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1. Faulty Controller Test amp Correct Overadjustment Readjust Out of Round Brake Drums Machine or Replace Dragging Brakes Incorrect Brake Replace Components Loose Bent or Broken Replace Brake Components Faulty Breakaway Switch Repair or Replace Loose Wheel Bearing Adjustment Adjust Bent Spindle Replace Axle 19 9111393 suiejs S Hunjesg Braking Systems Electric 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 O volts and as the controller bar is slowly actuated should gradually increase to about 12 volts If the controller does not produce this voltage control consult your controller manual 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 How to Measure Amperage System amperage is
2. 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 retighten the U bolt nuts to 100 120 Ft Lbs U bolts 130 170 Ft Lbs 34 U bolts Adjusting Screw 67 4 Re measure and B as before to assure that and dimensions are within 1 4e of each other If dimensions are not to specification then repeat adjustment procedure D 1 8 TH TH tt 33 H oc BENT1 16 EE Figure 1 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 and D between the front and rear tandem axles These distanc
3. Braking Systems Hydraulic Actuation Systems To effectively operate your hydraulic trailer brakes we recommend the Dexter E H electro hydraulic actuator controlled by the Predator DX2 electronic brake controller These high performance hydraulic power modules will supply pressurized brake fluid to your trailer brakes in proportion to the amount of braking effort called for by the towing vehicles deceleration rate It is the responsibility of the end user to ensure that their in cab electronic controller is compatible with the Dexter E H actuator Dexter Axle attempts to provide compatibility with most controllers available but is unable to anticipate design changes that might be introduced by the various controller manufacturers The E H 1000 will supply 1 000 psi for your drum brakes and the E H 1600 will generate 1 600 psi for maximum output for your Dexter disc brakes The sealed weather tight housing contains the electronics necessary to control the high pressure piston pump and proportioning valve for smooth efficient braking Electrical Schematic 12 VOLT 4OAMP CIRCUIT FROM TOW VEHICLE BREAKAWAY KIT BLACK __ BLACK ORANGE BLACK BREAKAWAY SWITCH YELLOW WHITE WHITE COMMON GROUND TRAILER AND TOW CHARGER ER D U mi IN CAB
4. CONTROLLER BLUE MNMUM 9 AMP HR BATTERY 28 Troubleshooting Guide Brakes are slow to respond 1 2 Re bleed the trailer brakes and actuator If the trailer is equipped with drum brakes readjust the drum brakes to the brake manufacture s recommended running clearance Slow response can be caused by trailer wiring that is too small For trailers where the E H unit is located less than 10 feet from the tow vehicle 12 gage wire is recommended for the black and white wires between the tow vehicle and the E H unit All other wires should be a minimum of 16 gauge For trailers where the E H unit is located more than 10 feet from the tow vehicle 10 gage wire is recommended for the black and white wires between the tow vehicle and the E H unit All other wires should be a minimum of 16 gauge Slow response can be caused by improper adjustment of the brake controller On inertia based electronic brake controls adjust the pendulum inertia sensor to a more aggressive setting and or increase the gain setting Unit will not run when the ignition is on and the brake pedal is depressed 1 2 4 Verify that the trailer and tow vehicle are wired as detailed on the electrical schematic With the ignition switch on and the brakes not applied you should have 12 13 volts between the black and white wires on the E H unit Clean and replace the ground between the trailer and the E H unit T
5. 24 UhisSetVOu 10100 teen 24 Self Adjusting Mechanism for 12 Brakes 25 Hydraulic Parking Brake Option 25 Disc Brakes 127 Actuation Systems 28 Electrical Schematic 28 Troubleshooting Guide 29 General Maintenance Hydraulic Brakes Drum Brake Adjustment Manual Wheel Cylinders 32 Brake Lines 32 Shoes and Linings 32 o Hardware nente en retorica ce 33 Instructions for Brake Caliper Kit 3 5K Disc Brakes 33 Instructions for Brake Rotor Kit 3 5K Disc Brakes 34 Instructions for Brake Rotor Kit 6K or 8K Disc Brakes 36 t Instructions for Brake Pad Kit 6K or 8K Disc Brakes 2 37 Instructions for Brake Caliper Kit 6 or 8K Disc Brakes 39 c Introduction to Troubleshooting 42 Troubleshooting Chart Hydraulic 43 w x Hubs Drums Bearings Hubs Drums Bearings a 45 Hub Removal Standard Bearings 45 Brake Drum Inspection 46 cs Bearing Inspection 47 Bearing Lubrication Grease a 49 Bearing Lubrication Oil sese 49 Recommended Wheel Bearing Lubrication Specifications 50 Seal Inspection and 2 52 B
6. Genuine Dexter axles and components are available nationwide from our plant locations listed below or through our network of distributors Check our web site for the distributor nearest you 2900 Industrial Parkway East Visit us online at www dexteraxle com Dexter Axle 11870 N 650 East Dexter Axle 222 Collins Rd 260 982 7511 Elkhart IN 46516 Ph 260 982 4047 Fax 574 295 8094 Ph 574 295 1900 Dexter Axle 1 Municipal Dr Dexter Axle 1400 Victoria Ave Carrollton MO 64633 San Bernardino CA 92408 Fax 660 542 1133 Fax 909 799 6258 e Ph 660 542 2232 Ph 909 796 2908 Dexter Axle 500 S E 27th St El Reno OK 73036 Fax 405 262 9089 Ph 405 262 6700 Company Headquarters Elkhart IN 46516 Fax 574 295 8666 Ph 574 295 7888 DEXTER AXLE N Manchester IN 46962 Dexter Axle Z West Pearl St Fremont IN 46737 Fax 260 495 1701 Ph 260 495 5100 Dexter Axle Road 75 East Albion IN 46701 Fax 260 636 3030 Ph 260 636 2195 Dexter Axle Perimeter Rd Monticello GA 31064 Fax 706 468 2966 Ph 706 468 6495 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 DEXTER AXLE www dexteraxle com 2900 Industrial Parkway East Elkhart IN 46516 Fax 574 295 8666 Ph 574 295 7888 2
7. Storage Storage PreparafiOn uu Hy 77 After Prolonged Storage Inspection Procedures TC Trip Preparation CheckliS uu HH ket 79 Maintenance Schedule Maintenance Schedule 80 Warranty Dexter Axle Limited Warranty n HH TH k t 81 Axle Identification Axle Identificatior u eee Datei eaten 84 1091007 J0 Introduction Important Safety Notice Appropriate service methods and repair procedures are essential for the safe reliable operation of all running gear as well as the personal safety of the individual doing the work This manual provides general directions for performing service and repair work with tested effective techniques Following these guidelines will help assure reliability There are numerous variations in procedures techniques tools parts for servicing axles as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Anyone who departs from the instructions provided in this manual must first establish that they neither compromise their personal safety nor the vehicle integrity by their choice of methods tools or parts Refer to your vehicle manufacturer s owners manual for additional procedures techniques and warnings prior to performing any
8. 08 Dexter Axle 2008 LIT 001 00
9. Contour Replacement tires must meet the same specifications as the originals Mismatched tires and rims may come apart with explosive force and cause personal injury to yourself or others Mismatched tires and rims can also blow out and cause you to lose control and have an accident which can result in serious injury or death 69 Wheels and Tires Do not attempt to repair or modify a damaged wheel Even minor modifications can cause a dangerous failure of the wheel and result in personal injury or death Torque Requirements In June of 2004 Dexter Axle ceased production of trailer wheels If your vehicle is equipped with Dexter steel wheels manufactured before that date the following wheel torque information will be applicable If your trailer is equipped with wheels produced by other manufacturers you must consult with the vehicle manufacturer to determine the appropriate torque level for your wheels However you must not exceed the limits of the wheel mounting studs on the axles 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 force For example a force of 90 pounds applied at the end of a wrench one foot long will yield 90 Ft Lbs of torque Torque wrenches are the best method to assure the proper amount of torque is being applied to a fastener Wheel
10. Drums Bearings 46 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 2 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 7 Brake Drum 7 090 diameter 3 10 Brake Drum 10 090 diameter 12 Brake Drum 12 090 diameter CD e 12 Brake Drum 12 340 diameter D 6K and 8K Rotor 1 03 minimum thickness 3 5K Rotor 85 minimum thickness N The machined inner surface of the brake drum that contacts the brake magnet is called the armature surface If the armature surface is scored or worn unevenly it should be refaced to a 120 micro inch finish by removing not more than 030 of material To insure proper contact between the armature face and the magnet face the magnets should be replaced whenever the armature surface is refaced and the armature surface should be refaced whenever the magnets are replaced Note It is important to protect the wheel bearing bores from metallic chips and contamination which result from drum turning or armature refacing operations Make certain that the wheel bearing cavities are clean and free of contamination before reinstalling bearing and seals The presence of these contaminants will cause premature wheel be
11. Reference Seal Part No Brake Size Hub Size Standard E Z Lube Oil 4 or 5 Bolt 010 009 00 K71 301 00 N A 10 x 2 4 5or6 Bolt 010 004 00 K71 303 00 N A lef x 255 5 Bolt Demount 010 054 00 K71 305 00 K71 305 00 6 or 8 Bolt 12 x2 8Bot K71 386 00 K71 386 00 K71 386 00 124 x 3 BBot K71 386 00 K71 386 00 K71 386 00 2 12 diameter seal journal prior to 10 97 2 25 diameter seal journal after 10 97 Replacement Parts Kits 76 Storage Storage Preparation If your trailer is to be stored for an extended period of time or over the winter it is important that the trailer be prepared properly 1 Remove the emergency breakaway battery and store inside out of the weather Charge the battery at least every 90 days 2 Jack up the trailer and place jack stands under the trailer frame so that the weight will be off the tires Follow trailer manufacturer s guidelines to lift and support the unit Never jack up or place jack stands on the axle tube or on the equalizers Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 3 Lubricate mechanical moving parts such as the hitch and suspension parts that are exposed to the weather 4 Boattrailer axles are subject to repeated
12. air into the hydraulic system 5 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 Braking Systems Hydraulic 36 2 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 3 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 35 Ft Lbs 4 Spin the rotor to ensure that there is enough clearance between the rotor and the crossover brake line 5 Reconnect the brake actuation system Refer to your Operation Maintenance Service Manual for proper operation 9iine1jp H Su18 S S Burjeig 6 Remount the wheel Refer to your Operation Maintenance Service Manual for proper wheel nut torque procedures 7 Spin the wheel to ensure that there is enough clearance between the wheel crossover brake line and rotor Instructions for Brake Pad Kit 6K or
13. 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 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 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 n an emergency situation they can provide some braking independent of the tow vehicle Parking Brake Option Not available on all sizes Dexter electric brakes with parking brake option are 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
14. 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 manufacturers recommendations for lifting and supporting the unit Make sure the wheel and drum rotates freely 9iine1jp H Su18 S S Burjeig Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 3 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn Note For drop spindle axles a modified adjusting tool may be necessary 4 Then rotate the star wheel in the opposite direction until the wheel turns freely with a slight lining drag 5 Replace the adjusting hole cover and lower the wheel to the ground 6 Repeat the above procedure on all brakes For best results the brakes should all be set at the same clearance II 31 Brakin
15. maintenance or repairs This is the safety alert symbol It is used to alert you to potential injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Getting Started Setup and Adjustment For proper performance all new axles should have the 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 311 29 3 suiejs S Hunjesg 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 the brakes The high 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
16. 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 Please consult the following troubleshooting charts to determine the causes and solutions for common problems found in trailer braking systems Best braking performance is achieved with a controller setting that is just short of wheel lock up or slide Overly aggressive braking which results in wheel lock up and sliding can cause a dangerous loss of control and result in personal injury or death 9I1128 3 suiejs S Hunjesg SYMPTOM CAUSES Open Circuits Troubleshooting REMEDIES Find amp Correct No Brakes 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 conet Non ee Replace Scored Weak Brakes 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 Corre
17. should now be free to move slightly Reinstall grease cap Typical E Z Lube After Spring 2002 D Washer Nut Retainer Nut ao bod 53 E Z Lube Lubrication Hubs Drums Bearings The 1 2 procedure is as follows Remove the rubber plug from the end of the grease cap 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 Pump grease into the fitting The old displaced grease will begin to flow back out the cap around the grease gun nozzle When the new clean grease is observed remove the grease gun wipe off any excess and replace the rubber plug in the cap 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 54 Nev R Lube Drums Bearings Dexter s Nev R Lube bearings are comprised of opposed tapered roller bearing cones sealed inside of a preci
18. 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 20 Magnet Amperes Chart Brake Amps Two Four Six Magnet Size Magnet Brakes Brakes Brakes Ohms 7 x 1 2 10 x 11 2 10 x 214 12 x 2 124 x 2 121 x If a resistor is used in the brake system it must be set at zero or bypassed completely to obtain the maximum amperage reading Individual amperage draw can be measured by inserting the ammeter in the line at the magnet you want to check Disconnect one of the magnet lead wire connectors and attach the ammeter between the two wires Make sure that the wires are properly reconnected and sealed after testing is completed 9111393 suiejs S Bune1g AMMETER 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 fus
19. 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 Equalizer Center Hanger Front Tie Plate Hanger Tie Plate Rear Hanger U Bolt U Bolt Spring Eye Bolts Keeper Bolts Overslung Shown The articulation of this suspension occurs when the rear end of each slipper spring slides against the wear surfaces provided in the rear hangers or equalizers This suspension is also available in single and multiple axle configurations 62 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 You must follow the maintenance procedures to prevent damage to important structural components Damage to certain structural components such as wheel bearings can cause the wheel to come off of the axle Loss of a wheel end while the trailer is moving can cause you to lose control and lead to an accident which can result in serious injury or death Susp
20. 50 GX Sun Refining and Sonoco Ultra Marketing Company Sonoco Dura Gear Shell Oil Company Spirax A Spirax G Spirax HD Spirax S Texaco Oil Company Multigear EP Multigear SS Troco Division Multigear Select Gear Oil Royal Manufacturing Union Oil Company Unocal MP Gear Lube 76 Triton Syn Lube EP 51 Hubs Drums Bearings Note The convenient lubrication provisions of the E Z Lube and the oil lubrication must not replace periodic inspection of the 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 Bad Seal Nicks and Tears REPLACE SEAL To replace the 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 sealant to the outside of the new seal ES Note P tex sealant should ermatex RUN x not be used on rubber encased T 3 seals x CES Z 3 Tap the new seal into place using NS a clean wood block Bearing Adjustment and Hub Replacement If the hub has been removed or bearing adjustment is required the following adjustment procedure must be followed 1 After placing the hub bearings washers and spindle n
21. 8K Hydraulic Disc 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 support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death Remove the wheel from the hub leaving the brake exposed Disconnect the brake actuation system Check that the hydraulic system has zero pressure and that the hub and rotor rotates freely Remove the brake pad retaining pin 5 Remove the old pads from the caliper assembly Save the brake pad retaining hardware for reinstalling the new pads onto the caliper POTENTIAL ASBESTOS DUST HAZARD Some older brake linings may contain asbestos dust which has been linked to serious or fatal illnesses Certain precautions need to be taken when servicing brakes Avoid creating or breathing dust Avoid machining filing or grinding the brake linings Do not use compressed air or dry brushing for cleaning dust can be removed with a damp brush Braking Systems Hydraulic Installing the new brake pads 1 First inspect the brake a
22. Circuit Terminal 7 Grey Auxiliary Circuit Terminal 8 License Tail amp Running Lights Terminal 3 Green Battery Charge Terminal 4 Black r White 1 Common Ground Green 3 Tail Running amp License Lights r Red 5 Stop amp Left Turn Black 4 Battery Charge Yellow 7 Aux Circuit 7 Orange 9 Aux Circuit Brown 6 Stop amp Right Turn Blue 2 Electric Brake Electric Brake Breakaway Switch sees Terminal 2 Blue P 1 Grey 8 Aux Circuit Common Ground Electric Brake _ 4 Ground Terminal o Terminal 1 1 White S range Auxiliary Circuit E Terminal 49 Double Stop amp Right Turn Signal Filament Terminal 6 i Bulb 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 Stop amp Stop amp LH Turn RH Turn Auxiliary Braking Systems Electric 10 Battery Charge Auxiliary RH Turn Auxiliary View Looking into Tow Vehicle Receptacle How to Use Your Electric Brakes Properly Your trailer brakes are designed to work in synchronization with your tow vehicle brakes Never use your tow vehicle or trailer brakes alone to stop the combined load Your brake controller must be set up according to the manufacturer s recommendations to ensure proper synchronization between
23. OPERATION MAINTENANCE SERVICE MANUAL 600 8 000 Ib Axles amp Related Components DEXTER AXLE www dexteraxle com 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 40 years of experience in the design testing and manufacturing of trailer axles The Dexter running gear system consists of spindles hubs drums and brakes 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 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 facili
24. OTENTIAL ASBESTOS DUST HAZARD Some older brake linings may contain asbestos dust which has been linked to serious or fatal illnesses Certain precautions need to be taken when servicing brakes Avoid creating or breathing dust Avoid machining filing or grinding the brake linings Do not use compressed air or dry brushing for cleaning dust can be removed with a damp brush After replacement of brake shoes and linings the brakes must be re burnished to seat in the new components This should be done by applying the brakes 20 to 30 times from an initial speed of 40 m p h slowing the vehicle to 20 m p h Allow ample time for brakes to cool between applications This procedure allows the brake shoes to seat in to the drum surface Introduction to Troubleshooting Proper brake function is critical to the safe operation of any vehicle If problems are encountered with your trailer braking system the following guide can be used to find the causes and remedies for some of the more common problems If you are unsure or unable to resolve the problem please contact your nearest repair facility for professional assistance Troubleshooting Most electric brake malfunctions that cannot be corrected by either brake adjustments or synchronization adjustments can generally be traced to electrical system failure Voltmeters and ammeters are essential tools for proper troubleshooting of electric brakes Mechanical causes are ordinarily
25. Worn Brake Linings Replace Shoe and Lining Incorrect Lining Install Correct Shoe and Lining Grease or Fluid Soaked Lining Repair Grease Seal or Wheel Cylinder Install New Shoe and Lining Weak Brakes Frozen Master Cylinder or Wheel Cylinder Pistons Recondition or Replace All Cylinders Brake Fluid Glazed Lining Reburnish or Replace Excessive Drum Wear Replace Trapped Air in Lines Bleed System Overloaded Trailer Correct Malfunctioning Actuating System Troubleshoot System Harsh Brakes Brake Adjustment Not Correct Manual Adjust Brakes Automatic Make Several Reverse Stops Grease or Fluid Replace Shoes Surging Brakes on Linings and Linings Grease or Oil on Linings Clean or Replace Out of Round Drums or Cracked Drums Machine or Replace 43 9iine1jp H 5 6 Burjeig SYMPTOM Troubleshooting Noisy Brakes CAUSES REMEDIES Underadjustment Adjust Lack of Lubrication Lubricate Broken Brake Components Replace Components Incorrect Brake Components Correct Loose Bent or Broken Brake Components Replace Components Lock
26. akes 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 POTENTIAL ASBESTOS DUST HAZARD Some older brake linings may contain asbestos dust which has been linked to serious or fatal illnesses Certain precautions need to be taken when servicing brakes 1 Avoid creating or breathing dust 2 Avoid machining filing or grinding the brake linings 3 Do not use compressed air or dry brushing for cleaning dust can be removed with a damp brush Brake Lubrication Before reassembling apply a light film of grease or anti seize compound on the brake anchor pin the actuating arm bushing and pin and the areas on the backing plate that are in contact with the brake shoes and magnet lever arm Apply a light film of grease on the actuating block mounted on the actuating arm Do not get grease or oil on the brake linings drums or magnets Magnets Your electric brakes are equipped with high qual
27. aring 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 47 Hubs Drums Bearings If any pitting spalling or corrosion is present then the bearing must be replaced The bearing cup inside the hub must be inspected IMPORTANT Bearings must always be replaced in sets of a cone and a cup Be sure to wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious eye injury 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 bore area replace the cup by tapping in with the brass drift punch Be sure the cup is seated all the way up against the retaining shoulder in the hub Replace only with bearings as specified in the Bearing Replacement Chart 48 Bearing Lubrication Grease N e Do not mix Lithium calcium sodium or barium complex c greases due to possible compatibility problems z When changing from one type of grease to another e it is necessary to insure all the old grease has been removed D Al
28. brake rotor Jack up trailer and secure on adequate capacity jack stands Follow trailer manufacturers recommendations for lifting and supporting the unit 34 Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 Remove the wheel from the hub leaving the brake exposed 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 9iine1jp H Su18 S S Buryjeig 5 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 2 Install the new brake rotor by fitting it onto the hub flush with the hubface 3 Remount the caliper assembly onto the caliper attaching bracket Place thread
29. 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 32 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 Hydraulic Disc 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 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 support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 Remove the wheel from the hub leaving the brake exposed 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 two caliper mounting bolts Do not allow the caliper to hang from
30. cessary 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 Storage 78 Trip Preparation Checklist 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 c There are a number of simple rules to follow in caring for your D Using the following checklist before starting a trip with your trailer is highly recommended Some of these items should be checked 2 3 weeks prior to a planned trip to allow sufficient time to perform maintenance 1 Check your maintenance schedule and be sure you are up to date 2 Check hitch Is it showing wear Is it properly lubricated 10 11 12 Fasten safety chains and breakaway switch actuating chain securely Make certain the breakaway battery is fully charged Inspect towing hookup for secure attachment Load your trailer so that approximately 10 of the 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 spe
31. cified in this manual Make certain the brakes are synchronized and functioning properly Check tightness of hanger bolt shackle bolt and U bolt nuts per torque values specified in manual Check operation of all lights Check that your trailer is towing in a level position and adjust hitch height if required 79 Maintenance Schedule Item Brake Magnets Brake Linings Suspension Parts Tire Condition Maintenance Schedule 3 Months or 3 000 Miles 6 Months or Function Required Weekly 6 000 Miles Adjust to proper operating clearance Inspect for wear and current draw Inspect for wear or contamination Check for correct amperage and modulation Inspec kinks Inspect wiring for bare spots fray etc Check battery charge and switch operation nspect for abnormal wear or scoring nspect for corrosion or wear Clean and repack nspect for leakage Replace if removed nspect for wear loss of arch nspect for bending loose asteners and wear Inspect for cuts wear bulging etc 80 12 Months or 12 000 Miles Dexter Axle Limited Warranty WHAT PRODUCTS ARE COVERED All Dexter trailer axles suspensions and brake control systems excluding Dexter 6000 series Manufactured Housing Axles LIMITED 2 YEAR WARRANTY Dexter Axle warrants to the original purchaser that its axles suspension systems and E H hydraulic brake actuators shall be free from defects
32. conform to the SAE standards for grade 8 The maximum torque level that can be safely applied to these studs is listed in the following chart Stud Size Maximum Torque 1 2 20 UNF class 2A 120 Ft Lbs 9 46 18 UNF class 2A 170 Ft Lbs 18 UNF class 2A 325 Ft Lbs Exceeding the above listed torque limits can damage studs and or nuts and lead to eventual fractures and dangerous wheel separation Wheels and Tires 375 Tires Before mounting tires onto the wheels make certain that the rim size and contour is approved for the tire as shown in the Tire and Rim Association Yearbook or the tire manufacturers catalog Also make sure the tire will carry the rated load If the load is not equal on all tires due to trailer weight distribution use the tire rated for the heaviest wheel position 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 befor
33. ct Loose Bent or Broken Brake Components Replace Components Out of Round Brake Drums Machine or Replace Insufficient Wheel Load Adjust System Resistor and Synchronize Faulty Controller Test amp Correct Intermittent Brakes Broken Wires Repair or Replace Braking Systems Electric Loose Connections Find amp Repair Faulty Ground Find amp Repair 18 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
34. d 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 manufacturers recommendations for lifting and supporting the unit Make sure the wheel and drum rotates freely 9I1128 3 suiejs S Hunjesg Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury 2 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 3 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn Note For drop spindle axles a modified adjusting tool may be necessary 4 Then rotate the star wheel in the opposite direction until the wheel turns freely with a slight lining drag 5 Replace the adjusting hole cover and lower the wheel to the ground 6 Repeat the above procedure on all brakes For best results the brakes should all be set at the same clearance Braking Systems Electric Brake Cleaning and Inspection Your trailer br
35. e centers of one axle and end centers of the other axle must not vary more than 1 4 Safety glasses should be worn at all times when assembling or disassembling axles and their components Dexter tubular axles are made of high strength steel for better fatigue life and superior welding qualities The round tubular axles provide a uniform section modulus no matter how the beam is rotated Brake spiders are positioned and welded to specific requirements at our factory Welding the spider directly to the axle beam provides a higher strength and more reliable brake attachment over bolt on versions In welding suspension components to a Dexter trailer axle extreme care must be exercised to obtain correct location and ensure the spring seat load bearing surfaces are parallel to each other Any welding of additional attachments to the axle should be approved by Dexter Axle s engineering department 60 Suspension Systems co N The suspension systems incorporated into Dexter axles are 5 designed to provide the trailer owner three basic functions 1 Attach the axle to the trailer a 2 Dampen the effects of road shock s 3 Cushion the cargo or load o 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 w
36. e 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 Ib 10 000 Ib and 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 6 000 Ib and 8 000 Ib axle models Disc brake effectiveness is the same going either in a forward or reverse direction All Dexter disc brakes should be actuated with a braking system that is capable of providing a maximum hydraulic pressure of 1 600 psi 27 9iine1jp H Su181S S Burjeig
37. e on adequate capacity jack stands Follow trailer manufacturers recommendations for lifting and supporting the unit Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 Remove the wheel from the hub leaving the brake exposed 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 39 Installing the new brake caliper Braking Systems Hydraulic 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 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 sid
38. e 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 73 Sail pue sjoauM Tire Wear Diagnostic Chart Wheels and Tires Wear Pattern Edge Wear Cupping A Flat Spots NW Cause Over Inflation Under Inflation Loss of camber or overloading Incorrect toe in Out of balance Wheel lockup amp tire skidding 74 Action Adjust pressure to particular load per tire catalog Adjust pressure to particular load per tire catalog Make sure load doesn t exceed axle rating Align at alignment shop Align at alignment shop Check bearing adjustment and balance tires Avoid sudden stops when possible and adjust brakes Replacement Parts Kits Electric Brake Magnets Magnet Kit Number Wire Nut Torque Brake Size one magnet per kit Color Brake Mounting 7 x 11 4 K71 057 00 45 70 10 x 24 K71 104 00 45 70 10 x 21 4 K71 105 00 4 4K 45 70 Brake Shoe Replacement Kits Shoe and Lining Replacement 1 Brake Brake Size Electric Hydraulic 10 x 274 K71 047 00 K71 267 00 Free Backing K71 393 00 C
39. e 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 35 Ft Lbs Connect the new crossover brake line on the bottom sides of the piston boss on both calipers Note Make sure the crossover line fits snug around the calipers and rotor without touching the rotor Spin the rotor to ensure there is proper clearance Torque the crossover 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 pads toward the calipers Align the holes in the brake pads with the ones in the calipers Insert the brake pad retaining pin and install the cotter ring 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 40 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 crossover brake line and the rotor 9iine1jp H Su18 S S Burjeig 41 Introduction to Troubleshooting P
40. earing Adjustment Hub Replacement 52 Typical E Z Lube After Spring 2002 EC E Z Lube Lubrication 2 54 Nev R Lube Drums Bearings Drum Removal 2 55 Bearing 209 Nev R Lube Bearing End Play Inspection 57 Bearing Replacement and Drum Installation Axle Installation Axle amp Suspension InstallatiOrn ers sne HH hy 60 Suspensions spension Systems aye eis eee nd eos EU Rv RES 61 Double Eye Leaf Springs 61 Grease Lubricated Suspension Bushings 62 Slipper Leaf 62 Inspection and Replacement 63 Suspension Fastener Torque Values 63 Torflex Suspension 65 Airex V Suspension rei tree ep Herne 66 Wheels and Tires Dr c 69 Wheel Selection 69 Torque Requirements Wheel Torque Requirements Maximum Wheel Fastener Torque 72 THOS ri PE 73 Tire Wear Diagnostic Chart n HH H t 74 Replacement Parts Kits Magnet Replacement Kits and Brake Nut 75 Brake Shoe Replacement Kits Bearing Replacement Chart Seal Replacement Reference
41. ension Fastener Torque Values Ft Lbs Item Max V2 U Bolt e U Bolt Non shoulder type with 94e 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 Shackle Bolt with 74e 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 S suoisuadsn 63 Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 After the unit is properly supported place a suitable block under the axle tube near the end to be repaired This block is to support the weight of the axle only so that suspension COMPONENTS can be removed 3 Disassemble the U bolts nuts and tie plates 4 Remove the spring eye bolts and remove the spring and place on a suitable work surface 5 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 injury 6 Drive the new bushing into the spring eye us
42. es fusing of brakes is not recommended Improperly functioning controllers or resistors N gt Another common electrical problem is shorted or partially shorted circuits indicated by abnormally high system amperage Possible causes are 1 Shorted magnet coils 2 Defective controllers 3 Bare wires contacting a grounded object II 21 Iad Braking Systems Electric Finding the cause of a short circuit in the system is done by isolating one section at a time If the high amperage reading drops to zero by unplugging the trailer then the short is in the trailer If the amperage reading remains high with all the brake magnets disconnected the short is in the trailer wiring All electrical troubleshooting procedures should start at the controller Most complaints regarding brake harshness or malfunction are traceable to improperly adjusted or non functioning controllers See your controller manufacturer s data for proper adjustment and testing procedures For best results all the connection points in the brake wiring should be sealed to prevent corrosion Loose or corroded connectors will cause an increase in resistance which reduces the voltage available for the brake magnets 22 Hydraulic Brakes Dexter offers several varieties of hydraulic trailer brakes Your vehicle may be equipped with drum brakes or disc brakes The hydraulic brakes on your trailer are much like those on your automobile or light t
43. es must be within 1 4 of each other After alignment is completed make sure all nuts and bolts are tightened to their respective torque values The limits of 146 and Ye 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 68 Wheels Wheel Selection Wheels are a very important and critical component 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 Sal pue sjoauM 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 maximum load of the tire and trailer 3 Offset This refers to the relationship of the center line of the tire to the hub face of the axle Care should be taken to match any replacement wheel with the same offset wheel as originally equipped Failure to match offset can result in reducing the load carrying capacity of your axle 4 Rim
44. est operation of the unit using the breakaway test procedure 29 9iine1jp H Su18 S S Burjeig Breakaway test procedure do not leave the breakaway switch pulled for more than two minutes during any of the steps outlined below Braking Systems Hydraulic 1 2 Pull the breakaway switch on the trailer If the unit runs and builds pressure that indicates the actuator is functioning properly The problem most likely is a defective electronic brake controller in the tow vehicle or defective wiring between the tow vehicle and the E H unit If the unit runs but will not build pressure the problem most likely is a defective solenoid valve in the E H unit and the actuator should be returned for repair If the unit still does not run after the breakaway battery is fully charged verify that the voltage between the white wire and yellow wire is at least 12 volts If the voltage is less than 12 volts either the breakaway switch or the breakaway wiring is defective If the voltage is greater than 12 volts the E H unit should be returned for repair Trailer brakes too aggressive 1 Reduce the gain setting on the in cab electronic brake controller 30 General Maintenance Hydraulic Brakes Drum Brake Adjustment Manual Most Dexter 1274 hydraulic brakes have a self adjusting feature If manual adjusting is required use the following procedure Brakes should be adjusted 1 after the
45. g Systems Hydraulic 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 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 Ye 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 itis important to replace both shoes on each brake and both brakes of the same axle This will help retain the balance of your brakes POTENTIAL ASBESTOS DUST HAZARD Some older brake linings may contain asbestos dust which has been linked to serious or fatal illnesses Certain precautions need to be taken when servicing brakes 1 Avoid creating or breathing dust 2 Avoid machining filing or grinding the brake linings 3 Do not use compressed air or dry brushing for cleaning dust can be removed with a damp brush After replacement of brake shoes and linings the
46. immersion Before storing remove brake drums clean dry and re lubricate moving brake components inspect bearings clean and re lubricate 5 On oil lubricated hubs the upper part of the roller bearings are not immersed in oil and are subject to potential corrosion For maximum bearing life it is recommended that you revolve your wheels periodically every 2 3 weeks during periods of prolonged storage o e D e CD After Prolonged Storage Inspection Procedure Before removing trailer from jack stands 1 Remove all wheels and hubs or brake drums Note which spindle and brake that the drum was removed from so that it can be reinstalled in the same location 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 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 ne
47. in material and workmanship for a period of two 2 years from the date of first sale of the trailer incorporating such components LIMITED 5 YEAR WARRANTY Dexter Axle warrants to the original purchaser that its Nev R Lube bearings and the suspension components only of its Torflex amp axles shall be free from defects in material and workmanship for a period of five 5 years from the date of first sale of the trailer incorporating such components 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 AuegeueMw 2 You must promptly notify us within the warranty period of any defect and provide us with the axle serial number and any substantiati
48. ing Brakes Underadjustment Adjust Out of Round Drums Machine or Replace Incorrect Tire Pressure Inflate Evenly on Both Sides to Req Pressures Pulls to One Side Unmatched Tires on Same Axle Match Tires on Axle Restricted Brake Lines or Hoses Repair or Replace Malfunctioning Cylinder 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 Dragging Blocked Master Cylinder Open with Compressed Air or Replace Cylinder Braking Systems Hydraulic Parking Brake Cable Frozen Free Cable and Lubricate Improper Lining Thickness or Location Install New Shoes and Linings 44 Hubs Drums Bearings Dexter Axle offers several types of bearing arrangements and lubrications methods Dexter s standard wheel bearing configuration consists of opposed tapered roller bearing cones and cups fitted inside of a precision machined cast hub This method of using tapered roller bearings requires that a minimal amount of axial end play be provided at assembly This end play is essential to the longevity of the bearings service life This design is t
49. ing a piloted drift punch or a close fitting bolt inserted through the bushing 7 Reinstall repaired or replaced components in reverse order Note For multiple axle units the weight of each axle must be supported as outlined in Step 2 before disassembly of any component of the suspension system If the equalizer or equalizer bushings must be replaced follow the instructions above for lifting and supporting the trailer unit and then proceed as follows Suspensions 64 1 With both axles blocked up remove the spring eye bolt shackle bolt and equalizer bolt from the equalizer to be repaired or replaced S 2 Take the equalizer to suitable work surface and remove the worn bushings using a suitable drift punch 3 Drive the new bushings into place using a piloted drift punch or a close fitting bolt through the bushing suoisuadsn 4 Reassemble in reverse order Be sure to wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious injury 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 Suspension The Torflex suspension sy
50. ith 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 2 Shackle Link 5 Front T O Rear Hanger Hanger uw Tie Plate Shackle Bolts Equalizer 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 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 61 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
51. ity 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 magnet should be flat Even if wear is normal as indicated by your straightedge the magnets should be replaced if any part of the magnet coil has become visible through the friction material facing of the magnet It is also recommended that the drum armature surface be refaced when replacing magnets see section on Brake Drum Inspection Magnets should also be replaced in pairs both sides of an axle Use only genuine Dexter replacement parts when replacing your magnets Straight Edge Gaps show ABNORMAL WEAR replace magnet NORMAL WEAR 9I1128 3 suiejs S Hunjesg 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 e or less Shoes contaminated with grease or oil or abnormally scored or gouged should also be replaced Hairline heat cracks are normal in bonded linings and should not be cause for concern When replacement is necessary 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 P
52. 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 35 5 Remount the wheel Refer to your Operation Maintenance Service Manual for proper wheel nut torque procedures Instructions for Brake Rotor Kit 6K or 8K Hydraulic Disc 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 support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 Remove the wheel from the hub leaving the brake exposed 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 four caliper mounting bolts Do not allow the caliper assembly to hang from the hose Do not disconnect the hose or allow
53. lu Grease Citgo Lithoplex MP 2 Lithoplex CM 2 Mystik JT 6 Hi Temp Grease 2 Exxon Mobil Company Oil Center Research Ronex MP Mobilith AW 2 Mobil I Synthetic Grease Liquid O Ring No 167L of Oklahoma Pennzoil Quaker State Synthetic Red Grease Company Shell ALBIDA EP 2 ALBIDA Grease SLC 220 Rotella Heavy Duty Lithium Complex 2 Royal Mfg Company Royal 98 Lithium Complex EP 2 Chevron Texaco Chevron Ulti Plex Grease EP 2 Texaco Starplex Moly MPGM 2 Valvoline Valvoline Multi Purpose GM Valvoline Durablend Great Plains Lubricants Chem Arrow Lithium Complex EP 2 Arrow 2282 50 Oil SAE 90 SAE 80W 90 SAE 75W 90 Approved Oil Sources Ashland Oil Valvoline Dura Blend Valvoline Power Lube CITGO Petroleum Co CITGO Premium Gear Oil MP Mystik JT 7 g suimaq sqnH sfiuuea Mystik Power Lube Exxon Company USA Gear Oil GX 80W 90 Industrial Oils Unlimited Super MP Gear Oil 80W 90 Kendall Refining Co Kendall NS MP Hypoid Gear Lube Lubriplate Division Lubriplate APG 90 Fiske Brothers Refining Mobil Oil Corporation Mobilube SHC Mobil 1 Synthetic Gear Lube Phillips 66 Petroleum Superior Multi Purpose Gear Oil Philguard Gear Oil Philsyn Gear Oil Pennzoil Products Co Gear Plus 80W 90 GL 5 Gear Plus Super 75W 90 Gear Plus Super EW 80W 90 Multi Purpose 4092 Gear Lube Oil Center Research Liquid O Ring 7
54. nal injury to yourself and or others 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 General Maintenance Electric Brakes Brake Adjustment Most Dexter 1274 electric brakes have a self adjusting feature If manual adjusting is required use the following procedure Brakes should be adjusted 1 after the first 200 miles of operation when the brake shoes an
55. nuts or bolts must be tightened and maintained at the proper torque levels to prevent loose wheels broken studs and possible dangerous separation of wheels from your axle which can lead to an accident personal injuries or death Be sure to use only the fasteners matched to the cone angle of your wheel usually 60 or 90 The proper procedure for attaching your wheels is as follows 1 Start all bolts or nuts by hand to prevent cross threading 70 2 Tighten bolts or nuts in the sequence shown for Wheel Torque Requirements 3 The tightening of the fasteners should be done in stages Following the recommended sequence tighten fasteners per wheel torque requirements diagram 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 Sal pue sjoauM Wheel Torque Requirements For Dexter Steel Wheels Prior to June of 2004 Torque Sequence Wheel Size 1st Stage 2nd Stage 3rd Stage 12 50 78 13 50 75 14 90 120 15 90 120 16 90 120 16 5 x 6 75 90 120 16 5 x 9 75 175 225 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 90 200 275 325 4 Flange Nuts 4 BOUE 5 BOLT 6 BOUT 8 BOLT 71 Maximum Wheel Fastener Torque The wheel mounting studs used on Dexter axles
56. oe The Retractor N ss Cylinder Springs CASS secondary shoe S Z gt is forced onto the lt N lt anchor pin and Backing f iN D from this point the secondary a and primary Secondary 4 shoes attempt to Shoe wrap around Primary Shoe In essence the Adjuster Spring brake has utilized Adjuster Assembly frictional force to help the applying force on both shoes Hold Down Spring 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 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 assembly Braking in reverse is significantly less effective than in the forward direction 24 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 brakes are applied through the surge mechanism and if there is more brake force on the trailer than the tow vehicle can override no backing is possible The free backing brake Hydraulic Wheel was developed to C
57. on which may include but is not limited to the return of part s that we may reasonably request 81 Warranty 3 The axles or suspensions must have been installed and maintained in accordance with good industry practice and any specific Dexter Axle recommendations including those specified in Dexter Axle s publication Operation Maintenance Service Manual EXCLUSIONS These warranties do not extend to or do not cover defects caused by 1 The connecting of brake wiring to the trailer wiring or trailer wiring to the towing vehicle wiring 2 The attachment of the running gear to the frame 3 Hub imbalance or any damage caused thereby 4 Parts not supplied by Dexter Axle 5 Any damage whatever caused by or related to any alteration of the axle including welding supplemental brackets to the axle 6 Use of an axle on a unit other than the unit to which it was originally mounted 7 Normal wear and tear 8 Alignment 9 Improper installation 10 Unreasonable use including failure to provide reasonable and necessary maintenance as specified in Dexter Axle s publication Operation Maintenance Service Manual including required maintenance after Prolonged Storage 12 Improper wheel nut torque 13 Cosmetic finish or corrosion LIMITATIONS 1 In all cases Dexter Axle reserves the right to fully satisfy its obligations under the Limited Warranties by refunding the then current list
58. ong with bearing adjustment proper lubrication is essential to the proper function and reliability of your trailer axle Bearings Ge N 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 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 3 Repeat this while rotating the bearing from roller to roller 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 49 Recommended Wheel Bearing Lubrication Specifications Hubs Drums Bearings Grease Thickener Type Lithium Complex Dropping Point 215 C 419 F Minimum Consistency NLGI No 2 Additives EP Corrosion amp Oxidation Inhibitors Viscosity Index 80 Minimum Approved Grease Sources ConocoPhillips 76 Lubricants Kendall Multiplex RED 2 L427 Super B
59. orrosion Resistant K71 423 00 4 4K K71 672 00 N A 12 x 2 5 2K K71 048 00 K71 268 00 12 x 2 7K K71 127 00 71 269 00 K71 270 00nn Free Backing 71 394 00 K71 395 00nn Free Backing 71 427 001 K71 428 00nH Corrosion Resist 124 x 21 2 K71 497 00 n K71 496 000 124 x 3 71 499 001 K71 498 00n K71 165 00 4 K71 166 008H prior to April of 2000 75 SIIW SMEd 1u8u182E 09H Bearing Replacement Chart Brake Hub Dexter Kit Industry Part Axle Size Size Bearings Number Cup Cone Capacity 7 x 1 4or5 Inner K71 306 00 L44610 L44649 2K Bolt Outer K71 306 00 L44610 L44649 10 x 1 40 5 Inner K71 307 00 LM67010 LM67048 2 8K Bolt Outer K71 306 00 L44610 L44649 10 x 2 4 5 0r6 Inner K71 390 00 L68111 L68149 3 5K Bolt Outer K71 306 00 L44610 L44649 10 x 21 4 6 Bolt Inner K71 390 00 L68111 L68149 4 4K Outer K71 307 00 LM67010 LM67048 122x24 6 Bolt Inner K71 308 00 25520 25580 5 2K Outer K71 307 00 LM67010 LM67048 12 x 2 5 Bolt Inner K71 308 00 25520 25580 6K Demount Outer K71 309 00 15245 15123 ier 520 6 Bolt Inner K71 308 00 25520 25580 6 Outer K71 309 00 15245 15123 12 x2 8 Bolt Inner K71 308 00 25520 25580 7K Outer K71 310 00 14145A 14276 1274 x 21 2 8 Bolt Inner K71 308 00 25520 25580 7 2K Outer K71 405 00 02420 02475 12 x 3 8 Bolt Inner K71 308 00 25520 25580 8K Outer K71 415 00 02420 02475 special application Seal Replacement
60. ovement at the tires outer diameter Resultant Tilt Bearing Size End Play 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 than it actually is This same phenomenon will occur when checking any wheel end even those equipped with conventional bearing sets M 57 g swun g sqnH sfiuuea Bearing Replacement and Drum Installation Hubs Drums Bearings 1 Using an arbor press and When replacing a Once the drum and bearing assembly is removed from the axle remove internal snap ring from the bearing bore that retains bearing mandrel press the bearing out of the drum Bearing will exit on the wheel side of the drum Nev R Lube bearing pack the bore in the hub should be cleaned and inspected for visual damage replace as necessary Install the new bearing using an arbor press fitted with a hollow or stepped punch face to n ud press only on the outer housing of the bearing i Bean Failure to follow procedure 9 will damage the bearing 1 and or seals during Hub installation Press bearing cH until it seats against the backup shoulder machined into the hub In
61. price of the defective axle or if the axle has been discontinued of the most nearly comparable current product 82 2 Dexter Axle reserves the right to furnish a substitute or replacement component or product in the event an axle or any component of the axle is discontinued or is otherwise unavailable AuegeueMw 3 These warranties are nontransferable GENERAL THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXCEPT THAT OF TITLE WHETHER WRITTEN ORAL OR IMPLIED IN FACT OR IN LAW INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE These warranties give you specific legal rights and you may also have other rights which vary from state to state THE DURATION OF ANY IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE DURATION OF THE EXPRESS WARRANTIES HEREIN DEXTER AXLE HEREBY EXCLUDES INCIDENTAL AND CONSEQUENTIAL DAMAGES INCLUDING LOSS OF TIME INCONVENIENCE LOSS OF USE TOWING FEES TELEPHONE CALLS OR COST OF MEALS FOR ANY BREACH OF ANY EXPRESS OR IMPLIED WARRANTY INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above exclusion or limitation may not apply to you Inquiries regarding these war
62. r on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death Hubs Drums Bearings 56 2 Check for excessive wheel end clearance by pulling the tire assembly towards you and by pushing the assembly away from you Slight end play 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 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 15 1 2 tire diameter 045 which is the total expected m
63. ranties should be sent to Dexter Axle P O Box 250 Elkhart Indiana 46515 83 E Axle Identification In the unlikely event that you should require service assistance from Dexter Axle please have the lot number of the axle available when you call On all axles produced after April 2001 this nine digit number can be found on the rear side of the axle beam approximately 18 from the curb side of the vehicle Look for the words DEXTER AXLE and the lot number will be located directly under the name Recreational Vehicle axles that have been certified for use in Canada will also bear the letters CSA Axle Identification 84 Dexter Online Parts Store From magnet and seal kits to complete brake and hub kits Dexter offers a complete line of genuine replacement parts for your trailer Most products are available in stock and ready to ship within 24 hours direct to you from the factory With dedicated customer support quick turnaround and a 30 day money back guarantee the Dexter Online Parts Store helps keep your trailer going Hub Components Brake Components Suspension Components Complete Hub Kits Brake Assemblies amp Kits Brake Controllers amp Actuators Ready for Immediate Shipment Direct to Your Door Visit us online at www dexteraxle com Service Record Date Service Performed Mileage Service Record Date Service Performed Mileage Service Record Date Service Performed Mileage
64. rflex axle and conventional air suspension technology This low maintenance suspension system carries the load on a 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 If the air actuation system has been installed make sure the air pressure in the air bags is bled off before lifting the trailer 66 Note Lifting the trailer with air system pressurized will c overextend the air bags and can result in damage to the air bags o e Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death
65. roper brake function is critical to the safe operation of any vehicle A properly installed vacuum hydraulic electric hydraulic or air hydraulic system should not require any special attention with the exception of routine maintenance as defined by the manufacturer If problems occur the entire tow vehicle trailer braking system should be analyzed by a qualified mechanic Typical problems in a hydraulic braking system are Air or vacuum leaks Hydraulic system leaks Air in brake lines Water or other impurity in brake fluid Rusted or corroded master or wheel cylinders Actuation system malfunction Please consult the following troubleshooting charts to determine the causes and solutions for common problems found in trailer braking systems The operating pressure required for Dexter brakes 7 diameter drum brakes maximum operating pressure is 750 psi 10 diameter and larger drum brakes maximum operating pressure is 1 000 psi Hydraulic disc brakes all sizes maximum operating pressure is 1 600 psi Braking Systems Hydraulic 42 SYMPTOM Troubleshooting No Brakes CAUSES REMEDIES Broken or Kinked i Brake Line Repair or Replace Severe Underadjustment Adjust Brakes Malfunctioning Actuation System Troubleshoot System Brake Adjustment Not Correct Manual Adjust Brakes Automatic Make Several Reverse Stops Excessively
66. ruck The hydraulic fluid from a master cylinder or actuation system is used to actuate the wheel cylinder which in turn applies force against the brake shoes and drum The main difference between automotive hydraulic brakes and hydraulic trailer brakes is the trailers actuation system These systems respond to the braking signal from the tow vehicle and supply the required brake fluid volume and pressure to the trailer brakes In the following pages you will find a more detailed description of the hydraulic brakes and actuation system used on your trailer The operating pressure required for Dexter brakes e 7 diameter drum brakes maximum operating pressure is 750 psi 10 diameter and larger drum brakes maximum operating pressure is 1 000 psi Hydraulic disc brakes all sizes maximum operating pressure is 1 600 psi 23 9iine1jp H suia s S Burjeig Braking Systems Hydraulic Hydraulic Drum Brake Operation Duo Servo The duo servo brake uses a dual piston wheel cylinder to apply the brakes This type of brake is typically used in an electric hydraulic vacuum hydraulic or air hydraulic system A description of operation of this brake is as follows When the brakes are applied the double acting wheel cylinder moves the primary and secondary shoes towards the drum The frictional force between the brake drum and lining attempts to turn ine primary shoe Anchor Post into the secondary Hydraulic Wheel sh
67. sion ground co one piece double cup arrangement These bearings are designed with a small amount of axial end play This end play is essential to E the longevity of the bearings service life 3 UJ CD D ec N 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 55 Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 Remove the wheel 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 Do not lift or support the traile
68. ssembly 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 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 Install the new brake pads by sliding them in one at a time between the caliper 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 38 4 Align the brake pad mounting holes with the holes in the caliper Insert the brake pad retaining pin and install the cotter ring 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 Hydraulic Disc Brakes Notice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance 9iine1jp H suia s S Burjeig Remove the old brake pads 1 Jack up trailer and secur
69. stall 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 FoncE Install steel washer onto spindle end Start self locking nut onto spindle thread by hand Complete installation using a 11 2 or 1746 socket and torque wrench 58 Nut should be torqued to 145 155 Ft Lbs this torque will set the internal bearing adjustment no other adjustments are to be made 10 Install torque instruction washer onto end of spindle 11 Install external snap ring onto end of spindle to retain washer N 12 Inspect assembly for excessive end play noise and rotation c restriction prior to mounting final wheel end hardware CD lt N 59 Axle Installation Axle amp Suspension Installation Responsibility for proper axle alignment lies with the axle installer The axle must be installed so that it will be parallel to the drive axle s of the tractor This will allow good vehicle control when cornering longer tire wear and it will eliminate dog tracking Alignment can be determined by measuring from the center of the trailer king pin to the center of each end of the axles The difference should not vary by more than 1 6 In the case of multiple axles the axles must also be in line with each other The difference between th
70. stem 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 Mounting Bracket an integral part of the axle assembly The Torflex amp axle provides improved suspension Spindle characteristics relative to leaf spring axles through g _ gt the unique arrangement Torsion Bar of a steel torsion bar Torsion Arm surrounded by four natural rubber cords encased in the main structural member of the axle beam 65 Suspensions 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 Except for periodic inspection of the fasteners used to attach the Torflex amp axle to the vehicle frame no other suspension maintenance is required on Torflex amp 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 cords Airflex Suspension The Dexter Airflex V suspension is a unique combination of To
71. the hose Installing the new brake caliper 1 First inspect the brake assembly for grooves flaking cracks heat checking thickness variation insufficient rotor 33 9iine1jp H Su18 S S Buryjeig Braking Systems Hydraulic thickness and look to see that the mounting hardware is straight Replace any component as needed or desired per manufacturer recommendations Install the new caliper assembly Make sure that the bleed screw points up 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 Reconnect the hose to the elbow adapter on the back of the caliper and torque to 10 12 Ft Lbs Reconnect the brake actuation system Refer to your actuation systems 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 Instructions for Brake Rotor Kit 3 5K Hydraulic Disc Brakes Notice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance Remove the old
72. 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 Recommended Number Hitch to Axle Minimum Hookup of Brakes Distance in Feet Wire Size Copper 2 t2AWG Under 30 12 AWG 30 50 10 AWG 6 Under 30 10 AWG 5 30 50 8 AWG 9I1128 3 suiejs S ueg Braking Systems Electric Synchronizing Your Trailer Brakes To insure safe brake performance and synchronization read the brake controller manufacturer s instructions completely before attempting any synchronization procedure Before road testing make sure the area is clear of vehicular and pedestrian traffic Failure to brake safely could result in an accident and perso
73. the trailer unit per manufacturers instructions You must follow the maintenance procedures to prevent damage to important structural components Damage to certain structural components such as wheel bearings can cause the wheel end to come off of the axle Loss of a wheel end while the trailer is moving can cause you to lose control and lead to an accident which can result in serious injury or death 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 For E Z Lube axles produced after February of 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 may be necessary 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 surface where the magnet contacts only in electric brakes Hubs
74. ties which enable us to provide you the trailer owner with the finest product possible For all your running gear needs Look finettoDenter Visit us online at www dexteraxle com Introduction Important u u eere te ede EHE ER 4 Getting Started Setup and Adjustment sse 4 Breaking Systems Electric Electric Brakes 5 Features 6 Parking Brake Option 6 Self Adjusting Feature 6 Brake Controllers esee 7 Typical Trailer Wiring eunt ttn 10 How to Use Your Electric Brakes 11 Trailer Wire Size 1 Synchronizing Your Trailer Brakes 22 General Maintenance Electric Brakes Brake Adjustment 13 Brake Cleaning and Inspection 214 Brake Lubrication 14 Magnets 15 Shoes and Linings 16 Introduction to Troubleshooting AA Tro bleshooltihg 5 7 2 Su aire nee ta min eet meri 17 Troubleshooting Chart Electric ee 18 How to Measure Voltage How to Measure Amperage eus Magnet Amperes Chart Braking Systems Hydraulic Hydraulic Brakes erret err Dt ER PED ER ESSE Errat 23 Hydraulic Brake Operation 24 Duo Servo
75. tric 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 9I1128 3 suiejs S Hunjesg Braking Systems Electric Dexter Electric Brakes Wired in parallel Breakaway Battery Provides power to actuate trailer brakes in the event of trailer breakaway Breakaway Switch Switches battery power to brakes if breakaway occurs Controller Electric brake controller provides power to the magnets to actuate the trailer brakes Battery Connector Used to connect and disconnect trailer and tow vehicle Always ground trailer brakes through connector Connect controller directly 9I1128 3 suiejs S Hunjesg Typical Trailer Wiring Double Stop amp Left Turn Signal To Terminal 5 Yellow Red Auxiliary
76. ttach to the internal parking brake lever For 12 brakes produced after February of 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 The internal parking brake lever of Dexter 1274 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 26 Hydraulic Disc Brakes Dexter Axle manufactures two types of disc brakes the floating caliper and the fixed caliper brake With both styles the disc brake uses friction pads astride a ventilated rotor which is attached to the wheel hub When the brake is actuated the pads are pressed against the sides of the rotor causing drag to slow the rotating disc This action converts th
77. 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 Not available on all sizes Dexter electric brakes may be equipped with a forward self adjust feature This will allow the brakes to adjust 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 DX2 This controller features a patented accelerometer design which senses the deceleration of the towing vehicle and sends a proportional voltage to the electric trailer brakes Other features include a visual gain setting for quick and easy adjustment and a digital LED display to show the voltage output A manual override sends full voltage to the trailer brakes regardless of gain setting for emergency conditions and also illuminates the brake lights to warn of an impending stop Most electric brake controllers provide a modulation function that varies the current to the elec
78. ut 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 Ft Lbs 12 wrench or pliers with full hand force 2 Then loosen the spindle nut to remove the torque Do not rotate the hub 52 Finger tighten the spindle nut until just snug 4 Backthe spindle nut out slightly until the first castellation lines up with the cotter key hole and insert the cotter pin Bend over the cotter pin legs to secure the nut Nut should be free to move with only restraint being the cotter pin For E Z Lube axles using the new nut retainer 1 5 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 Ft Lbs 12 wrench or pliers with full hand force Then loosen the spindle nut to remove the torque Do not rotate the hub g sunig sqng sfiuuea 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 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
79. ylinder allow backing in this application This brake has a primary shoe on a pivot which allows normal application in the forward direction but allows the Adjuster Spring primary shoe to Adjuster Assembly rotate away from the drum surface when backing Anchor Post Hold Down Spring Primary Shoe Self Adjusting Mechanism for 12 Hydraulic Brakes Forward self adjust hydraulic brakes were introduced in March of 1997 This feature adjusts the brakes on both forward and reverse stops Brake adjustment occurs only when lining wear results in enough gap between the shoes and the drum surface This added clearance will allow the adjuster mechanism to rotate the screw assembly at the bottom of the brake That action expands the distance between the shoes and thus closes the gap to the drum surface Hydraulic Parking Brake Option Not available on all sizes 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 12 brakes manufactured before February of 2002 the parking cable body 9iine1jp H Su18 S S Burjeig 25 Braking Systems Hydraulic 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 a
80. ypically 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 Bearings Whenever the hub equipment on your axle must be removed for inspection or maintenance the following procedure should be utilized g sunig sqng sfiuuea 45 1 Elevate and support

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