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TSE T50 BWRC, Owner'S Manual, Page: 85 / 129

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TSE T50 BWRC Owner'S Manual Download Page 85

-42-

Loose, Bent or Broken

Brake Components

Underadjustment

Out-of-Round Drums

Replace Components

Adjust

Machine or Replace

Locking Brakes

Incorrect Tire

Pressure

Restricted Brake

Lines or Hoses

Malfunctioning Cylinder

Assembly

Defective or Damaged

Shoe and Lining

Blocked Master

Cylinder

Parking Brake

Cable Frozen

Unmatched Tires

on Same Axle

One Side 

Out-of-Adjustment

Improper Lining

Thickness or Location

Inflate Evenly on Both

Sides to Req. Pressures

Match Tires on Axle

Repair or Replace

Install New Shoe and

Lining-Complete Axle

Adjust

Replace Rubber Parts

Fill with DOT4 Fluid

Open with Compressed

Air or Replace Cylinder

Free Cable 

and Lubricate

Install New Shoes

and Linings

Pulls to One Side

Improper Fluid

Dragging

Check for Stuck

or Sluggish Pistons

SYMPTOM

CAUSES

REMEDIES

Lack of Lubrication

Broken Brake

Components

Incorrect Brake

Components

Adjust

Lubricate

Replace Components

Correct

Underadjustment

Noisy Brakes

Troubleshooting

Braking Systems - Hydraulic

Summary of Contents for T50 BWRC

Page 1: ...Owner s Manual Model T50 52 BWRC Tensioner Reel Carrier Serial Number 19 5228 01 www tse international com 5301 Shreveport Blanchard Hwy Shreveport Louisiana 71107 USA P 318 929 2368 F 318 929 4853 ...

Page 2: ...s up to 96 inches in diameter and 11 500 lbs in weight TSE s exclusive quick change reel shaft system allows easy reel changes without any tools being required The 16 inch bronze disc brake on the reel shaft provides tail tension to the bullwheels A 3 roller tail fairlead with urethane lined rollers ensures that the conductor is guided from the reel stand or carrier into the first groove of the bu...

Page 3: ...e to be returned prepaid to TSE Items not returned within 30 days will result in the RGA closure and may result in a denial of the claim 3 Warranty submission must be on the standard TSE International Inc claim form Claims that are not will be classified as pending until proper forms are submitted All claims must have an estimated cost associated with each item under discrepancy 4 Major subcompone...

Page 4: ...dual application of the equipment described in this manual The contents of this manual are intended as a basis of for operation maintenance and parts listing of the unit in its intended and anticipated use as it stands alone in conjunction with other equipment The Equipment described in this manual is potentially dangerous if improperly or carelessly operated For the protection of personnel and eq...

Page 5: ... innovative products with Premium Customer Service Our comprehensive Service Department provides TSE customers with the service parts and technical assistance they need to maintain their equipment in top operating condition For Customer Service on Your Model Serial No PLEASE CALL 1 800 825 2402 Our People Care Our Equipment is the Proof T50 52 BWRC 19 5228 01 ...

Page 6: ...der the replacement part locate the part from the drawings in this manual and give the following information 1 Unit Model No From the plates on the unit s frame 2 Unit Serial No From the plate on the unit s frame will contain numbers only 3 Part Number If available 4 Description If part no not available 5 Quantity Required On large components such as transmissions engines multiple pump drives etc ...

Page 7: ...y trained operators who are critically aware of the proper procedures operating parameters and limitations potential dangers and application of this equipment should be allowed to touch the controls at any time There is potential DANGER of ELECTRICAL SHOCK when operating this machine Ground the unit in accordance with the regulations of the using organization Various methods of bonding isolation a...

Page 8: ...which after shipment from the factory of TSE has not been altered changed repaired or treated in any manner whatsoever unless such alteration change repair or treatment has been previously authorized in writing by TSE or has been performed by the authorized service representative of TSE This Warranty to repair is the only Warranty either express implied or statutory upon which the said machinery i...

Page 9: ...THODS Grounding Equipment and Methods information is covered in the following publication IEEE GUIDE TO INSTALLATION OF OVERHEAD TRANSMISSION LINE CONDUCTORS IEEE STD 524 2003 The above publication is available through the following organization THE INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS INC 3 PARK AVENUE NEW YORK NY 10016 5997 USA ...

Page 10: ...hese decals be missing they could prevent the proper operation and or maintenance of the unit which may result in personal injury or property damage If any of these decals are missing please contact us for a replacement Order the decal s by stating the decal description number and quantity TSE INTERNATIONAL 5301 SHREVEPORT BLANCHARD HWY SHREVEPORT LA 71107 ATTENTION SERVICE MANAGER TELEPHONE 800 8...

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Page 13: ...601116 C LED LIGHTING DIAGRAM STD 7PT PLUG 6600630 A REEL SHAFT ASSEMBLY 880256 G BRAKE CALIPER INSTALLATION 8601819 GENERAL ASSEMBLY B W MODULE 6600588 HYDRAULIC BRAKE PLUMBING 660110 K BRAKE CALIPER ASSEMBLY 7601221 A FAIRLEAD ASSEMBLY 562029 E BREAKAWAY WIRING 7600462 B REWIND ASSEMBLY OPTIONAL 7600204 A DRIVE ASSEMBLY OPTIONAL SECTION V VENDOR INFORMATION BRAKE CALIPER MOTOR AXLE ...

Page 14: ... 19 5 Unit Width 7 7 Unit Height 9 10 BULLWHEEL SPECIFICATIONS Diameter Nominal Diameter 52 Replaceable Segments 11 Urethane Linings per Bullwheel Maximum Conductor Size 1 500 Diameter Braking Hydraulic Disc Type Number of Grooves 4 REEL SPECIFICATIONS Maximum Reel Diameter 96 Maximum Reel Width 54 Maximum Reel Weight 11 500 lbs Spindle Diameter 2 5 8 diameter Over Spin Brake 16 Mechanical Disc UN...

Page 15: ...pare the unit for operation as follows 1 Locate the unit on as level ground as possible lined up with the towers at a minimum distance of 300 feet from the foot of the first tower or 3 times the height of the first tower whichever is greatest 2 CAUTION ANCHORING THE UNIT IS EXTREMELY IMPORTANT Anchor the unit in opposition to the direction of the pulling force with anchors that will hold three tim...

Page 16: ...ft See Figure 2 3 Connect the rope to the pulling line 4 Pull the rope to rotate the bullwheels until the pulling line is threaded around the bullwheels 5 Connect the pulling line to the conductor 6 Apply the brakes by turning the bullwheel pressure control clockwise Figure 2 Reeving the Bullwheels TENSIONING The function of the tensioner is to control the release of the conductor from the storage...

Page 17: ...IS ALLOWED TO BECOME EXCESSIVE THE CONDUCTOR WILL TEND TO PULL DOWN BETWEEN THE LAYERS WHICH COULD DAMAGE THE CONDUCTOR 7 Adjust tension control as required during pulling operation in order to maintain the desired tension in the conductor 8 To stop the pull the pulling unit must stop first Do not attempt to stop the pull using the tensioner REMOVING THE REEL 1 Turn the reel until the drive arm an...

Page 18: ...n the lifting loop side open the locking latch and swing it back out of the way shown in Figure 5 4 Put the reel shaft in the reel making sure the conductor or rope will wind on or off from the top of the reel in the correct direction shown in Figure 2 5 Make sure the reel shaft drive pins are fully engaged in reel drive holes 6 Install the lifting loop tight against side of the reel to hold it fi...

Page 19: ... 5 Use valve on control console to payout or pull in rope as required 6 Evenly lay rope onto reel with levelwind 7 After pullback is complete shut down the power supply HYDRAULIC REWIND OPTIONAL If the unit is equipped with a hydraulic rewind device to aid in taking up or paying out the conductor operate as follows 1 Place the motor into fully locked position CAUTION HYDRAULIC MOTOR MUST BE IN FUL...

Page 20: ...e of cardboard or other material as detector rather than your hand Pressurized hydraulic fluid escaping from a faulty component can penetrate the skin and cause serious injury 7 Do not change the pressure setting of any hydraulic valves unless authorized instruction has been obtained 8 Ensure that all tire and rim parts are undamaged and correctly assembled before inflating the tires 9 Use an infl...

Page 21: ...light any occurrence of a potentially hazardous malfunction On a daily basis walk around the unit and look closely for any indication of the following 1 Loose threaded connections 2 Metal fatigue or excessive corrosion 3 Abraded hose surfaces 4 Hydraulic fluid leakage 5 Possible obstruction of moving parts especially in the drive train To ensure proper operation and long life of your TSE Internati...

Page 22: ...RAULIC FLUID IS USED IN YOUR MACHINE ISO 46 567851 HYDRAULIC SYSTEM FLUID UTILITY EP 2 GREASE MULTIPURPOSE GREASE BEARINGS SHAFTS FRICTION COMPONENTS LUBRIPLATE CHAIN CABLE FLUID PENETRATING FLUID SAE 10 ISO 32 CHAINS WIRE ROPES CABLES SPARTAN EP150 INDUSTRIAL GEAR OIL ISO 150 GEARBOXES REDUCERS SEE VENDOR LITERATURE FOR VARIATIONS AND AMOUNTS SUPER MPGO 80W90 PETROLEUM OIL BLEND PUMP DRIVES ...

Page 23: ...INTS X L CHAIN DRIVES O L LUBRICATE COUPLINGS X BOLTED CONNECTIONS X X INSPECT CORRECT HYDRAULIC PLUMBING X HYDRAULIC RESERVOIR 4 X O CLEAN LUBRICATE HYDRAULIC FILTERS 2 R 3 HYDRAULIC HOSES X F FLUSH CHANGE MISC COMPONENTS 1 L 1 Items such as engines pumps pump drives motors reducers brakes etc on your equipment should be serviced according to the manufacturer s maintenance schedule see outside ve...

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Page 39: ... by clamping on to housing 28 Loosen and remove seven bolts 39 holding motor assembly together Remove end cover 37 carefully as piston 35 and spring 36 may fall out If piston does not come out carefully pry piston 35 out of endcover 37 and lay aside Remove O Ring seal 12 and backup seal 13 from endcover and discard seals Remove spring 36 and lay aside Lift commutator container and commutator 34 fr...

Page 40: ... rotor 32 onto divider plate 31 with side of rotor with chamfer in splines facing divider plate 31 Place manifold 33 onto rotor 32 with seal groove side up Install manifold seal 10 Install the commutator seal 11 into the commutator 34 with the metal side facing up Use finger pressure to press the seal down flush with the surface of the commutator Place the commutator container onto the manifold 33...

Page 41: ...AUXILIARY VIEWS HIGH PRESSURE SEAL METAL BACKUP SHIM SHAFT SEAL METAL BACKUP SHIM BACKUPSEAL SEAL CARRIER WIRE RING FIGURE 1 1 4 6 5 2 7 3 FIGURE 2 FIGURE 3 1 2 3 4 5 6 ...

Page 42: ...ngs 2 21 Bearing Spacer 22 Thrust Ring 23 Bearing Hub 24 Thrust Bearings DR 2 DT 1 25 Rear Housing Bearing 26 Planetary Mount Studs 4 27 Mounting Nuts 4 28 Housing 29 Shaft 30 Drive Link 31 Divider Plate 32 Rotor Assembly 33 Manifold 34 Commutator Assembly 35 Endcover Piston 36 Piston Spring DIRECT DRIVE OPTION WARN HUB OPTION 37 Endcover 38 I D Tag Assembly 39 Assembly Bolts 7 40 Driver Cover Scr...

Page 43: ...www dexteraxle com OPERATION MAINTENANCE SERVICE MANUAL 600 8 000 lb Axles Related Components ...

Page 44: ...nd 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 ou...

Page 45: ...ge 20 How to Measure Amperage 20 Magnet Amperes Chart 21 Braking Systems Hydraulic Hydraulic Brakes 23 Hydraulic Brake Operation 24 Duo Servo 24 Uni Servo 24 Self Adjusting Mechanism for 121 4 Brakes 25 Hydraulic Parking Brake Option 25 Disc Brakes 27 Actuation Systems 28 Electrical Schematic 28 Troubleshooting Guide 29 General Maintenance Hydraulic Brakes 31 Drum Brake Adjustment Manual 31 Wheel ...

Page 46: ...5 Suspensions Suspension Systems 57 Double Eye Leaf Springs 57 Grease Lubricated Suspension Bushings 58 Slipper Leaf Springs 58 Inspection and Replacement 59 Suspension Fastener Torque Values 59 Torflex Suspension 61 Airflex Suspension 62 Wheels and Tires Wheels 66 Wheel Selection 66 Torque Requirements 67 Wheel Torque Requirements 68 Maximum Wheel Fastener Torque 69 Tires 70 Tire Wear Diagnostic ...

Page 47: ... instructions provided in this manual must first establish that they neither compromise their personal safety nor the vehicle integrity by their choice of methods tools or parts Refer to your vehicle manufacturer s owners manual for additional procedures techniques and warnings prior to performing any maintenance or repairs CAUTION This is the safety alert symbol It is used to alert you to potenti...

Page 48: ...e of the drums which moves the actuating levers in the direction that the drums are turning The resulting force causes the actuating cam block at the shoe end of the lever to push the primary shoe out against the inside surface of the brake drum The force generated by the primary shoe acting through the adjuster moves the secondary shoe out into contact with the brake drum Increasing the current f...

Page 49: ...applied to the parking lever creates a torque through the pivot pin and cam assembly Torque transferred to the parking cam results in a spreading force between the primary and secondary shoes The shoes in turn move towards the drum until contact is made Friction generated between the drum and lining contact surface keeps the drum from rotating under normal loading conditions Self Adjusting Feature...

Page 50: ...e lights to warn of an impending stop Most electric brake controllers provide a modulation function that varies the current to the electric brakes with the pressure on the brake pedal or amount of deceleration of the tow vehicle Electronic or timing controllers do not provide proportional modulation These controllers tend to be inexpensive but not the best choice for optimum braking It is importan...

Page 51: ...ems Electric Breakaway Battery Provides power to actuate trailer brakes in the event of trailer breakaway Dexter Electric Brakes Wired in parallel Breakaway Switch Switches battery power to brakes if breakaway occurs ...

Page 52: ...ler Electric brake controller provides power to the magnets to actuate the trailer brakes Battery Connect controller directly Connector Used to connect and disconnect trailer and tow vehicle Always ground trailer brakes through connector ...

Page 53: ...al 1 Orange Auxiliary Circuit Terminal 9 Batt Stop Right Turn Signal Terminal 6 Electric Brake Terminal 2 Blue Electric Brake Ground Terminal 1 White Double Filament Bulb Brown Yellow White Green Red Black Orange Brown Blue Grey 3 To Tail Running License Lights 5 Stop Left Turn 4 Battery Charge 7 Aux Circuit 9 Aux Circuit 6 Stop Right Turn 2 Electric Brake 8 Aux Circuit Clearance Tail Lights Stop ...

Page 54: ... 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...

Page 55: ...e 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 applyin...

Page 56: ...pension 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 starwheel of the adjuster assembly to exp...

Page 57: ...eformed springs and replace as necessary CAUTION 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...

Page 58: ... 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...

Page 59: ... 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 brakes must be re bu...

Page 60: ... electrical system failure Voltmeters and ammeters are essential tools for proper troubleshooting of electric brakes Mechanical causes are ordinarily obvious i e bent or broken parts worn out linings or magnets seized lever arms or shoes scored drums loose parts etc Replace defective parts with genuine Dexter replacements Please consult the following troubleshooting charts to determine the causes ...

Page 61: ...ponents Out of Round Brake Drums Insufficient Wheel Load Faulty Controller Broken Wires Loose Connections Find Correct Adjust Brakes Test Correct Clean or Replace Clean Correct Cause of Corrosion Replace Machine or Replace Correct Adjust Brakes Reburnish or Replace Correct Adjust Correct Test Correct Replace Components Machine or Replace Adjust System Resistor and Synchronize Test Correct Repair o...

Page 62: ...ntroller Overadjustment Out of Round Brake Drums Incorrect Brake Components Loose Bent or Broken Brake Components Faulty Breakaway Switch Loose Wheel Bearing Adjustment Adjust Clean or Replace Find Repair Find Repair Adjust Correct Change Test Correct Adjust Lubricate Replace Component Correct Clean or Replace Machine or Replace Test Correct Readjust Machine or Replace Replace Replace Repair or Re...

Page 63: ...o 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 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...

Page 64: ...mmeter 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 The most common electrical problem is low or no voltage and amperage at the brakes Common causes of this condition are 1 Poor electrical connections 2 Open circuits 3...

Page 65: ...connected 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...

Page 66: ...utomotive 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 CAUTION The operating pressure requir...

Page 67: ...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 dru...

Page 68: ...juster 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 attache...

Page 69: ...etween 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 121 4 brakes transfers the applied cable force through a cam mechanism The cam mechanism generates a spreading force between the primary and secondary shoes The shoes...

Page 70: ...e 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 lb 10 000 lb and 12 000 lb 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 inboar...

Page 71: ...nsure 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 1000 psi for your drum brakes and the E H 1600 will generate 1600 psi for maximum performance from y...

Page 72: ... All other wires should be a minimum of 16 gauge 6 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 Verify that the trailer and tow vehicle are wired as deta...

Page 73: ...ctuator should be returned for repair 4 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 5 If the voltage is less than 12 volts either the breakaway switch or the breakaway wiring is defective 6 If the voltage is greater than 12 volts the E H unit should be returned for repair Trailer bra...

Page 74: ...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 starwheel of the adjuster assembly to expand the brake s...

Page 75: ...if they are usable Replacement is necessary if the lining is worn to within 1 16 or less contaminated with grease or oil or abnormally scored or gouged Hairline heat cracks are normal in bonded linings and should not be cause for concern When replacement is necessary it is important to replace both shoes on each brake and both brakes of the same axle This will help retain the balance of your brake...

Page 76: ...tice 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 CAUTION Do not lift or support the trailer on any part of the axle or suspension system Never go under any trail...

Page 77: ...re rotor against the hub face when reassembling the caliper After the caliper is assembled remove the lug nuts 4 Reconnect the hose to the elbow adapter on the back of the caliper and torque to 10 12 Ft Lbs 5 Reconnect the brake actuation system Refer to your actuation systems Operation Maintenance Service Manual for proper operation 6 Bleed and flush brake system per your actuation systems Operat...

Page 78: ...stalling 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 Rem...

Page 79: ... 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 air into the hydraulic system 5 With the caliper assembly out of the way remove the brake rotor Save the brake mount...

Page 80: ...r 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 8K Disc Hydraulic Brakes Notice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance Remove the old brake pads 1 Jack up trailer and secure on adequate capacity jack st...

Page 81: ...leaning dust can be removed with a damp brush Installing the new brake pads 1 First inspect the brake assembly for grooves flaking cracks heat checking thickness variation insufficient rotor thickness and look to see that the mounting hardware is straight Replace any component as needed or desired per manufacturer recommendations 2 Press the caliper pistons into the calipers until enough clearance...

Page 82: ... brake pads 1 Jack up trailer and secure on adequate capacity jack stands Follow trailer manufacturers recommendations for lifting and supporting the unit CAUTION 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 unexpecte...

Page 83: ...r 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 5 Reassemble the brake pads into the disc brake Make sure...

Page 84: ... 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 CAUTION The...

Page 85: ...g Thickness or Location Inflate Evenly on Both Sides to Req Pressures Match Tires on Axle Repair or Replace Install New Shoe and Lining Complete Axle Adjust Replace Rubber Parts Fill with DOT4 Fluid Open with Compressed Air or Replace Cylinder Free Cable and Lubricate Install New Shoes and Linings Pulls to One Side Improper Fluid Dragging Check for Stuck or Sluggish Pistons SYMPTOM CAUSES REMEDIES...

Page 86: ...Shoe and Lining Recondition or Replace All Cylinders Brake Fluid Reburnish or Replace Replace Bleed System Correct No Brakes Weak Brakes Frozen Master Cylinder or Wheel Cylinder Pistons Manual Adjust Brakes Automatic Make Several Reverse Stops SYMPTOM CAUSES REMEDIES Malfunctioning Actuating System Troubleshoot System Grease or Fluid on Linings Replace Shoes and Linings Manual Adjust Brakes Automa...

Page 87: ...sists 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 seale...

Page 88: ...r 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 lb and 8 000 lb axles a hub puller may be necessary to assist in drum removal Brake Drum Inspection There ...

Page 89: ...never 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 prese...

Page 90: ...ning 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 Bearing Lubrication Grease Along with bearing adjustment proper lubrication is essential to the proper function and reliability of your trailer axle Bearings should be lubricated every 12 months or 12 000 miles The method to repack beari...

Page 91: ...lug hole in the cap itself Recommended Wheel Bearing Lubrication Specifications Grease Thickener Type Lithium Complex Dropping Point 215O C 419O F Minimum Consistency NLGI No 2 Additives EP Corrosion Oxidation Inhibitors Viscosity Index 80 Minimum Approved Sources Mobil Oil Mobilgrease HP Mobilith AW2 Exxon Standard Ronex MP Kendall Refining Co Kendall L 427 Super Blu Ashland Oil Co Valvoline Mult...

Page 92: ...ing cavity If there is any question of condition replace the seal Use only the seals specified in the Seal Replacement Chart 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 Note Permatex sealant should not be used on rubber encased seals 3 Tap...

Page 93: ...out slightly until the first castellation lines up with the cotter key hole and insert the cotter pin 5 Bend over the cotter pin legs to secure the nut 6 Nut should be free to move with only restraint being the cotter pin For E Z Lube axles using the new nut retainer 1 Finger tighten the nut until just snug align the retainer to the machined flat on the spindle and press the retainer onto the nut ...

Page 94: ...e grease gun wipe off any excess and replace the rubber plug in the cap 5 Rotate hub or drum while adding grease Note The E Z Lube feature is designed to allow immersion in water Axles not equipped with E Z Lube are not designed for immersion and bearings should be repacked after each immersion If hubs are removed from an axle with the E Z Lube feature it is imperative that the seals be replaced B...

Page 95: ...ement 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 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 Hubs Drums Bearings ...

Page 96: ... 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 ...

Page 97: ...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 t...

Page 98: ...fitted with a hollow or stepped punch face to press only on the outer housing of the bearing Failure to follow procedure will damage the bearing and or seals during installation Press bearing until it seats against the backup shoulder machined into the hub 5 Install internal snap ring into hub 6 Clean and inspect spindle shaft Apply a light coating of anti seize lubricant to the spindle shaft prio...

Page 99: ...l 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 12 Inspect assembly for excessive end play noise and rotation restriction prior to mounting final wheel end hardware ...

Page 100: ...on 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 Equalizer Rear Hanger Front Hanger Tie Plate U Bolt Shackle Bolts Shackle Link Underslung Shown Articulation of this suspension occurs when the spring becomes loaded and consequently lengthens The double pivot action of the s...

Page 101: ...ngs have an eye formed in one end only with the other end formed into a reverse curve The attachment of these springs is as follows 1 The front eye is attached directly into the front hanger with a bolt and nut 2 The rear end of the spring is captured in the rear hanger or equalizer with a keeper bolt that prevents the spring from coming out when the trailer is jacked up for service The articulati...

Page 102: ...ff 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 Suspension Fastener Torque Values Torque lbs ft Item Min Max 3 8 U Bolt 30 50 7 16 U Bolt 45 70 1 2 U Bolt 45 70 9 16 U Bolt 65 95 5 8 U Bolt 100 120 Non shoulder type with 9 16 threads Shackle Bolt Snug fit only Parts must rotate freely L...

Page 103: ...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 CAUTION 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 using a piloted drift punch or a close fitting bolt inserted thro...

Page 104: ...ve 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 system is a torsion arm type suspension w...

Page 105: ...ed in this manual CAUTION 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 suspension is a unique combination of Torflex 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 sto...

Page 106: ...erly supported vehicles can fall unexpectedly and cause serious injury or death 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 meas...

Page 107: ... 64 Suspensions 4 Re measure A and B as before to assure that A and B dimensions are within 1 16 of each other If dimensions are not to specification then repeat adjustment procedure Figure 1 ...

Page 108: ... distances must be within 1 8 of each other 3 After alignment is completed make sure all nuts and bolts are tightened to their respective torque values 4 The limits of 1 16 and 1 8 appear very small in comparison to the overall dimensions of the vehicle but they are recognized as the maximum permissible limit of misalignment Also the relatively small size of those limits makes accurate measurement...

Page 109: ...ity Make sure that the wheels have enough load carrying capacity and pressure rating to match the rated load of the tire 3 Offset This refers to the relationship of the center line of the tire to the hub face of the axle Care should be taken to match any replacement wheel with the same offset wheel as originally equipped Failure to match offset can result in reducing the load carrying capacity of ...

Page 110: ...els 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 lbs ft of t...

Page 111: ... 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 Wheel Torque Requirements For Dexter Steel Wheels Prior to June 2004 Wheel Torque Sequence Size 1st Stage 2nd Stage 3rd Stage 12 20 25 35 40 50 75 13 20 25 35 40 50 75 14 20 25 50 60 90 120 15 20 25 50 60 90 120 16 20 25 50 60 90 120 16 5 x 6 75 20 25 50 ...

Page 112: ...l that can be safely applied to these studs is listed in the following chart Stud Size Max Torque 1 2 20 UNF class 2A 120 lb ft 9 16 18 UNF class 2A 170 lb ft 5 8 18 UNF class 2A 325 lb ft CAUTION Exceeding the above listed torque limits can damage studs and or nuts and lead to eventual fractures and dangerous wheel separation Wheels and Tires ...

Page 113: ... Use the capacity rating molded into the tire sidewall divided by 1 10 for trailer use Use tire mounting procedures as outlined by the Rubber Manufacturer s Association or the tire manufacturers Tire inflation pressure is the most important factor in tire life Inflation pressure should be as recommended by the manufacturer for the load Pressure should be checked cold before operation Do not bleed ...

Page 114: ...correct toe in Out of balance Wheel lockup tire skidding Adjust pressure to particular load per tire catalog Adjust pressure to particular load per tire catalog Make sure load doesn t exceed axle rating Align at alignment shop Align at alignment shop Check bearing adjust ment and balance tires Avoid sudden stops when possible and adjust brakes Wear Pattern Cause Action g ...

Page 115: ...7 x 11 4 K71 045 00 N A 7 x 1 N A K71 466 00 10 x 21 4 K71 047 00 K71 267 00 Free Backing K71 393 00 Corrosion Resistant K71 423 00 12 x 2 5 2K K71 048 00 K71 268 00 12 x 2 7K K71 127 00 K71 269 00 LH K71 270 00 RH Free Backing K71 394 00 LH K71 395 00 RH Free Backing Corrosion Resistant K71 427 00 LH K71 428 00 RH 121 4 x 21 2 K71 497 00LH K71 496 00RH N A 121 4 x 33 8 K71 499 00LH K71 498 00RH K...

Page 116: ... K71 308 00 25520 25580 6K Outer K71 309 00 15245 15123 12 x 2 8 Bolt Inner K71 308 00 25520 25580 7K Outer K71 310 00 14145A 14276 121 4 x 21 2 8 Bolt Inner K71 308 00 25520 25580 7 2K Outer K71 415 00 02420 02475 121 4 x 33 8 8 Bolt Inner K71 308 00 25520 25580 8K Outer K71 415 00 02420 02475 Special Application Seal Replacement Reference Brake Hub Seal Part No Size Size Std E Z Lube Oil 7 x 11 ...

Page 117: ...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 Boat trailer axles are subject to repeated immersion Befor...

Page 118: ...th 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 CAUTION 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 con...

Page 119: ... breakaway battery is fully charged 4 Inspect towing hookup for secure attachment 5 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 6 Do Not Overload Stay within your gross vehicle rated capacity consult your trailers identification plate 7 Inflate tires according to manufacturer s specifications inspect tire...

Page 120: ...ines Inspect for cracks leaks kinks Trailer Brake Wiring Inspect wiring for bare spots fray etc Breakaway System Check battery charge and switch operation At Every Use Hub Drum Inspect for abnormal wear or scoring Wheel Bearings Cups Inspect for corrosion or wear Clean repack Seals Inspect for leakage Replace if removed Springs Inspect for wear loss of arch Suspension Parts Inspect for bending loo...

Page 121: ...rial 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 mad...

Page 122: ... publication Operation Maintenance Service Manual including required maintenance after Prolonged Storage 12 Improper wheel nut torque 13 Cosmetic finish or corrosion LIMITATIONS 1 In all cases Dexter Axle reserves the right to fully satisfy its obligations under the Limited Warranties by refunding the then current list price of the defective axle or if the axle has been discontinued of the most ne...

Page 123: ...NTIAL 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 a...

Page 124: ...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 Kits Brake Controllers Actuators Ready for Immediate Shipment Direct to Your Door Visit us online at www dexteraxle ...

Page 125: ...Service Record Date Service Performed Mileage ...

Page 126: ...Service Record Date Service Performed Mileage ...

Page 127: ...Service Record Date Service Performed Mileage ...

Page 128: ... 92408 Fax 909 799 6258 Ph 909 796 2908 Dexter Axle 500 S E 27th St El Reno OK 73036 Fax 405 262 9089 Ph 405 262 6700 Dexter Axle Road 75 East Albion IN 46701 Fax 260 636 3030 Ph 260 636 2195 Dexter Axle 11870 N 650 East N Manchester IN 46962 Fax 260 982 7511 Ph 260 982 4047 Company Headquarters 2900 Industrial Parkway East Elkhart IN 46516 Fax 574 295 8666 Ph 574 295 7888 Dexter Axle 1 Municipal ...

Page 129: ...www dexteraxle com 2900 Industrial Parkway East Elkhart IN 46516 Fax 574 295 8666 Ph 574 295 7888 2 07 Dexter Axle 2007 LIT 001 00 ...

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