight and free of rust pits missing chrome or cracks in the chrome plating Replace if necessary Anchor yoke bores must be free of corrosion and excessive wear O rings must be free from nicks and cuts Replace as necessary Caliper assembly must be free of fluid leaks and torn or deteriorated dust boots and rings Repair as required Rotor inspect for grooves flaking cracks heat checking excessive thickness variation insufficient overall rotor thickness and overall width measurement from inboard rotor face to rotor mounting surface Machine or replace as necessary 9iine1jp H suia s S Burjeig Rotor Overall Width 3 655 New 3 59 Service Limit 003 T I R 010 T I R Maximum Thickness Variation 0008 Hub and Rotor Removal and Installation 1 With hubcap removed and oil drained straighten locking tabs on tang washer and remove outer locknut tang washer inner locknut bearing washer and outer bearing Remove hub and rotor assembly Note A puller may be required due to unitized seal press fit on spindle Remove inner bearing and seal Service bearings as necessary Prior to rea
65. racked the air pressure in the tube may cause the pieces of the rim to explode with great force and can cause serious injury or death Sail pue sjoauM Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on your trailer axle Torque is a measure of the amount of tightening applied to a fastener nut or bolt and is expressed as length times force For example a force of 90 pounds applied at the end of a wrench one foot long will yield 90 Ft Lbs of torque Torque wrenches are the best method to assure the proper amount of torque is being applied to a fastener Wheel nuts or bolts must be tightened and maintained at the proper torque levels to prevent loose wheels broken studs and possible dangerous separation of wheels from your axle which can lead to an accident personal injuries or death Be sure to use only the fasteners matched to the cone angle of your wheel usually 60 or 90 The proper procedure for attaching your wheels is as follows 1 Start all bolts or nuts by hand to prevent cross threading 2 Tighten bolts or nuts in the following sequence 3 The tightening of the fasteners should be done in stages Following the recommended sequence tighten fasteners per wheel torque requirements diagram 75 Wheels and Tires 4 Wheel nuts bolts should be torqued before first road use and after each wheel removal Check and re torque after the firs
66. rformance requires The brakes should be adjusted in the following manner 1 Jack up trailer and secure on adequate capacity jack stands Follow trailer manufacturer s recommendations for lifting and supporting the unit Make sure the wheel and drum rotates freely Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury 2 If equipped remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 3 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn 4 Then rotate the star wheel in the opposite direction until the wheel turns freely with a slight lining drag 5 Replace the adjusting hole cover and lower the wheel to the ground 6 Repeat the above procedure on all brakes For best results the brakes should all be set at the same clearance Braking Systems Electric Brake Cleaning and Inspection Your trailer brakes must be inspected and serviced immediately if a loss of performance is indicated With normal use servicing at one year intervals is usually adequate With increased usage this w
67. s When loaded to capacity you may not be able to lock your brakes as electric brakes are designed to slow the trailer at a controlled rate and not designed to lock up the wheels on a fully loaded trailer Our brakes are designed to meet all applicable safety standards All of our brakes will perform better after numerous burnish stops to seat the brake linings to the drums Q don t feel have enough brakes or capacity on my axles Can 1 easily upgrade A Usually depending on the trailer configuration you can upgrade your running gear to a higher capacity rating We recommend consulting with the trailer manufacturer first before doing so Q Can change my brakes from electric to hydraulic or vice versa A This can be done on most axle models We recommend contacting the trailer manufacturer prior to changing your braking system to identify any potential problems Electric Brakes The electric brakes on your trailer are similar to the drum brakes on your automobile The basic difference is that your automotive brakes are actuated by hydraulic pressure while your electric trailer brakes are actuated by an electromagnet With all of the brake components connected into the system the brake should operate as follows see electric brake assembly illustration When the electrical current is fed into the system by the controller it flows through the electromagnets in the brakes The high capacity e
68. s make contact during stopping and the armature surface where the magnet contacts only in electric brakes 55 i J Hubs Drums Bearings The drum surface should be inspected for excessive wear or heavy scoring If worn more than 020 oversized or the drum has worn out of round by more than 015 then the drum surface should be re machined If scoring or other wear is greater than 090 on the diameter the drum must be replaced When turning the drum surface the maximum rebore diameter for a 1274 brake drum is 12 340 For electric brakes only the machined inner surface of the brake drum that contacts the brake magnet is called the armature surface If the armature surface is scored or worn unevenly it should be refaced to a 120 micro inch finish by removing not more than 030 of material To insure proper contact between the armature face and the magnet face the magnets should be replaced whenever the armature surface is refaced and the armature surface should be refaced whenever the magnets are replaced Note It is important to protect the wheel bearing bores from metallic chips and contamination which result from drum turning or armature refacing operations Make certain that the wheel bearing cavities are clean and free of contamination before reinstalling bearing and seals The presence of these contaminants will cause premature wheel bearing failure Bearing Inspection Wash all grease and oil from the beari
69. secure the cotter pins in the clevis and adjuster pins 49 To insure brakes meet Federal performance requirements Dexter Axle recommends that only original equipment premium grade linings be used Failure to use proper linings can result in poor braking and cause accidents and injuries Air Brake Manual Slack Adjustment 1 Grease cam bracket and spider fittings 2 Adjust the slack adjuster until the brake lining comes into contact with the brake drum A For green brakes there should be a slight amount of wheel drag at initial adjustment to compensate for any lining irregularities such as high spots B For burnished or broken in brakes back off the slack adjuster to achieve 010 clearance between the drum and shoes 3 Apply brakes using normal truck operating pressure 80 90 psi Note A green brake is an unground unburnished brake Normal manufacturing tolerances dictate that there is a break in period required after which the lining will seat into the brake drum During this break in period the user must be aware that additional brake adjustment will be mandatory to achieve optimum braking performance USE OF AIR PRESSURE IN EXCESS OF 130 PSI COULD RESULT IN FAILURE OF THE AIR CHAMBER OR SPRING BRAKE CHAMBER Braking Systems Air 50 4 Check the amount of push rod travel at the clevis pin The stroke should be as follows Chamber Type 39 w Aly suigjs S Bur
70. ssembly insure that the hub bearing housing is clean Reinstall inner bearing Coat the O D of a new seal with a bore sealant Permatex or equivalent prior to installation Mount hub and rotor assembly on spindle and install outer bearing bearing washer and inner bearing nut 39 Braking Systems Hydraulic Tighten inner nut to 100 Ft Lbs while turning hub to seat bearings Loosen nut to remove pre load torque Hand tighten nut then back off turn minimum 1 4 turn maximum Install tab washer and outer locknut Torque locknut to 100 175 Ft Lbs Insure that the inner nut does not rotate Bend 2 tabs over flat on outer locknut to secure Install hub cap and add oil to hub Capacity is 2 5 oz of SAE 90W gear oil Installation 1 Installation is reverse of disassembly Use appropriate tools and methods to retract caliper pistons sufficiently to reinstall caliper over the new pads Caliper and anchor yoke O rings should be lubricated with a light film of high temperature brake lubricant prior to slider bolt installations Slider bolts should be installed from the outboard side of the caliper Insure the anti rattle springs are located properly Use extreme care when installing the slider bolts to prevent damage to the rings Installation tool 071 182 00 threaded onto the slider bolts is recommended DO NOT FORCE OR HAMMER BOLTS IN Secure slider bolts with new locknut Actuate brakes num
71. t 50 miles and again at 100 miles Check periodically thereafter Wheel Torque Sequence Torque Torque Min Max Description Application Ft Lbs Ft Lbs 033 052 01 Greased 34 10 Hex Nut 006 117 00 Demountable 210 Rim Clamp 56 18 90 Cone Nut 006 109 00 Clamp Ring 210 94 16 Spherical Nut 006 064 01 02 Single Wheel 006 069 01 02 Inner Dual Threads 1 16 Spherical Nut 006 070 01 02 56 18 Non Swiveling 006 058 00 Wheels Flange Nut 56 18 Swiveling 006 209 00 Wheels Flange Nut M22 1 5 006 118 00 Swivelling Flangenut 76 Tires Before mounting tires onto wheels make certain that the rim size and contour is approved for the tire as shown in the Tire and Rim Association Yearbook or the tire manufacturers catalog Also make sure the tire will carry the rated load If the load is not equal on all tires due to trailer weight distribution use the tire rated for the heaviest wheel position Use tire mounting procedures as outlined by the Rubber Manufacturers Association or the tire manufacturers Tire inflation pressure is the most important factor in tire life Inflation pressure should be as recommended by the manufacturer for the load Pressure should be checked cold before operation Do not bleed air from tires when they are hot Check inflation pressure weekly during use to insure the maximum tire life and tread wear The following tire wear diagnostic chart will help you pinpoint the causes and solut
72. tall the camshaft into the spider Install 005 075 00 washer and lock ring retainer on the camshaft before sliding the camshaft through the camshaft support bracket Install the slack adjuster and 005 134 00 washer and 069 078 00 lock ring retainer for 28 spline camshafts or 005 075 00 washer and 069 020 00 lock ring retainer for 10 spline camshafts Lubricate cam roller notches with anti seize lubricant prior to installing cam roller assemblies onto the brake shoes Bend roller retainer loop down so that retainer will be at same level as the shoe table and will not interfere with the brake drum during the life of the lining blocks Install W shaped retractor spring retainer pin into the 0 50 diameter shoe web holes near the camshaft roller end of the shoe Install retractor spring between shoes Place top shoe onto spider as in service Pivot bottom shoe on the camshaft head and twist the shoe 90 under the spindle properly placing shoe on the spider as in service Install two 2 keeper springs on the anchor end of the shoes Lubricate anchor pin bores and shoe anchor pins with antiseize lubricant Repeat procedure 10 for the bottom shoe Lift top shoe upwards to clear anchor pin hole Install anchor pin Connect slack adjuster to brake chamber pushrod Note Always use new springs when servicing brakes Always use Dexter shoes when replacing shoes 48 Air Brake Automatic Slack
73. th placement of air chamber and slack adjuster assemblies that will insure the correct directional rotation of the camshafts when the axle is installed It is the responsibility of the axle installer to adjust the brakes properly The recommended adjustment procedure is covered in the section pertaining to brakes Please consult the following troubleshooting charts to determine the causes and solutions for common problems found in trailer braking systems 52 Troubleshooting SYMPTOM CAUSES REMEDIES S Cam Flipped Replace Linings and Drum If Needed Air System Troubleshoot per Malfunction System Mfgr s Directions No Brakes Brakes Out of Adjust Brakes Aly swayshs 9 Adjustment Air Lines Kinked or Broken Replace Slack Adjuster i Bicker Repair or Replace Air Chamber Malfunction Replace Brakes Out of Adjustment Adjust Excessive Drum Wear Replace Drums Excessive Lining Wear Replace Linings Oil Soaked Linings Replace Linings Weak Brakes r Overloaded Trailers Use Proper Load Troubleshoot per AirSystem Maltunction System Mfgr s Directions Wrong Size Use Correct Size Air Air Chamber Chamber for Application Worn Anchor Pin Bushings or Replace Bushings Camsh
74. too deep may damage the seal and may come in contact with the inner bearing preventing it from rotating freely Proper installation will maintain the seal flatness in the hub within 010 A seal that is cocked too much inside the hub will be more likely to leak Installation Adjustment For ABS installation 1 Assure that the ABS sensor is pushed fully into its retainer clip sensor tip is as far outboard as possible Install hub and drum squarely to the spindle centerline so that the exciter ring inside the drum will contact the sensor tip and push it back to the proper sensor to exciter ring running clearance gap should not exceed 1 6 inch For non ABS installation begin with step 3 3 Install the bearing and washer into the hub Thread on the inner nut rotate the hub and tighten the nut to 100 Ft Lbs of torque Loosen the nut to remove preload torque do not rotate hub Hand tighten the nut then back it off 14 to 96 turn Place the tang washer on the spindle and bend two tangs inward over the nut This will keep the inner nut from turning while torque is applied to the outer nut Install the outer nut and torque it to 100 175 Ft Lbs Insure that the inner nut does not turn Bend two tangs from the tang washer over the outer nut flats to secure 62 8 Install cap with the O ring and plug installed Rotate the hub m and check the bearing adjustment The allowable end play S 001
75. try of the S head spreads the brake shoes to contact the brake drum surface The air brake systems are an effective very durable braking system for use in high mileage or extreme operating conditions They can be outfitted with ABS anti lock brake systems automatic slack adjusters and spring brakes to comply with Federal Motor Vehicle Safety Standard Part 571 121 Push Rod Length Q Rest Braking Systems Air 42 Air Brake Components Air Chambers The air chambers convert the compressed air into a mechanical force on the slack adjuster The force on the slack adjuster operates on the end of the lever and converts the chamber output force to a torque on the S cam Federal and state regulations state the maximum pushrod stroke length as an indication of brake adjustment This stroke is shown by the maximum stroke indicator located on the air chamber pushrod Maximum allowable stroke is achieved when the indicator is fully extended from the air chamber housing Note Due to manufacturing tolerances some brakes may not meet the maximum stroke length in the green state and may require several burnish stops to allow the brake shoes to conform to the drum diameter Spring Brake For parking and emergency braking purposes a spring brake chamber can be used in conjunction with the standard air chamber The spring brake contains an additional air diaphragm and a very strong spring When air is applied to the spring brake the
76. ts to the original purchaser that its Genuine Replacement Parts shall be free from defects in material and workmanship for a period of two 2 years from the date parts were installed and serviced LIMITED 3 YEAR WARRANTY FOR PARTICIPATING OEMS Dexter Axle warrants to the original purchaser of a trailer equipped with axle models D90 D100GD D100HD D120 or D150 and installed with properly matched Genuine Dexter Hanger and Attaching Parts Kits HAP Kits or Dexter Heavy Duty Suspension System HDSS that this combination of components shall be free from defects in material and workmanship for a period of three 3 years The warranty period shall begin from the date of the original purchase of the trailer 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 5 years from the date of first sale of the trailer incorporating such components 85 Warranty 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 defecti
77. uck The hydraulic fluid from a master cylinder or actuation system is used to actuate the wheel cylinder which in turn applies force against the brake shoes and drum The main difference between automotive hydraulic brakes and hydraulic trailer brakes is the trailers actuation system These systems respond to the braking signal from the tow vehicle and supply the required brake fluid volume and pressure to the trailer brakes The maximum operating pressure for Dexter 1214 hydraulic brakes is 1 000 PSI Braking Systems Hydraulic 24 Hydraulic Drum Brake Operation Duo Servo The duo servo brake uses a dual piston wheel cylinder to apply the brakes This type of brake is typically used in an electric hydraulic vacuum hydraulic or air hydraulic system A description of operation of this brake is as follows When the brakes are applied the double acting wheel cylinder moves the primary and secondary shoes towards the drum The frictional force between Shing the brake drum and lining attempts to turn the primary shoe into the secondary shoe The secondary shoe ds forced onto the anchor Shoe pin and from this point the secondary and Adjuster Spring Adjuster Assembly primary shoes attempt to wrap around In essence the brake has utilized frictional force to help the applying force on both shoes Anchor Post Hydraulic Wheel Actuating Pin Cylinder Actuating Pin Primary
78. uring brake application Various brands of ASA s may work differently The initial adjustment and set up of the ASA s is critical to proper function of the air brake See instructions for slack adjuster procedure Note Automatic slack adjusters are required on some commercial trailers over 26 000 Ibs manufactured after 10 20 94 per FMVSS Part 571 121 DO NOT REPLACE AUTOSLACKS WITH MANUAL SLACK ADJUSTERS ON THESE TRAILERS S Cams The S cams rotate from the torque applied by the slack adjusters resulting in spreading the brake shoes which applies the braking force to the drum The S cams are supported by two nylon grease lubricated bushings Due to the high forces exerted on the cam bushings periodic inspection lubrication and maintenance is required to achieve proper braking performance 44 Brake Shoes The air brake shoes are the final link in the braking system The brake shoes are supported by pins inserted into the brake spider and rollers that contact the S cam surface The shoes have a replaceable lining riveted to them The linings have two different blocks designated Cam and Anchor side The brake shoes on your Dexter axle are specifically designed for that axle Only Dexter authorized parts should be used for replacement since there are small dimensional differences between air brake parts suppliers that can significantly affect the function of the brake Improperly fitted brake parts can cause brakes to malfunctio
79. utions need to be taken when servicing brakes 1 Avoid creating or breathing dust 2 Avoid machining filing or grinding the brake linings 3 Do not use compressed air or dry brushing for cleaning dust can be removed with a damp brush After replacement of brake shoes and linings the brakes must be re burnished to seat in the new components This should be done by applying the brakes 20 to 30 times from an initial speed of 40 m p h slowing the vehicle to 20 m p h Allow ample time for brakes to cool between applications This procedure allows the brake shoes to seat in to the drum surface Braking Systems Electric Introduction to Troubleshooting Proper brake function is critical to the safe operation of any vehicle If problems are encountered with your trailer braking system the following guide can be used to find the causes and remedies for some of the more common problems If you are unsure or unable to resolve the problem please contact your nearest repair facility for professional assistance Troubleshooting Most electric brake malfunctions that cannot be corrected by either brake adjustments or synchronization adjustments can generally be traced to electrical system failure Voltmeters and ammeters are essential tools for proper troubleshooting of electric brakes Mechanical causes are ordinarily obvious i e bent or broken parts worn out linings or magnets seized lever arms or shoes score
80. ve 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 the axle serial number and any substantiation which may include but is not limited to the return of part s that we may 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 in Dexter Axle s current publication Operation Maintenance Service Manual EXCLUSIONS These warranties do not extend to or do not cover defects caused by d The connecting of brake wiring to the trailer wiring or trailer wiring to the towing vehicle wiring The attachment of the running gear to the frame Hub imbalance or any damage caused thereby Parts not supplied by Dexter Axle Any damage whatever caused by or related to any alteration of the axle including welding supplemental brackets to the axle Use of an axle on a unit other than the unit to which it was originally mou
81. wires on the E H unit Clean and replace the ground between the trailer and the E H unit Test operation of the unit using the breakaway test procedure Breakaway test procedure do not leave the breakaway switch pulled for more than two minutes during any of the steps outlined below 1 2 Pull the breakaway switch on the trailer If the unit runs and builds pressure that indicates the actuator is functioning properly The problem most likely is a defective electronic brake controller in the tow vehicle or defective wiring between the tow vehicle and the E H unit If the unit runs but will not build pressure the problem most likely is a defective solenoid valve in the E H unit and the actuator should be returned for repair If the unit still does not run after the breakaway battery is fully charged verify that the voltage between the white wire and yellow wire is at least 12 volts If the voltage is less than 12 volts either the breakaway switch or the breakaway wiring is defective If the voltage is greater than 12 volts the E H unit should be returned for repair Trailer brakes too aggressive 1 Reduce the gain setting on the in cab electronic brake controller 35 9iine1jp H sura s S Burjeig General Maintenance Hydraulic Brakes Drum Brake Adjustment Most Dexter 1274 hydraulic brakes have a self adjusting feature If manual adjusting is required use the following procedure Brak
82. y adjustment and a digital LED display to show the voltage output A manual override sends full voltage to the trailer brakes regardless of gain setting for emergency conditions and also illuminates the brake lights to warn of an impending stop Most electric brake controllers provide a modulation function that varies the current to the electric brakes with the pressure on the brake pedal or amount of deceleration of the tow vehicle Electronic or timing controllers do not provide proportional modulation These controllers tend to be inexpensive but not the best choice for optimum braking It is important that your brake controller provide approximately 2 volts to the braking system when the brake pedal is first depressed and gradually increases the voltage to 12 volts as brake pedal pressure is increased If the controller jumps immediately to a high voltage output even during a gradual stop then the electric brakes will always be fully energized and will result in harsh brakes and potential wheel lockup 311 29 3 suiejs S Bunjeig How to Use Your Electric Brakes Properly Your trailer brakes are designed to work in synchronization with your tow vehicle brakes Never use your tow vehicle or trailer brakes alone to stop the combined load Your brake controller must be set up according to the manufacturer s recommendations to ensure proper synchronization between the tow vehicle and the trailer Additionally you may have to
83. y and cause serious injury or death 3 Lubricate mechanical moving parts such as the hitch and suspension parts that are exposed to the weather 4 Boat trailer axles are subject to repeated immersion Before storing remove brake drums clean dry and re lubricate moving brake components inspect bearings clean and re lubricate 5 On oil lubricated hubs the upper part of the roller bearings are not immersed in oil and are subject to potential corrosion For maximum bearing life it is recommended that you revolve your wheels periodically every 2 3 weeks during periods of prolonged storage 82 After Prolonged Storage Inspection Procedure Before removing trailer from jack stands 1 Remove all wheels and hubs or brake drums Note which spindle and brake that the drum was removed from so that it can be reinstalled in the same location Inspect suspension for wear Check tightness of hanger bolt shackle bolt and U bolt nuts per recommended torque values Check brake linings brake drums and armature faces for excessive wear or scoring Check brake magnets with an ohmmeter The magnets should check 3 2 ohms If shorted or worn excessively they must be replaced Lubricate all brake moving parts using a high temperature brake lubricant LUBRIPLATE or Equivalent Do not get grease or oil on brake linings or magnet face 11 Remove any rust from braking surface and armature surface of drums with fin
84. yjeig 5 With air pressure applied to brakes check for lining to drum contact The contact should approach 100 Use a 010 feeler gage if in doubt It should not fit between the lining and drum during brake application 6 Release air pressure from the brakes and confirm that all brakes release to the normal relaxed position A When properly adjusted the angle between the push rod and the slack adjuster should be approximately 90 5 when the brakes are applied B Proper maximum stroke should be achieved after adjusting the autoslack Reference the push rod stroke length chart 51 Braking Systems Air Introduction to Troubleshooting Proper brake function is critical to the safe operation of any vehicle A properly installed air brake system should not require any special attention with the exception of routine maintenance as defined by the manufacturer If problems occur the entire tow vehicle trailer braking system should be analyzed by a qualified mechanic To assure safe operation and maximum durability of parts such as brake linings and tires it is necessary to position and install the axle properly It is recommended that the axle assembly be installed so that camshafts rotate in the same direction as the wheels Installation in which the camshaft rotation is opposite that of wheel rotation could cause noisy brakes chatter and wheel hop With this thought in mind the axle should be ordered wi
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