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DEXTER AXLE - Proud Canadian

1. D e C 1 8 A a BA 1 16 f i Figure 1 Lu e ees Tandem Axle Adjustment 1 Suspensions Adjust the second axle using it s left hand spring seat adjusters to assure distances C and D are within tolerance Measure the distances C and D between the front and rear tandem axles These distances must be within 1 8 of each other After alignment is completed make sure all nuts and bolts are tightened to their respective torque values The limits of 1 16 and 1 8 appear very small in comparison to the overall dimensions of the vehicle but they are recognized as the maximum permissible limit of misalignment Also the relatively small size of those limits makes accurate measurements important 58 Wheels Wheel Selection Wheels are very important and critical components of your running 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 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 rated load of the
2. Broken Brake Components Replace Components Incorrect Brake Components Correct Locking Brakes Loose Bent or Broken Brake Components Replace Components Underadjustment Adjust Pulls to One Side Out of Round Drums Machine or Replace Incorrect Tire Pressure Inflate Evenly on Both Sides to Req Pressures Dragging Unmatched Tires on Same Axle Match Tires on Axle Restricted Brake Lines or Hoses Repair or Replace Malfunctioning Cylinder Assembly Check for Stuck or Sluggish Pistons 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 Blocked Master Cylinder Open with Compressed Air or Replace Cylinder Parking Brake Cable Frozen Free Cable and Lubricate Improper Lining Thickness or Location Install New Shoes and Linings 297 9i ne1p AH suiejs s uerg Troubleshooting SYMPTOM CAUSES REMEDIES Broken or Kinked fH Brake Line Repair or Replace Severe No Brakes Und
3. The internal parking brake lever of Dexter 121 4 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 Park Cable 9i ne1p AH swiayshs uerg aD Braking Systems Hydraulic Disc Brakes Dexter Axle manufactures several 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 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 3 500 1
4. 55 Iad Suspensions Except for periodic inspection of the fasteners used to attach the TORFLEX axle to the vehicle frame no other suspension maintenance is required on TORFLEX axles They are of course subject to the maintenance and inspection procedures regarding brakes hubs bearings seals wheels and tires as outlined in this manual DO NOT WELD ON THE TORFLEX BEAM It has rubber cords inside and the heat generated by welding could damage the cord Airflex Suspension The Dexter AIRFLEX suspension is a unique combination of Torflex axle and conventional air suspension technology This low maintenance suspension system carries the load ona cushion of air usually supplied by an on board compressor and storage tank A load leveling valve maintains a constant ride height regardless of load As load is added to the trailer the valve will automatically signal the compressor to supply more air As loads are removed the same valve will exhaust air to maintain the same height and ride characteristics The AIRFLEX suspension can be supplied with a dump valve which allows the trailer to be lowered several inches to facilitate loading or leveling Once loaded the valve is reversed and the system is pressurized to raise the trailer back up to normal running height Axle Adjustment 1 Support the trailer frame on a level surface If the wheels are already mounted make sure they are clear of the ground
5. Brake lock up should be avoided as it results in poor vehicle stability and control General Maintenance Electric Brakes Brake Adjustment 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 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 914199 suigjs S Hulyeig Do not lift or support trailer on any part of the axle or the suspension system Never crawl under your trailer unless it is resting on properly placed jack stands 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 starwheel 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 Note For drop spindle axles a modified adjusting tool may be necessary 4 Then rotate the starwheel 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 shoul
6. Instructions for Brake Rotor Kit 3 5K Disc Hydraulic Brakes Notice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance Remove the old brake rotor 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 place supports on any part of the suspension system Never crawl under your trailer unless it is resting on properly placed jack stands 2 Remove the wheel from the hub leaving the brake exposed 3 Disconnect the brake actuation system Check that the hydraulic system has zero pressure and that the hub and rotor rotates freely 4 Remove the two caliper mounting bolts Do not allow the caliper assembly to hang from the hose Do not disconnect the hose or allow air into the hydraulic system With the caliper assembly out of the way remove the brake rotor Save the brake mounting hardware for reinstalling the brake calipers Installing the new brake rotor 1 First inspect the brake assembly for grooves flaking cracks heat checking thickness variation insufficient rotor thickness and look to see that the mounting hardware is Braking Systems Hydraulic 30 straight Replace any component as needed or desired per manufacturer recommendations 2 Install the new brake rotor by fitting it onto the hub flush with the hubface 3 Remoun
7. 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 3 Fasten safety chains and breakaway switch actuating chain securely Make certain the breakaway battery is fully charged 67 Storage ok 9 Inspect towing hookup for secure attachment Load your trailer so that approximately 10 of the trailers total weight is on the hitch For light trailers this should be increased to 15 Do Not Overload Stay within your gross vehicle rated capacity consult your trailers identification plate Inflate 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 brakes are synchronized and functioning properly 10 Check tightness of hanger bolt shackle bolt and U bolt nuts per torque values specified in manual 11 Check operation of all lights 12 Check that your trailer is towing in a level position and adjust hitch height if required 68 Brake Adjustment Brake Magnets Brake Linings Brake Controller Brake Cylinders Trailer Brake Wiring Breakaway System Hub Drum Wheel Bearings amp Cups Suspension Parts Wheel Nuts and Bolts Tire Inflation Pressure Tir
8. 39 Brake Drum Inspection es ccceeeceeeseeeeeeeeneeteeeeeeeeenenenes 40 Bearing Inspection cinereis nte nitet nci 41 Bearing Lubrication Grease ssseseeees 42 Bearing Lubrication Oil eee 43 Recommended Wheel Bearing Lubrication Specs 43 Seal Inspection and Replacement sesssss 44 Bearing Adjustment and Hub Replacement 44 Typical E Z Lube Prior to Spring 2002 45 Typical E Z Lube After Spring 2002 sssss 45 E Z Ll ube M EUbrICatlOTic ss iiio eve ae 46 Nev R Lube Drums Bearings e 47 Drum Removal iiti rre Hellen 47 Bearing Inspection ccesecccceeeeeeseeceeeeecereseeeneneneeneeneeneees 48 Nev R Lube Bearing End Play Inspection 49 Bearing Replacement and Drum Installation 49 Suspensions Suspension Systems ceu iicet critt secre repre snot d Berge ced dtum 51 Double Eye Leaf Springs eccceescesseeseseeeeeeeeeteeeeeeeeeeeaees 51 Slipper Leaf Springs rrm rarei 52 Inspection and Replacement seeeeeenee 53 Suspension Fastener Torque Values Chart 53 Torflex amp Suspension seseeseseeeeeneene 55 Airflex V SUSPENSION cioe DI is pere cine 56 Wheels and Tires lp 59 Wheel Selection ii
9. Nut Retainer n Nut E CQ bod 45 Iad E Z Lube Lubrication The procedure is as follows 1 Remove the rubber plug from the end of the grease cap 2 Place a standard grease gun onto the grease fitting located in the end of the spindle Make sure the grease gun nozzle is fully engaged on the fitting 3 Pump grease into the fitting The old displaced grease will begin to flow back out the cap around the grease gun nozzle 4 When the new clean grease is observed remove the grease gun wipe off any excess and replace the rubber plug in the cap 5 Rotate hub or drum while adding grease Note The E Z Lube feature is designed to allow immersion in water Axles not equipped with E Z Lube are not designed for immersion and bearings should be repacked after each immersion If hubs are removed from an axle with the E Z Lube feature it is imperative that the seals be replaced BEFORE bearing lubrication Otherwise the chance of grease getting on brake linings is greatly increased Inner Bearing Rubber Plug Outer Bearing Grease Flow Grease Fitting Spring Loaded Metal End Cap Double Lip Seal Hubs Drums Bearings 46 Nev R Lube Drums Bearings Dexter s Nev R Lube bearings are comprised of opposed tapered roller bearing cones sealed inside of a precision ground one piece double cup arrangement These bearings are designed with a small amount of axial end play This end p
10. S Be sure to wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious injury suoisuadsn All of the pivot points on your standard suspension system have been fitted with anti friction bearing materials which do not require routine lubrication When otherwise servicing the unit these pivot points may be lubricated if you so desire If your trailer has been fitted with the Heavy Duty Attaching Parts Kit you should lubricate periodically to ensure long component life Torflex amp 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 axles through the Mounting Bracket Axle Tube unique arrangement of a steel torsion bar surrounded by four natural rubber cords encased in the main structural member of the axle beam Torsion Arm The wheel hub 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 Spindle Torsion Bar Iad
11. 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 Getting Started Setup and Adjustment For proper performance all new axles should have the following 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 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 will operate as follows Retractor Spring Primary Shoe Secondary Shoe Actuating Lever Shoe Hold Down Spring Front of Brake Adjuster Magnet Adjuster Spring When the electrical current is fed into the system by the controller it flows through the electromagnets in the brakes The hig
12. 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 effective than in the forward direction 23 9ine1pAH swiayshs Burjeig aD Braking Systems Hydraulic Another variation is called a free backing brake which is commonly used on trailers with a surge hitch system When backing with a surge brake hitch normal r li Anchor Post brakes are app ed Retractor Hydraulic Wheel through the surge pilis Cylinder Springs mechanism and if there is more brake force on Backing D the trailer than the tow Plate vehicle can override no S96 Hold Down backing is possible The Seconda NX S Z Spring free backing brake was snog A Pri Shi developed to allow Adjuster Spring rimary Shoe backing in this Adjuster Assembly application This brake has a primary shoe on a pivot which allows normal application in the forward direction but allows the primary shoe to rotate away from the drum surface when backing Self Adjusting Mechanism for 12 4 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 res
13. allow air into the hydraulic system With the caliper assembly out of the way remove the brake rotor Save the brake mounting hardware for reinstalling the brake calipers Installing the new brake rotor 1 First inspect the brake assembly for grooves flaking cracks heat checking thickness variation insufficient rotor thickness and look to see that the mounting hardware is straight Replace any component as needed or desired per manufacturer recommendations Install the new brake rotor by fitting it onto the hub flush with the hubface Note Use two lug nuts to secure rotor against the hub face when reassembling the calipers After the calipers are assembled remove the lug nuts Remount the caliper assembly onto the caliper attaching bracket It may be necessary to push the piston into the calipers to obtain enough clearance Torque mounting bolts to 25 50 Ft Lbs Spin the rotor to ensure that there is enough clearance between the rotor and the cross over brake line Reconnect the brake actuation system Refer to your Operation Maintenance Service Manual for proper operation Remount the wheel Refer to your Operation Maintenance Service Manual for proper wheel nut torque procedures Spin the wheel to ensure that there is enough clearance between the wheel cross over brake line and rotor Instructions for Brake Pad Kit 6K or 8K Disc Hydraulic Brakes Notice to Buyer It is recommended that all brakes be replace
14. of the widest end of the bearing into the outer edge of the grease pile closest to the thumb forcing grease into the interior of the bearing Hubs Drums Bearings 3 Repeat this while rotating the bearing from roller to roller 42 4 Continue this process until you have the entire bearing completely filled with grease 5 Before reinstalling apply a light coat of grease on the bearing cup Bearing Lubrication Oil If your axles are equipped with oil lubricated hubs periodically check and refill the hub as necessary with a high quality hypoid gear oil to the level indicated on the clear plastic oil cap The oil can be filled from either the oil fill hole if present in the hub or through the rubber plug hole in the cap itself sBuueeg sunig sqng Recommended Wheel Bearing Lubrication Specifications Grease Thickener Type esee Lithium Complex Dropping Point ssesssss 215 C 4199F Minimum CONSISTENCY sarisepi iesenii auaina NLGI No 2 Additives EP Corrosion amp Oxidation Inhibitors viscosity INGOX crm 80 Minimum Approved Sources Mobil Oil eeeeeeene Mobilgrease HP Mobilith AW2 Exxon Staindatdi et iceci teca eee xa ane tta e ns Ronex MP Kendall Refining Co eseseessss Kendall L 427 Ashland Oil Co Valvoline Multipurpose GM 46 Lu bricarits cove ccce iron to onte ttc 76 Mu
15. pads toward the calipers Align the holes in the brake pads with the ones in the calipers Insert the brake pad retaining bolt and torque to 15 25 Ft Lbs Reconnect the brake actuation system Refer to your Operation Maintenance Service Manual for proper operation Bleed and flush brake system per your actuation systems Operation Maintenance Service Manual Remount the wheel Refer to your Operation Maintenance Service Manual for proper wheel nut torque procedures Spin wheel to ensure proper clearance between the wheel cross over brake line and the rotor 9ine1pAH swayshs Burjeig 35 Iad Braking Systems Hydraulic 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 36 SYMPTOM Troubleshooting Noisy Brakes CAUSES REMEDIES Underadjustment Adjust Lack of Lubrication Lubricate
16. the controller does not produce this voltage control consult your controller manual 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 314129 3 suigjs S Burjeig Iad Braking Systems Electric 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 Magnet Amperes Chart Brake Amps Two Four Six Size Magnet Brakes Brakes Brakes 7x 1 4 2 5 5 0 10 0 15 0 10 x 11 2 3 0 6 0 12 0 18 0 10 x 2 4 3 0 6 0 12 0 18 0 12x2 3 0 6 0 12 0 18 0 12 4 x 2 2 3 0 6 0 12 0 18 0 12 4 x 3 s 3 0 6 0 12 0 18 0 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 c
17. tire 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 Soll pue sjaauM Use only the approved rim contours as shown in the Tire and Rim Yearbook or the tire manufacturer s catalog The use of other rim contours is dangerous Failure to use the proper rim contour can result in explosive separation of the tire and wheel and could cause a serious accident 59 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 cracked 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 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 Ibs ft of torque Torque wrenches are the best method to assure the proper amount of torque is being applied to a fastener Wheel nut or bolts must be tightened and maintained at th
18. 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 Note The capacity rating molded into the sidewall of the tire is not always the proper rating for the tire if used in a trailer application Use the following guidelines 1 LT and ST tires Use the capacity rating molded into the tire 2 Passenger Car Tires Use the capacity rating molded into the tire sidewall divided by 1 10 for trailer use Use tire mounting procedures as outlined by the Rubber Manufacturer s 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 solutions of tire wear problems Tire wear should be checked frequently because once a wear pattern becomes firmly established in a tire it is difficult to stop even if the underlying cause is corrected 62 Tire Wear Diagnostic Chart Wear Pattern Adjust pressure to Center Wear Over Inflation particular loa
19. 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 914199 SW JS Hulyeig Braking Systems Electric Dexter Electric Brakes Wired in parallel RR a Breakaway Battery Provides power to actuate trailer brakes in the event of trailer breakaway Controller Controls the set point at which the trailer brakes are energized during braking Battery Connect to controller per manufacturer s directions Breakaway Switch Switches battery Connector power Used to connect and disconnect to brakes if trailer and tow vehi
20. 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 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 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 Brake Caliper Kit 3 5K Disc Hydraulic Brakes Notice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance 28 Remove the old brake caliper 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 place supports on any part of the suspension system Never crawl under your trailer unless it is resting on properly placed jack stands 2 Remove the wheel from the hub leaving the brake exposed 3 Disconnect the brake actua
21. 0 000 an 12 000 Ib axle models The fixed caliper method uses pistons situated on both sides of the rotor During actuation hydraulic pressure pushes against the pistons to apply the inboard and outboard brake pads equally to decelerate the rotating rotor The caliper is fixed and stays stationary during brake actuation and brake adjustment Brake pad to rotor clearance is maintained as lining wear occurs via the brake piston and internal caliper seal The fixed caliper design is used on the Dexter 8 000 Ib axle model Disc brakes yield the same brake action 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 26 General Maintenance Hydraulic Brakes Drum Brake Adjustment Manual 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 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 trailer on any part of the axle or the suspension system Never crawl under your trailer unless it is resting on properly placed jack stands 2 Remove t
22. If the air actuation system has been installed make sure the air pressure in the air bags is bled off before lifting the trailer CAUTION Lifting the trailer with air system pressurized will overextend the air bags and can result in damage to the air bags 56 S 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 suoisuadsn 2 Measure from king pin to spindle center on each side To simplify this process plumb lines may be dropped from the king pin and from the centerline of each spindle end Measurements A and B can then be taped on the floor to eliminate any miss measurement due to sagging of the tape long measurements Compare A and B measurements see Figure 1 3 Loosen all the U bolt nuts slightly and move the axle assembly with the adjusting screws located on the front and rear of the axle seat Move front axle to correct alignment position based on previous findings of A and B measurements Make sure both front and rear adjusting screws are snug after axle is realigned Then re tighten the U bolt nuts to 100 to 120 Ib ft Adiusting Sorew Iad 4 Re measure A and B as before to assure that A and B dimensions are within 1 16 of each other If dimensions are not to specification then repeat adjustment procedure
23. Md DEXTER AXLE Operation Maintenance Service Manual 600 8 000 Lb Axles amp Related Components 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 The Dexter product line the most complete in the industry is the result of over 30 years of experience in the design testing and manufacture of trailer axles The Dexter running gear system consists of spindles hubs drums brakes and wheels which are engineered to provide you the finest towing and stopping performance currently available in the industry 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 the axle beam hubs drums spindles brakes magnets rims wheels and most of the steel stampings used in the attachment of your axle to your trailer Dexter has the most complete state of the art manufacturing facilities which
24. YEAR WARRANTY Dexter Axle warrants to the original purchaser that its Nev R Lube bearings and the suspension components only of its Torflex axles shall be free from defects in material and workmanship for a period of five years from the date of first sale of the trailer incorporating such components LIMITED 7 YEAR WARRANTY Dexter Axle warrants to the original purchaser that its Predator Series electric brake controllers shall be free from defects in material and workmanship for a period of seven 7 years from the date of purchase EXCLUSIVE REMEDY Dexter Axle will at its option repair or replace the affected components of any defective axle repair or replace the entire defective axle or refund the then current list price of the axle In all cases a reasonable time period must be allowed for warranty repairs to be completed Allowance will only be made for installation costs specifically approved by Dexter Axle WHAT YOU MUST DO In order to make a claim under these warranties 1 You must be the original purchaser of the vehicle in which the Spring Suspension Axles or Torflex Axles were originally installed 2 You must promptly notify us within the warranty period of any defect and provide us with any substantiation that we may reasonably request 70 3 The axles wheels or suspensions must have been installed and maintained in accordance with good industry practice and any specific Dexter Axle re
25. an 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 AMMETER 20 The most common electrical problem is low or no voltage and amperage at the brakes Common 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 ooRoOomNm 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 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 be
26. available on line at the Dexter Marketplace ready for immediate shipment direct to your door www dexteraxle com Bearing Replacement Chart Replacement Parts Kits JJ cD T 9 e CD Brake Hub Dexter Kit Industry Part zj Size Size Bearings Number Cup Cone CD 7x1 4or5 Inner K71 306 00 L44610 L44649 z Bolt Outer K71 306 00 L44610 L44649 10x1 4or5 Inner K71 307 00 LM67010 LM67048 B Bolt Outer K71 306 00 L44610 L44649 10x2 4 4or5 Inner K71 390 00 L68111 L68149 N Bolt Outer K71 306 00 L44610 L44649 E 12x2 6 Bolt Inner K71 308 00 25520 25580 IL Outer K71 307 00 LM67010 LM67048 ce 12x2 5 Bolt Inner K71 308 00 25520 25580 Demount Outer K71 309 00 15245 15123 12x2 8 Bolt Inner K71 308 00 25520 25580 Outer K71 310 00 14125A 14276 12x2 6Bolt Inner K71 308 00 25520 25580 Outer K71 309 00 15245 15123 12 x 2 2 8 Bolt Inner K71 308 00 25520 25580 Outer K71 415 00 02420 02475 12 x 39 s 8 Bolt Inner K71 308 00 25520 25580 Outer K71 415 00 02420 02475 Special Application Seal Replacement Reference Brake Hub Seal Part No Size Size Std E Z Lube Cil 7x 11 4 4 or 5 Bolt 010 009 00 K71 301 00 NA 10 x 21 4 4 5 or 6 Bolt 010 004 00 K71 303 00 NA 12x2 5 Bolt Demount 6 or 8 Bolt 010 054 00 K71 305 00 K71 305 00 12 4 x 2 o 8 Bolt K71 386 00 K71 386 00 K71 386 00 12 4 x 33 s 8 Bolt K71 386 00 K71 386 00 K71 386 00 2 12 diameter seal journa
27. cle breakaway Occurs Always ground trailer brakes through connector 314129 3 suigjs S Hulyeig Iad Typical Trailer Wiring Pouble Stop amp Left Turn Signal Bulb g To Terminal 5 9 m9 I 9 ic Yellow Auxiliary Circuit License Tail amp Terminal 7 m White 1 Common Ground Running Lights 1 Terminal 3 Grey Auxiliary Circuit r Green 3To Tail Running amp Terminal 8 License Lights z r Hed 5 Stop amp Left Turn I Black 4 Battery Charge Battery Charge 4 eel Circui Terminal 4 Black gt Yellow 7 Aux Circuit 1 Orange 9 Aux Circuit Brown 6 Stop amp Right Turn j Blue 2 Electric Brake Electric Brake i Terminal 2 Blue 7 Batt Hreakpwoy Switch Grey 8 Aux Circuit i White Common Ground Electric Brake p 1 Ground Terminal Pa o Terminal 1 1 White S range Auxiliary Circuit amp Terminal 9 Double Stop amp Right Turn Signal Filament D Terminal 6 i Bulb l Trailer Towing Vehicle 7 Circuit Receptacle 9 Circuit Receptacle Auxiliary Stop amp Clearance amp Battery LH Turn Tail Lights Charge Ground Clearance amp Tail Lights inm amp Stop amp urn RH Turn Battery Brakes V Charge Brakes Stop amp Ground Braking Systems Electric Auxiliary 10 Auxiliary RH Turn Auxiliary View Looking into Tow Vehicle Receptacle How to Use Your Elec
28. commendations including those specified in Dexter Axle s publication Operation Maintenance Service Manual EXCLUSIONS These warranties do not extend to or do not cover defects caused Auguew 1 The connecting of brake wiring to the trailer wiring or trailer wiring to the towing vehicle wiring 2 The attachment of the running gear to the frame 3 Hub imbalance or any damage caused thereby 4 Parts not supplied by Dexter Axle 5 Any damage whatever caused by or related to any alteration of the axle including welding supplemental brackets to the axle Use of an axle on a unit other than the unit to which it was originally mounted 7 Normal wear and tear 8 Alignment 9 1 9 Improper installation 0 Unreasonable use including failure to provide reasonable and necessary maintenance as specified in Dexter Axle s publication Operation Maintenance Service Manual including required maintenance after Prolonged Storage 12 Improper wheel nut torque 13 Cosmetic finish or corrosion LIMITATIONS 1 Inall 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 i
29. d all be set at the same clearance Iad 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 work 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 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 replaced if worn unevenly or abnormally As indicated below a straightedge should be used to check magnet condition For best results the magn
30. d at the same time to insure balanced braking performance Remove the old brake pads 1 Jack up trailer and secure on adequate capacity jack stands 32 Follow trailer manufacturers recommendations for lifting and supporting the unit Do not lift or place supports on any part of the suspension system Never crawl under your trailer unless it is resting on properly placed jack stands 2 Remove the wheel from the hub leaving the brake exposed 3 Disconnect the brake actuation system Check that the hydraulic system has zero pressure and that the hub and rotor rotates freely 4 Remove the brake pad retaining bolt 5 Remove the old pads from the caliper assembly Save the brake pad retaining hardware for reinstalling the new pads onto the caliper 9i ne1p AH swash uerg Installing the new brake pads 1 First inspect the brake assembly for grooves flaking cracks heat checking thickness variation insufficient rotor thickness and look to see that the mounting hardware is straight Replace any component as needed or desired per manufacturer recommendations 2 Press the caliper pistons into the calipers until enough clearance is available to fit the new pads between the pistons and the rotor Note Use two lug nuts to secure rotor against the hub face when reassembling the new pads After the pads are assembled remove the lug nuts 3 Install the new brake pads by sliding them in one at a time between the cal
31. d per tire catalog Adjust pressure to Edge Wear Under Inflation particular load per tire catalog Make sure load doesn t Side Wear Loss of camber exceed axle rating or overloading Align at alignment shop Soll pue sjaauM mm Incorrect toe in Align at alignment shop Cupping Out of balance Check bearing adjust v ment and balance tires Avoid sudden stops Wheel lockup amp when possible and rc tire skidding adjust brakes 63 aD Replacement Parts Kits Replacement Parts Kits Magnet Replacement Kits Brake Magnet Kit No Wire Nut Torque Size one magnet per kit Color Brake Mounting 7 x 11 4 K71 057 00 White 45 70 10 x 234 K71 104 00 Green 45 70 12x2 K71 105 00 White 25 50 12x2 K71 125 00 7K Black 25 50 12 45 x2 KT1 441 00 Red 55 80 121 4 x 33 s K71 375 00 oval magnet White 55 80 Brake Shoe Replacement Kits Brake Size Shoe and Lining Replacement 1 Brake Electric Hydraulic 7 x 1 4 K71 045 00 N A 7 x 194 N A K71 466 00 10 x 21 4 K71 047 00 K71 267 00 Free Backing K71 393 00 Corrosion Resistant K71 423 00 12 x 2 5 2K K71 048 00 K71 268 00 12x2 7K K71 127 00 Free Backing Free Backing Corrosion Resistant K71 269 00 th K71 270 00 rH K71 394 00 iu K71 395 00 rH K71 427 00 th K71 428 00 rH 12 4 x 2 2 K71 497 00 K71 496 00n4 N A 12 x 3 s K71 499 00 H K71 498 00rH K71 165 00 i4 K71 166 00 nu Over 200 repair kits now
32. dure allows the brake shoes to seat in to the drum surface 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 SYMPTOM Troubleshooting CAUSES Open Circuits 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 Broken Brake Components Replace Com
33. e proper torque levels to prevent loose wheels broken studs and possible dangerous separation of wheels from your axle 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 sequence shown for Wheel Torque Requirements The tightening of the fasteners should be done in stages Following the recommended sequence tighten fasteners per wheel torque chart below 4 Wheel nuts bolts should be torqued before first road use and after each wheel removal Check and re torque after the first 10 miles 25 miles and again at 50 miles Check periodically thereafter Wheels and Tires 60 Wheel Torque Requirements Soll pue sjaauM Wheel Torque Sequence Size 1st Stage 2nd Stage 3rd Stage 12 20 25 35 40 50 75 13 20 25 35 40 50 75 14 20 25 50 60 90 120 15 20 25 50 60 90 120 16 20 25 50 60 90 120 16 5 x 6 75 20 25 50 60 90 120 16 5 x9 75 55 60 120 125 175 225 14 5 Demount Tighten sequentially to 85 95 17 5 Hub Pilot 50 60 100 120 190 210 Clamp Ring amp Cone Nuts 17 5 Hub Pilot 50 60 190 200 275 325 5 s Flange Nuts 4 BOLT 5 BOLT 6 BOLT 8 BOLT 261 Iad Wheels and Tires Tires Before mounting tires onto the wheels make certain that the rim size and contour is approved for the
34. e Condition Maintenance Schedule Function Required Test that they are operational Adjust to proper operating clearance Inspect for wear and current draw Inspect for wear or contamination Check for correct amperage amp modulation Check for leaks sticking Inspect for cracks leaks kinks Inspect wiring for bare spots fray etc Check battery charge and switch operation Inspect for abnormal wear or scoring Inspect for corrosion or wear Clean amp repack Inspect for leakage Replace if removed Inspect for wear loss of arch Inspect for bending loose fasteners wear Tighten to specified torque values Inspect for cracks dents or distortion Inflate tires to mfg s specifications Inspect for cuts wear bulging etc 3 Months or 3000 Miles At Every 69 6 Months or 6000 Miles 12 Months or 12000 Miles ainpayss a2ueuajule A aD Warranty Dexter Axle Limited Warranty WHAT PRODUCTS ARE COVERED All Dexter trailer axles wheels and suspensions excluding Dexter 6000 series Manufactured Housing Axles LIMITED 2 YEAR WARRANTY Dexter Axle warrants to the original purchaser that its axles wheels suspension systems and Predator Series 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 LIMITED 5
35. e distributor nearest you Visit us at our website www dexteraxle com Dexter Axle Dexter Axle 11870 N 650 East Road 75 East Dexter Axle N Manchester IN 46962 Albion IN 46701 222 Collins Rd Fax 260 982 7511 Fax 260 636 3030 Elkhart IN 46516 Ph 260 982 4047 Ph 260 636 2195 Fax 574 295 8094 Ph 574 295 1900 Dexter Axle West Pearl St Fremont IN 46737 Fax 260 495 1701 RAS Ph 260 495 5100 400 Collins Rd Elkhart IN 46516 Fax 574 522 5208 Ph 574 295 3535 Dexter Axle Dexter Axle 1 Municipal Dr 2700 S Yates Ave Carrollton MO 64633 Los Angeles CA 90040 Fax 660 542 1133 Fax 323 724 8193 e Ph 660 542 2232 Ph 323 726 3157 Dexter Axle 500 S E 27th St El Reno OK 73036 Fax 405 262 9089 Ph 405 262 6700 Dexter Axle Perimeter Rd Monticello GA 31064 Fax 706 468 2966 Ph 706 468 6495 Company Headquarters 2900 Industrial Parkway East Elkhart IN 46516 Fax 574 295 8666 Ph 574 295 7888 DEXTER AXLE NO PART OF THIS CATALOG MAY BE REPRODUCED WITHOUT DEXTER AXLE S PERMISSION ALL PART NUMBERS DIMENSIONS AND SPECIFICATIONS IN THIS CATALOG ARE SUBJECT TO CHANGE WITHOUT NOTICE 3 03 Dexter Axle 2003 LIT 001 00
36. els 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 Storage 66 2 Inspect suspension for wear 3 Check tightness of hanger bolt shackle bolt and U bolt nuts per recommended torque values 4 Check brake linings brake drums and armature faces for excessive wear or scoring 5 Check brake magnets with an ohmmeter The magnets should check 3 2 ohms If shorted or worn excessively they must be replaced 6 Lubricate all brake moving parts using a high temperature brake lubricant LUBRIPLATE or Equivalent aheiojs Do not get grease or oil on brake linings or magnet face 7 Remove any rust from braking surface and armature surface of drums with fine emery paper or crocus cloth Protect bearings from contamination while so doing 8 Inspect oil or grease seals for wear or nicks Replace if necessary 9 Lubricate hub bearings Refer to procedure in manual 10 Reinstall hubs and adjust bearings per instructions in manual 11 Mount and tighten wheels per instructions in manual 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
37. enable us to provide you the trailer owner with the finest product possible For all your running gear needs Look frst toDenter Now visit us at our web site www dexteraxle com Iad Introduction Important Safety Notice 0 00 eeceeceeeeeeeeeeeeeeeeneeeeeeeeaeeeeeeseeeeteeeneees 4 Getting Started Setup and Adjustment ussuuuss 4 Braking Systems Electric Electric Brake Siran s emet serie eeu r nenii 5 Features c c 6 Parking Brake Option sse 6 Self Adjusting Feature essen 6 Brake Controllers iot ise ceci tees tse kite conc 7 Typical Trailer WINO sietach 10 How To Use Your Electric Brakes Properly 11 Trailer Wire Size Chart ssessseeeeeee 11 Synchronizing Your Trailer Brakes esssssss 12 General Maintenance Electric Brakes sssss 13 Brake AG UStMOMNt c 13 Brake Cleaning and Inspection seesesessss 14 Brake LUbfFICatlOlo s eniin eres tetas ardens 14 MEDICINE 15 Shoes and Linirigs recenter pete eret rer tele toros 16 Introduction to Troubleshooting n 16 Troubleshooting Chart Electric eesssesess 17 Tioubleshooltlrig tuia euet tire ER inet ER Spe debt dues 19 How to Measure Voltage eese 19 H
38. eradjustment Adjust Brakes Malfunctioning Actuation System Troubleshoot System 1 Manual Adjust Brakes Brake Pojuntment Automatic Make Several SE ares Reverse Stops Excessively Worn Replace Shoe Brake Linings and Lining Incorrect Lining shoe ana LIMNI Repair Grease Seal or puer or Fluid Wheel Cylinder Install aked zining New Shoe and Lining Frozen Master Cylinder Recondition or Replace or Wheel Cylinder Pistons All Cylinders Brake Fluid Weak Brakes Glazed Lining Reburnish or Replace Excessive Drum Wear Replace Trapped Air in Lines Bleed System Overloaded Trailer Correct Malfunctioning Actuating System Troubleshoot System Brake Adjustment Not Correct Harsh Brakes Manual Adjust Brakes Automatic Make Several Reverse Stops Grease or Fluid Replace Shoes on Linings and Linings Grease or Oil on Linings Clean or Replace Surging Brakes Braking Systems Hydraulic Out of Round Drums or Cracked Drums Machine or Replace 38 Hubs Drums Bearings Dexter Axle offers several types of bearing arrangements and FA lubrications methods c2 Dexter s standard wheel bearing configuration consists of opposed tapered roller bearing cones and cups fitted inside of a 3 precision machined cast hub This method of using
39. et 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 314129 3 suigjs S Hulyeig aD 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 within 1 6 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 Acceptable Hairline Cracks 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 proce
40. ew brake caliper 1 First inspect the brake assembly for grooves flaking cracks heat checking thickness variation insufficient rotor thickness and look to see that the mounting hardware is straight Replace any component as needed or desired per manufacturer recommendations Braking Systems Hydraulic 34 Connect the new cross over brake line on the bottom sides Assemble the new caliper assembly Note Use two lug nuts to secure rotor against the hub face when reassembling the calipers After the brake is assembled remove the lug nuts One caliper will be used on the inboard side with the hydraulic line fitting adapter installed on the top side of the piston boss The other caliper will be used on the outboard side with the bleed screw installed at the top of the piston boss Install both of these calipers onto the attaching bracket Make sure that the bleed screw points up and is located on the outboard caliper Torque bolts to 25 25 Ft Lbs of the piston boss on both calipers Note Make sure the cross over line fits snug around the calipers and rotor without touching the rotor Spin the rotor to ensure there is proper clearance Torque the cross over line to 12 15 Ft Lbs Torque the bleed screw and the hydraulic line fitting adapter to 60 76 Inch Lbs Reassemble the brake pads into the disc brake Make sure to locate the brake lining side of the pads toward the rotor surface and the steel side of the
41. h capacity electromagnets 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 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 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 914199 suiejs S Hulyeig Iad aD 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 2 They can be modulated to provide more or less braking force thus easing the brake load on the towing vehicle 3 They have very little lag time from the moment the tow vehicle s brakes are actuated until the trailer brakes are actuated 4 Inan emergency situation they can provide some braking independent of the tow vehicle Par king Brake Option not available on all sizes Dexter electric brakes with parking brake option are
42. han it actually is This same phenomenon will occur when checking any wheel end even those equipped with conventional bearing sets Bearing Replacement and Drum Installation 1 Once the drum and bearing assembly is removed from the axle remove internal snap ring from the bearing bore that retains bearing 2 Using an arbor press and mandrel press the bearing out of the drum Bearing will exit on the wheel side of the drum 49 sBuueeg suinig sqng aD Hubs Drums Bearings 3 o Qo 10 11 12 When replacing a Nev R Lube bearing pack the bore in the hub should be cleaned and inspected for visual damage replace as necessary Installing the new bearing should be conducted using an Be arbor press and a d hollow or stepped mandrel to press only i on the outer housing Bearing of the bearing 3 assembly failure to follow procedure will Hub damage bearing and N i uii or seals during installation Press bearing until it seats against the backup shoulder machined into the hub Install internal snap ring into hub Clean and inspect spindle shaft Apply a light coating of anti seize lubricant to the spindle shaft prior to assembling drum Install drum assembly onto spindle Do Nor Force Install steel washer onto spindle end Start self locking nut onto spindle thread by hand Complete installation using a 1 or 17 16 socket and torque wrench Nut should be tor
43. he 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 starwheel 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 Note For drop spindle axles a modified adjusting tool may be necessary 4 Then rotate the starwheel 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 Most of the brake components are very similar to those used in electric brakes and maintenance is comparable for the hub and drum shoes and linings and bearings Specific maintenance activities are as follows B72 9i ne1p AH swiayshs Huryesg aD Braking Systems Hydraulic 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 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 146 or less contaminated
44. iper pistons and the rotor The pads are the same for the inner and outer side of the rotor Make sure the brake lining side of the pad faces the rotor and the steel backing faces the caliper pistons 4 Align the brake pad mounting holes with the holes in the caliper Insert the brake pad retaining bolt and torque to 15 25 Ft Lbs Iad 33 aD 5 Reconnect the brake actuation system Refer to your Operation Maintenance Service Manual for proper operation 6 Remount the wheel Refer to your Operation Maintenance Service Manual for proper wheel nut torque procedures Instructions for Brake Caliper Kit 6K or 8K Disc Hydraulic Brakes Notice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance Remove the old brake pads 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 place supports on any part of the suspension system Never crawl under your trailer unless it is resting on properly placed jack stands 2 Remove the wheel from the hub leaving the brake exposed 3 Disconnect the brake actuation system Check that the hydraulic system has zero pressure and that the hub and rotor rotates freely 4 Remove the hose from the caliper then remove the four caliper mounting bolts Do not allow the caliper to hang from the hose Installing the n
45. l prior to 10 97 2 25 diameter seal journal after 10 97 65 ID 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 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 3 Lubricate mechanical moving parts such as the hitch and suspension parts that are exposed to the weather 4 Boattrailer 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 Onoil 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 After Prolonged Storage Inspection Procedures Before removing trailer from jack stands 1 Remove all whe
46. lay is essential to the longevity of the bearings service life Drum Removal Whenever the hub equipment on your axle must be removed for inspection or maintenance the following procedure should be utilized 1 Elevate and support the trailer unit per manufacturer s instructions 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 g sunig sqnH shuuea 2 Remove the wheel 3 Remove the grease cap from the hub by carefully prying progressively around the flange 4 Remove snap ring on the end of the spindle Remove torque instruction washer 5 Unscrew the spindle nut counterclockwise and remove the spindle washer 6 Carefully remove the hub from the spindle The Nev R Lube bearing cartridge will remain in the hub Note Do not remove cartridge bearing from the hub bore unless replacement of the bearing cartridge is intended Special tools and techniques are required for removal of the old bearing Bearing Inspection Important 1 Elevate and support the trailer unit per manufacturer s instructions 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 Check for excessive wheel end clearance by pulling the tire assembly towards you and by pushing the assembly away from you Slight end pla
47. ltiplex EP Citgo Petroleum renes Lithoplex MP 2 Mp sep Mystik JT 6 Hi Temp Grease Cil SAE 90 SAE 80W 90 SAE 75W 90 Approved Sources Union Oil Co eeeese Unocal MP Gear Lube Exxon CO USA creen Gear Oil GX 80W 90 Mobil Oil Corp eseeeeeesss Mobilube SHC 75W 90 Pennzoil Prod Co Gear Plus 80W 90 GL 5 Gear Plus Super 75W 90 Note The convenient lubrication provisions of the E Z Lube and the oil lubrication must not replace periodic inspection of the bearings Iad 43 Iad Hubs Drums Bearings Seal Inspection and Replacement Whenever the hub is removed inspect the seal to assure that it 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 To replace g Bad Seal Nicks and Tears the seal REPLACE SEAL 1 Pry the seal out of the hub with a screwdriver Never drive the seal out with the inner bearing as you may damage the bearing 2 Apply a PERMATEX Sa sealant to the outside of the M C WO new seal Wiese gt Y Note Permatex sealant Ne should not be used on rubber encased seals 3 Tap the new seal into place using a clean wood block ALT SN Bearing Adjustment and Hub Replacement If the hub has been removed or bearing adjustment is required the following adjustment pr
48. mechanically operated by a cable Cable force applied to the parking lever creates a torque through the pivot pin and cam assembly Torque transferred to the parking cam results in a spreading force between the primary and secondary shoes The shoes in turn move towards the drum until contact is made Friction generated between the drum and lining contact surface keeps the drum from rotating under normal loading conditions Self Adjusting Feature 12 brakes 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 Series DX2 This controller features a patented pendulum 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 easy adjustment and a digital LED display to show the voltage output A manual override sends full voltage
49. move freely In multiple axle installations the action is the same with the additional movement of the equalizer assembly This serves to transfer instantaneous loads from one axle to another in an effort to equalize the load between the axles Iad 51 Iad Suspensions Grease Lubricated Suspension Bushings Dexter Axle offers an optional heavy duty attaching parts kit for double eye leaf spring suspensions up to 7 000 Ib axle capacity The kit contains extra heavy shackle links bronze bushings for the spring eyes and suspension bolts and equalizers equipped with grease fittings to provide a convenient means to lubricate all the pivot points For availability contact your nearest Dexter Axle facility or visit us online at www dexteraxle com for a complete listing of genuine repair parts 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 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 multi
50. nce and synchronization read the brake controller manufacturer s instructions completely before attempting any synchronization procedure Before making road tests make sure the area is clear of vehicular and pedestrian traffic Make several hard stops from 20 m p h on a dry paved road free of sand 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 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 Minimum vehicle stopping distances are achieved when wheels approach lock up
51. ngs Whenever the hub equipment on your axle must be removed for inspection or maintenance the following procedure should be utilized 39 Iad Hubs Drums Bearings 1 Elevate and support the trailer unit per manufacturers instructions Failure to do proper and periodic maintenance of these important structural parts may result in severe and catastrophic injury or damage to property 2 Remove the wheel 3 Remove the grease cap by carefully prying progressively around the flange of the cap If the hub is an oil lube type then the cap can be removed by unscrewing it counterclockwise while holding the hub stationary 4 Remove the cotter pin from the spindle nut or in the case of E Z Lube versions bend the locking tang to the free position For E Z Lube axles produced after February 2002 a new type of retainer is used Gently pry off retainer from the nut and set aside 5 Unscrew the 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 7 For 7 200 Ib and 8 000 Ib axles a hub puller should be used to assist in drum removal Brake Drum Inspection There are two areas of the brake drum that are subject to wear and require periodic inspection These two areas are the drum surface where the brake shoes make contact during stopping and the armature
52. ocedure must be followed 1 After placing the hub bearings washers and spindle nut back on the axle spindle in reverse order as detailed in the previous section on hub removal rotate the hub assembly slowly while tightening the spindle nut to approximately 50 lbs ft 12 wrench or pliers with full hand force 2 Then loosen the spindle nut to remove the torque Do not rotate the hub 3 Finger tighten the spindle nut until just snug 4 Back the spindle nut out slightly until the first castellation lines up with the cotter key hole and insert the cotter pin or locking tang in the case of E Z Lube V 44 5 Bend over the cotter pin legs to secure the nut or locking tang in the case of E Z Lube 6 Nut should be free to move with only restraint being the cotter pin or locking tang For axles using the new nut retainer 1 Finger tighten the nut until just snug align the retainer to the machined flat on the spindle and press the retainer onto the nut The retainer should snap into place Once in place the retainer nut assembly should be free to move slightly 2 If the nut is too tight remove the retainer and back the nut off approximately one twelfth of a turn and reinstall the retainer The nut should now be free to move slightly 3 Reinstall grease cap Typical E Z Lube Prior to Spring 2002 sBuueeg sunig sqng D Washer Castellated Nut eid Typical E Z Lube After Spring 2002 D Washer
53. ow to Measure Amperage eee 20 Magnet Amperes Chart 20 Braking Systems Hydraulic Hydraulic Drum Brakes etes 22 Actuation Systems i5 tta date naniii eee epica 22 Hydraulic Brake Operation sssseee 23 D SENO e 23 Uni SeN Onari 23 Self Adjusting Mechanism for 12 4 Brakes 24 Hydraulic Parking Brake Option sesseeesss 24 Disc Brakes ente eei eg ep n ERE eiiis 26 General Maintenance Hydraulic Brakes sssss 27 o Drum Brake Adjustment Manual ossessi 27 Wheel Cylinders seen 28 ES Brake Eines rrt cet etie Et inre eet eL peus 28 SMOSS ANA Einirigs 2 coiere Lee eroe rente repens npe 28 e HALO WAL 2 3 eite reir ecovia sid orer ec rnit dei T 28 ce Instructions for Brake Caliper Kit 3 5K Disc Brakes 28 e Instructions for Brake Rotor Kit 3 5K Disc Brakes 30 D Instructions for Brake Rotor Kit 6K or 8K Disc Brakes 31 Instructions for Brake Pad Kit 6K or 8K Disc Brakes 32 i Instructions for Brake Caliper Kit 6K or 8K Disc Brakes 34 2 Introduction to Troubleshooting seisis 36 ul Troubleshooting Chart Hydraulic seesssss 37 Hubs Drums Bearings H bs Dr mis Bearings e nim aiara 39 Hub Removal Standard Bearings ssssse
54. ple axle configurations Equalizer Center Hanger Front Tie Plate Hanger Tie Plate Rear Hanger U Bolt U Bolt Spring Eye Bolts Keeper Bolts Overslung Shown 52 Inspection and Replacement All the components of your suspension system should be visually inspected at 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 below suoisuadsng Failure to do proper and periodic maintenance of these important structural parts may result in severe and catastrophic injury or damage to property Suspension Fastener Torque Values Item Torque Ibs ft Min Max 3 s U Bolt 30 50 The U Bolt 45 70 1 2 U Bolt 45 70 Non shoulder type with 16 threads Shackle Bolt Snug fit only Parts must rotate freely Locking nuts Spring Eye Bolt or cotter pins are provided to retain nut bolt Equalizer Bolt assembly Shoulder Type 30 50 Shackle Bolt with 7 16 threads Worn spring eye bushings sagging springs or broken springs should be replaced using the following method 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 Suspensions After the unit is properly
55. ponents 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 17 314129 3 SW JS Burjeig 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 Synchronization 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 Brake Drums Machine or Replace Faulty Controller Test amp Correct O
56. qued to 145 155 lb ft this torque will set the internal bearing adjustment no other adjustments are to be made Install torque instruction washer onto end of spindle Install external snap ring onto end of spindle to retain washer Inspect assembly for excessive end play noise and rotation restriction prior to mounting final wheel end hardware 50 Suspension Systems co The suspension systems incorporated into Dexter axles are i designed to provide the trailer owner three basic functions 1 Attach the axle to the trailer z 2 Dampen the effects of road shock 5 3 Cushion the cargo or load N All Dexter suspension systems are available in single and multiple axle configurations The three types most commonly available are double eye leaf spring slipper spring and Torflex Double Eye Leaf Springs Double eye springs have eyes formed in each end of the spring with anti friction bushings fitted for wear resistance The springs are held to the axle tube using a system of U bolts and clamp plates and are attached to the trailer as shown Center Hanger i Shackle Link Front T O Rear Hanger Hanger Tie Plate Underslung Shown Articulation of this suspension occurs when the spring becomes loaded and consequently lengthens The double pivot action of the shackle links accommodates this articulation and allows the system to
57. rum brakes and the E H 1600 will generate 1600 psi for maximum output from your Dexter disc brakes The sealed watertight housing contains the electronics necessary to control the high pressure piston pump and proportioning valve for smooth efficient braking 22 Hydraulic 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 a vacuum hydraulic electric hydraulic or air hydraulic system A description of operation of this brake is as follows When the brakes are 1 Anchor Post applied the double ydraulic Wheel acting wheel cylinder Springs Cylinder moves the primary and x secondary shoes Backing towards the drum The Plate frictional force between the brake Secondary drum and lining Shoe attempts to turn the primary shoe into the secondary shoe The secondary shoe is forced onto the anchor pin and from this point the secondary and primary shoes attempt to wrap around In essence the brake has utilized frictional force to help the applying force on both shoes Spring Primary Shoe Adjuster Spring Adjuster Assembly 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 Uni Servo
58. s 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 Iad af Iad WRITTEN ORAL OR IMPLIED IN FACT OR IN LAW INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE These warranties give you specific legal rights and you may also have other rights which vary from state to state THE DURATION OF ANY IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE DURATION OF THE EXPRESS WARRANTIES HEREIN DEXTER AXLE HEREBY EXCLUDES INCIDENTAL AND CONSEQUENTIAL DAMAGES INCLUDING LOSS OF TIME INCONVENIENCE LOSS OF USE TOWING FEES TELEPHONE CALLS OR COST OF MEALS FOR ANY BREACH OF ANY EXPRESS OR IMPLIED WARRANTY INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above exclusion or limitation may not apply to you Inquiries regarding these warranties should be sent to Dexter Axle P O Box 250 Elkhart Indiana 46515 Warranty 7D Genuine Dexter axles and components are available nationwide from our plant locations listed below or through our network of distributors Check our website for th
59. sisti sistiese en eanan ieia oia 59 Torque Requirements eese 60 Wheel Torque Requirements Chart sssesss 61 Ure M M 62 Tire Wear Diagnostic Chart sseee 63 Replacement Parts Kits Magnet Replacement Kits esececesesceeseceeeeseeeeeseeeeeseeeeeeseees 64 Brake Shoe Replacement Kits sees 64 Bearing Replacement Chart 65 Seal Replacement Reference sss 65 Storage Storage Preparation ires iisrsssinsseii eiris desitire ironiari aeai 66 After Prolonged Storage Inspection Procedures 66 Trip Preparation Checklist orte eterne 67 Maintenance Schedule Maintenance Schedule Chart sss 69 Warranty Dexter Axle Limited Warranty ccccscceessseeseseeeeessseeeseneeeesoees 70 sjuajuo jo a qe Iad Introduction Important Safety Notice Appropriate service methods and proper 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
60. st 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 21 314129 3 suigjs S Burjeig aD Braking Systems Hydraulic Hydraulic Drum Brakes The hydraulic brakes on your trailer are much like those on your automobile or light truck The hydraulic fluid from a master cylinder 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 operating pressure required for Dexter brakes e 7 diameter brakes maximum operating pressure is 750 PSI 10 diameter and larger maximum operating pressure is 1 000 PSI Actuation Systems To effectively operate your hydraulic trailer brakes Dexter recommends the Predator E H electrohydraulic actuator powered by the Predator series 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 The Predator E H 1000 will supply 1000 psi for your d
61. 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 Disassemble the U bolts nuts and tie plates Remove the spring eye bolts and remove the spring and place on a suitable work surface If the spring eye bushings are to be replaced drive out the old bushing using a suitable drift punch Be sure to wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious inury 7 Drive the new bushing into the spring eye using a piloted drift punch or a close fitting bolt inserted through the bushing 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 eye bolt shackle bolt and equalizer bolt from the equalizer to be repaired or replaced Take the equalizer to suitable work surface and remove the worn bushings using a suitable drift punch Drive the new bushings into place using a piloted drift punch or a close fitting bolt through the bushing Reassemble in reverse order 54
62. surface where the magnet contacts only in electric brakes 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 is as follows 40 e 7 Brake Drum 7 090 diameter m e 10 Brake Drum 10 090 diameter e 12 Brake Drum 12 090 diameter i e 121 4 Brake Drum 12 340 diameter SG e 8K Rotor 1 03 minimum thickness e 3 5K Rotor 85 minimum thickness The machined inner surface of the brake drum that contacts the eo brake magnet is called the armature surface If the armature d surface is scored or worn unevenly it should be refaced to a 120 eo 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 contaminan
63. t the caliper assembly onto the caliper attaching bracket Place thread locking compound on threads of mounting bolts Torque mounting bolts to 40 50 Ft Lbs Note Use two lug nuts to secure rotor against the hub face when reassembling the calipers After the calipers are assembled remove the lug nuts 4 Reconnect the brake actuation system Refer to your Operation Maintenance Service Manual for proper operation 5 Remount the wheel Refer to your Operation Maintenance Service Manual for proper wheel nut torque procedures 9i ne1p AH swiayshs Huryesg Instructions for Brake Rotor Kit 6K or 8K Disc Hydraulic Brakes Notice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance Remove the old brake rotor 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 place supports on any part of the suspension system Never crawl under your trailer unless it is resting on properly placed jack stands 2 Remove the wheel from the hub leaving the brake exposed 3 Disconnect the brake actuation system Check that the hydraulic system has zero pressure and that the hub and rotor rotates freely 31 Iad Braking Systems Hydraulic 4 Remove the four caliper mounting bolts Do not allow the caliper assembly to hang from the hose Do not disconnect the hose or
64. tapered roller e bearings requires that a minimal amount of axial end play be provided at assembly This end play is essential to the longevity eo of the bearings service life This design is typically lubricated with grease packed into the bearings Oil lubrication is another method which is available in some of the larger axle capacities E Z Lube is another option chosen by some trailer manufacturers If your axle is equipped with the Dexter E Z Lube feature the bearings can be periodically lubricated without removing the hubs from the axle This feature consists of axle spindles that have been specially drilled and assembled with grease fittings in their ends When grease is pumped into the fitting it is channeled to the inner bearing and then flows back to the outer bearing and eventually back out the grease cap hole Nev R Lube option is the latest innovation from Dexter Nev R Lube bearings are comprised of opposed tapered roller bearing cones sealed inside of a precision ground one piece double cup arrangement These bearings are designed with a small amount of axial end play This end play is essential to the longevity of the bearings service life They are lubricated assembled and sealed at the factory No further lubrication is ever needed Before attempting any disassembly of your Dexter axle make sure you read and follow the instructions for the appropriate axle type Hub Removal Standard Beari
65. tion system Check that the hydraulic system has zero pressure and that the hub and rotor roates freely 4 Remove the hose from the caliper Then remove the two caliper mounting bolts Do not allow the caliper to hang from the hose 9i ne1pAH swiayshs Burjeig Installing the new brake caliper 1 First inspect the brake assembly for grooves flaking cracks heat checking thickness variation insufficient rotor thickness and look to see that the mounting hardware is straight Replace any component as needed or desired per manufacturer recommendations 2 Install the new caliper assembly Make sure that the bleed screw points up 3 Remount the caliper assembly onto the caliper attaching bracket Ensure that there is thread locking compound on the threads of the new mounting bolts Torque mounting bolts to 40 50 Ft Lbs Note Use two lug nuts to secure rotor against the hub face when reassembling the caliper After the caliper is assembled remove the lug nuts 4 Reconnect the hose to the elbow adapter on the back of the caliper and torque to 10 12 Ft Lbs 5 Reconnect the brake actuation system Refer to your actuation systems Operation Maintenance Service Manual for proper operation Iad 29 Iad 6 Bleed and flush brake system per your actuation systems Operation Maintenance Service Manual 7 Remount the wheel Refer to your Operation Maintenance Service Manual for proper wheel nut torque procedures
66. tric 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 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 Number Hitch to Axle Recommended of Distance Minimum Hookup Brakes In Feet Wire Size Copper 2 12 AWG 4 Under 30 12 AWG 4 30 50 10 AWG 6 Under 30 10 AWG 6 30 50 8 AWG 314129 3 suigjs S Burjeig Iad Braking Systems Electric Synchronizing Your Trailer Brakes To insure safe brake performa
67. ts will cause premature wheel bearing failure Bearing Inspection Wash all grease and oil from the bearing cone using a suitable solvent Dry the bearing with a clean lint free cloth and inspect each roller completely Never spin the bearing with compressed air THIS CAN DAMAGE THE BEARING 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 Iad Afi Be sure to wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious eye injury 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 3 After cleaning the hub a bore area replace the cup by tapping in with the brass drift punch Be sure the cup is seated all the way up y against the retaining shoulder in the hub Bearing Lubrication Grease Along with bearing adjustment proper lubrication is essential to the proper function and reliability of your trailer axle Bearings should be lubricated every 12 months or 12 000 miles The method to repack bearing cones is as follows 1 Place a quantity of grease into the palm of your hand 2 Press a section
68. ults 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 Brake Option The parking feature on Dexter hydraulic brakes is cable operated On the 10 and 12 brakes the parking cable body is mounted to the brake backing plate The cable end is attached to the internal parking brake lever to actuate the brake On Dexter 121 4 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 12 4 24 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 The internal parking brake lever of 10 and 12 Dexter brakes which is mounted to the secondary shoe transfers applied cable force through a parking strut which is attached to the primary shoe This transferred load 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
69. veradjustment 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 Repair or Replace Switch Loose Wheel f Bearing Adjustment Adjust Bent Spindle Replace Axle 18 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 scored drums loose parts etc Replace defective parts with genuine Dexter replacements 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
70. y is acceptable 3 Rotate tire slowly forwards and backwards The wheel assembly should turn freely and smoothly 4 Excessive wheel end play restriction to rotation noise or bumpy rotation should be remedied by replacing the bearing unit 5 Bearing units should be inspected every year or 12 000 miles whichever comes first Note A slight amount of grease weeping from the seal area is normal Excessive leakage may indicate abnormal bearing operation Hubs Drums Bearings 48 Nev R Lube Bearing End Play Inspection The following lists the maximum axial end play for each of the sizes of Nev R Lube bearings and the amount of tilt that can be expected Since there are a large number of wheel and tire combinations in use on trailers the tilt is expressed in inches per inch The movement as measured at the tire tread can be found by the following method Example if the tilt value is shown as 003 per inch and the tire measures 30 in diameter simply multiply 003 X 30 090 which is the total expected movement at the tires outer diameter Bearing size End play Resultant tilt value 35 MM 005 axial 003 per inch 42 MM 006 axial 005 per inch 50 MM 008 axial 004 per inch It is important to note that most mounted tires will deflect fairly easily when enough hand pressure is applied while shaking the tire Excessive pressure will result in the perception that the bearings tilt is greater t

DEXTER AXLE - Proud Canadian

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