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 • Tandem axle trailer with electric brakes. • Front and rear drop-leg jacks. • Tie down lugs. At TSE, engineering is a process of continuous product improvement; therefore, speciﬁ cations are subject to change without notice. Toll Free: 800.825.2402 5301 Shreveport-Blanchard Hwy Telephone: 318.929.2368...
Page 3 30 days allowing for sufficient time for submission to TSE. Warranties claimed without a valid claim number may be denied. 2. Please retain any defective parts for a period of 60 days. TSE reserves the right to inspect and/or evaluate any parts submitted for warranty consideration.
Page 4 Recommendations for improving this publication are encouraged and should be forwarded to: TSE INTERNATIONAL 5301 Shreveport-Blanchard Hwy. Shreveport, Louisiana 71107 This is not a tension stringing operation procedures manual. No attempt is made or implied herein to instruct the user in methods peculiar to the individual application of the equipment described in this manual.
Page 5 PREMIUM CUSTOMER SERVICES TSE supports its 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...
Page 6 On large components such as transmissions, engines, multiple pump drives, etc., the manufacturer’s serial number and spec. number is necessary to ensure receiving the proper replacement part. www.tse-international.com 5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA P: 318-929-2368...
Page 7 Make certain all personnel are clear of this equipment before starting engine or operation. Before leaving the operators position, make sure that directional controls are in the neutral position and all brakes are set. www.tse-international.com 5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA P: 318-929-2368 F: 318-929-4853...
Page 8 This Warranty to repair applies only to new and unused machinery, 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.
Page 9 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 www.tse-international.com 5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA P: 318-929-2368 F: 318-929-4853...
Page 10 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...
Page 13 CONTENTS T50/52-BWRC SECTION I INTRODUCTION SECTION II OPERATIONS SECTION III MAINTENANCE SECTION IV PARTS LIST F602499 FINAL ASSEMBLY - T50/52-BWRC 8602491 GENERAL ASSEMBLY - T50/52-BWRC 7601116-C LED LIGHTING DIAGRAM, STD – 7PT PLUG 6600630-A REEL SHAFT ASSEMBLY 880256-G BRAKE CALIPER INSTALLATION 8601819 GENERAL ASSEMBLY - B/W MODULE 6600588...
Page 14 This service manual has been prepared to acquaint the reader with the components of the unit and assist in its operation and maintenance. GENERAL DESCRIPTION The TSE Model T50/52 BWRC is a trailer mounted, multi-groove, bullwheel tensioner designed to control the pay out of conductor from a storage reel. SPECIFICATIONS Rated Tension 5,000 lbs.
Page 15 SECTION II OPERATION This section contains procedures designed to insure safe and efficient operation of the tensioner. CAUTION: WHEN THIS SIGN APPEARS ON THESE PAGES, IT INDICATES WHERE SPECIAL ATTENTION SHOULD BE PAID TO THE INSTRUCTION GIVEN. PERSONAL INJURY OR EQUIPMENT DAMAGE MAY OCCUR IF THE INSTRUCTIONS ARE NOT FOLLOWED.
Page 16 unit as shown in Figure 1. Follow proper grounding procedures as required by IEEE and/or the applicable standards in your area. Use of a ground mat and a running ground on the conductor are highly recommended. 4. Put a hazard barrier around the perimeter of the unit to keep unauthorized personnel away from the equipment.
Page 17 CAUTION: TAIL TENSION IS CRITICAL TO PREVENT CONDUCTOR SLIPPAGE ON THE BULLWHEELS AND IN SOME CASES; TO PREVENT BIRDCAGING OF THE CONDUCTOR AS IT PASSES AROUD THE BULLWHEELS. THEREFORE, THE REELSHAFT BRAKE CONTROL MUST BE ADJUSTED TO PROVIDE PROPER TAIL TENSION. THE HANDWHEEL PRESSURE SHOULD BE SET TO KEEP THE CONDUCTOR FROM SLIPPING ON THE BULLWHEEL.
Page 18 3. On the lifting loop side, open the locking latch and swing it back out of the way, shown in Figure 5. Figure 5: Removing Locking Latch 4. Attach lifting hooks to the drive arm and lifting loop. Ensure they are balanced so the reel remains level during lifting.
Page 19 CAUTION/WARNING! THE REEL MUST BE UNDERWOUND WHEN PLACED IN THE MACHINE AS VIEWED FROM THE REAR OF THE UNIT. SEE FIGURE 2. POLEMASTER REWIND (OPTIONAL) If your unit is equipped with the optional polemaster system, operate as follows: 1. Install the polemaster reel on the shaft and insert lock pin. 2.
Page 20 Section III Maintenance This section contains schedules, recommendations, and procedures designed to ensure that the equipment is prepared for safe and efficient operation and to prolong the service life of the equipment. These maintenance instructions constitute basic requirements for an operational environment that is not extreme in temperature, humidity, airborne abrasives, or other conditions which would require preventative maintenance techniques to combat.
Page 21 TSE International and our component suppliers. Prior to start-up of new TSE International products, all fluid levels are to be checked to ensure correct operating levels. All lubrication and maintenance points are to be inspected and lubricated as illustrated on the Lubrication and Maintenance Instructions sheet.
Page 22 LUBRICATION DATA LUBRICANT LUBRICANT INFORMATION PART APPLICATION GRADES TSE STANDARD HYDRAULIC FLUID (REFER TO HYDRAULIC OIL DECAL HYDRAULIC SYSTEM AW46 LOCATED ON HYDRAULIC RESERVOIR ISO 46 567851 FLUID TO DETERMINE WHAT HYDRAULIC FLUID IS USED IN YOUR MACHINE) BEARINGS, SHAFTS,...
Page 23 SUGGESTED MAINTENANCE SCHEDULE The following schedule should be carried out by qualified personnel using proper lubricants to suit environmental and operating conditions. NOTE: THESE ARE SUGGESTED RECOMMENDATIONS ONLY. SPECIFIC SITUATIONS MAY REQUIRE A DIFFERENT LUBRICATION SCHEDULE. ALTER AS NECESSARY. HOURS 1000 SERVICE DAILY...
Page 39 PI666252 White Hydraulics, Inc. P.O. Box 1127 2/01 Hopkinsville, KY 42241 Phone- (270) 885-1110 Fax- (270) 886-8462 Service Instructions For The For Use With DR (640) Series Seal Kit 700666252 ***USE EXPLODED VIEW ON BACK FOR REFERENCE*** NOTE: The DR (640) series is available with either a direct drive option or a warn hub option. After determining which option you have, use the appropriate instruction in steps A and P below.
Page 40 oil, place installation sleeve over shaft and push shaft seal onto shaft (lip facing down) until it contacts thrust washer. Remove installation sleeve and lightly coat backup seal (6) with clean oil. Install backup seal (6) with lip facing down followed by metal backup shim (5) (See Figure 1 for correct seal position). Install seal carrier (14) onto shaft with large end facing down.
Page 41 AUXILIARY VIEWS WIRE RING HIGH PRESSURE SEAL METAL BACKUP SHIM SHAFT SEAL METAL BACKUP SHIM SEAL CARRIER BACKUP SEAL FIGURE 1 FIGURE 2 FIGURE 3...
Page 42 DR (640) Motor Components Flange Seal 13. Backup Seal 25. Rear Housing Bearing 37. Endcover Wire Ring 14. Seal Carrier 26. Planetary Mount Studs (4) 38. I.D. Tag Assembly Metal Backup Shim 15. Thrust Washer 27. Mounting Nuts (4) 39. Assembly Bolts (7) High Pressure Seal 16.
Page 43 OPERATION MAINTENANCE SERVICE MANUAL 600 - 8,000 lb. Axles & Related Components www.dexteraxle.com...
Page 44 Introduction This manual is designed to provide information for you to understand, use, maintain, and service your trailer running gear system. Your axles are manufactured by Dexter Axle. The Dexter product line, the most complete in the industry, is the result of over 30 years of experience in the design, testing and manufacturing of trailer axles.
Page 45: Table Of Contents
Introduction Important Safety Notice ................. 4 Getting Started - Setup and Adjustment ..........4 Braking Systems - Electric Electric Brakes ..................5 Features ....................6 Parking Brake Option ..............6 Self Adjusting Feature ..............6 Brake Controllers ................7 Typical Trailer Wiring ..............10 How To Use Your Electric Brakes Properly .......
Page 46 Hubs/Drums/Bearings Hubs/Drums/Bearings ..............44 Hub Removal - Standard Bearings ..........44 Brake Drum Inspection ............... 45 Bearing Inspection ..............46 Bearing Lubrication - Grease ............. 47 Bearing Lubrication - Oil ............. 48 Recommended Wheel Bearing Lubrication Specifications ..48 Seal Inspection and Replacement ..........49 Bearing Adjustment and Hub Replacement .......
Page 47: Important Safety Notice
Important Safety Notice Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all running gear as well as the personal safety of the individual doing the work. This manual provides general directions for performing service and repair work with tested, effective techniques.
Page 48: Electric Brakes
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...
Page 49: Features
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.
Page 50: Brake Controllers
Brake Controllers Electric brake controllers provide power to the magnets to actuate the trailer brakes. Dexter Axle offers a state-of-the-art inertial controller called the Predator Series™ DX2. This controller features a patented pendulum design which senses the deceleration of the towing vehicle and sends a proportional voltage to the electric trailer brakes.
Page 51 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.
Page 52 Controller 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: Typical Trailer Wiring
Typical Trailer Wiring Double Stop & Left Turn Signal Filament To Terminal #5 Bulb Yellow Auxiliary Circuit License Tail & White #1 Common Ground Terminal #7 Running Lights #3 To Tail Running & Green Grey Terminal #3 Auxiliary Circuit License Lights Terminal #8 #5 Stop &...
Page 54: How To Use Your Electric Brakes Properly
How to Use Your Electric Brakes Properly Your trailer brakes are designed to work in synchronization with your tow vehicle brakes. Never use your tow vehicle or trailer brakes alone to stop the combined load. Your brake controller must be set up according to the manufacturer's recommendations to ensure proper synchronization between the tow vehicle and the trailer.
Page 55: Synchronizing Your Trailer Brakes
Synchronizing Your Trailer Brakes To insure safe brake performance and synchronization, read the brake controller manufacturer's instructions completely before attempting any synchronization procedure. CAUTION Before road testing, make sure the area is clear of vehicular and pedestrian traffic. Failure to brake safely could result in an accident and personal injury to yourself and/or others.
Page 56: General Maintenance - Electric Brakes
General Maintenance - Electric Brakes Brake Adjustment Most Dexter 12 " electric brakes have a self adjusting feature. If manual adjusting is required, use the following procedure: Brakes should be adjusted (1) after the first 200 miles of operation when the brake shoes and drums have “seated,” (2) at 3,000 mile intervals, (3) or as use and performance requires.
Page 57: Brake Cleaning And Inspection
Brake Cleaning and Inspection Your trailer brakes must be inspected and serviced immediately if a loss of performance is indicated. With normal use, servicing at one year intervals is usually adequate. With increased usage, this work should be done more frequently as required. Magnets and shoes must be changed when they become excessively worn or scored, a condition which can reduce vehicle braking.
Page 58: Magnets
Magnets Your electric brakes are equipped with high quality electromagnets that are designed to provide the proper input force and friction characteristics. Your magnets should be inspected and replaced if worn unevenly or abnormally. As indicated below, a straightedge should be used to check magnet condition.
Page 59: Shoes And Linings
Shoes and Linings A simple visual inspection of your brake linings will tell if they are usable. Replacement is necessary if the lining is worn (to within " or less), contaminated with grease or oil, or abnormally scored or gouged. Hairline heat cracks are normal in bonded linings and should not be cause for concern.
Page 60: Introduction To Troubleshooting
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.
Page 61: Troubleshooting Chart - Electric
Troubleshooting SYMPTOM CAUSES REMEDIES Open Circuits Find & Correct Severe No Brakes Adjust Brakes Underadjustment Faulty Controller Test & Correct Short Circuits Find & Correct Grease or Oil on Clean or Replace Magnets or Linings Clean & Correct Corroded Connections Cause of Corrosion Worn Linings Replace...
Page 62 Troubleshooting SYMPTOM CAUSES REMEDIES Wrong Magnet Correct Lead Wire Color Adjust Incorrect Adjustment Grease or Oil on Clean or Replace Linings or Magnets Brakes Pull to One Side Broken Wires Find & Repair Find & Repair Bad Connections Adjust Underadjustment Improper Correct Synchronization...
Page 63: How To Measure Voltage
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.
Page 64: Magnet Amperes Chart
Magnet Amperes Chart Brake Amps/ Four Magnet Size Magnet Brakes Brakes Brakes Ohms 7 x 1 10.0 15.0 10 x 1 12.0 18.0 10 x 2 12.0 18.0 12 x 2 12.0 18.0 12.0 18.0 12.0 18.0 If a resistor is used in the brake system, it must be set at zero or bypassed completely to obtain the maximum amperage reading.
Page 65 Possible causes are: 1. Shorted magnet coils 2. Defective controllers 3. Bare wires contacting a grounded object Finding the cause of a short circuit in the system is done by isolating one section at a time. If the high amperage reading drops to zero by unplugging the trailer, then the short is in the trailer.
Page 66: Hydraulic Brakes
Hydraulic Brakes Dexter offers several varieties of hydraulic trailer brakes. Your vehicle may be equipped with the traditional drum brakes or you may have disc brakes. The hydraulic brakes on your trailer are much like those on your automobile or light truck. 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.
Page 67: Hydraulic Brake Operation
Hydraulic Brake Operation Duo-Servo The duo-servo brake uses a dual piston wheel cylinder to apply the brakes. This type of brake is typically used in a vacuum/ hydraulic, electric/hydraulic or air/hydraulic system. A description of operation of this brake is as follows: When the brakes are applied, the double-acting wheel cylinder moves the primary and secondary shoes towards the drum.
Page 68: Self-Adjusting Mechanism For
backing with a surge brake hitch, normal brakes are applied through the surge mechanism and if there is more brake Anchor Post force on the trailer than Hydraulic Wheel Retractor Cylinder the tow vehicle can Springs override, no backing is possible.
Page 69 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.
Page 70: Disc Brakes
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.
Page 71: Actuation Systems
Actuation Systems To effectively operate your hydraulic trailer brakes we recommend the Dexter E/H electro/hydraulic actuator, controlled by the Predator series DX2™ electronic brake controller. These high performance hydraulic power modules will supply pressurized brake fluid to your trailer brakes in proportion to the amount of braking effort called for by the towing vehicles' deceleration rate.
Page 72: Electrical Schematic
Troubleshooting Guide Brakes are slow to respond 1. Re-bleed the trailer brakes and actuator. 2. If the trailer is equipped with drum brakes, readjust the drum brakes to the brake manufacture's recommended running clearance. 3. Slow response can be caused by trailer wiring that is too small.
Page 73 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. 3. 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.
Page 74: General Maintenance - Hydraulic Brakes
General Maintenance - Hydraulic Brakes Drum Brake Adjustment - Manual Most Dexter 12 " electric brakes have a self adjusting feature. If manual adjusting is required, use the following procedure: Brakes should be adjusted (1) after the first 200 miles of operation when the brake shoes and drums have “seated,”...
Page 75: Wheel Cylinders
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.
Page 76: Hardware
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.
Page 77: Instructions For Brake Rotor Kit - 3.5K Disc Brakes
4. Remove the hose from the caliper. Then remove the two caliper mounting bolts. Do not allow the caliper to hang from the hose. Installing the new brake caliper 1. First inspect the brake assembly for grooves, flaking, cracks, heat checking, thickness variation, insufficient rotor thickness, and look to see that the mounting hardware is straight.
Page 78 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 unexpectedly and cause serious injury or death.
Page 79: Instructions For Brake Rotor Kit - 6K Or 8K Disc Brakes
Instructions for Brake Rotor Kit 6K or 8K Disc Hydraulic Brakes Notice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance. Remove the old brake rotor 1. Jack up trailer and secure on adequate capacity jack stands.
Page 80: Instructions For Brake Pad Kit - 6K Or 8K Disc Brakes
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.
Page 81 2. Remove the wheel from the hub, leaving the brake exposed. 3. Disconnect the brake actuation system. Check that the hydraulic system has zero pressure and that the hub and rotor rotates freely. 4. Remove the brake pad retaining bolt. 5.
Page 82: Instructions For Brake Caliper Kit - 6K Or 8K Disc Brakes
4. Align the brake pad mounting holes with the holes in the caliper. Insert the brake pad retaining bolt and tighten nut until snug against shoulder of bolt. 5. Reconnect the brake actuation system. Refer to your Operation Maintenance Service Manual for proper operation.
Page 83 Installing the new brake caliper 1. First inspect the brake assembly for grooves, flaking, cracks, heat checking, thickness variation, insufficient rotor thickness, and look to see that the mounting hardware is straight. Replace any component as needed (or desired) per manufacturer recommendations. 2.
Page 84: Introduction To Troubleshooting
Introduction to Troubleshooting Proper brake function is critical to the safe operation of any vehicle. A properly installed vacuum/hydraulic, electric/hydraulic or air/hydraulic system should not require any special attention with the exception of routine maintenance as defined by the manufacturer. If problems occur, the entire tow vehicle/trailer braking system should be analyzed by a qualified mechanic.
Page 85: Troubleshooting Chart - Hydraulic
Troubleshooting SYMPTOM CAUSES REMEDIES Adjust Underadjustment Lack of Lubrication Lubricate Noisy Brakes Broken Brake Replace Components Components Incorrect Brake Correct Components Loose, Bent or Broken Replace Components Brake Components Locking Brakes Underadjustment Adjust Out-of-Round Drums Machine or Replace Incorrect Tire Inflate Evenly on Both Pressure Sides to Req.
Page 86 Troubleshooting SYMPTOM CAUSES REMEDIES Broken or Kinked Repair or Replace Brake Line Severe No Brakes Adjust Brakes Underadjustment Malfunctioning Troubleshoot System Actuation System Manual-Adjust Brakes Brake Adjustment Automatic-Make Several Not Correct Reverse Stops Excessively Worn Replace Shoe Brake Linings and Lining Install Correct Incorrect Lining Shoe and Lining...
Page 87: Hubs/Drums/Bearings
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.
Page 88: Brake Drum Inspection
CAUTION 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.
Page 89: Bearing Inspection
.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 ” 10" Brake Drum-10.090" diameter ” 12" Brake Drum-12.090" diameter ” " Brake Drum-12.340" diameter ”...
Page 90: Bearing Lubrication - Grease
IMPORTANT: Bearings must always be replaced in sets of a cone and a cup. CAUTION 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.
Page 91: Bearing Lubrication - Oil
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.
Page 92: Seal Inspection And Replacement
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.
Page 93: Bearing Adjustment And Hub Replacement
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 nut back on the axle spindle in reverse order as detailed in the previous section on hub removal, rotate the hub assembly slowly while tightening the spindle nut to approximately 50 lbs.-ft.
Page 94: E-Z Lube® Lubrication
E-Z Lube® Lubrication The procedure is as follows: 1. Remove the rubber plug from the end of the grease cap. 2. Place a standard grease gun onto the grease fitting located in the end of the spindle. Make sure the grease gun nozzle is fully engaged on the fitting.
Page 95: Nev-R-Lube™ Drums/Bearings
Nev-R-Lube™ Drums/Bearings Dexter’s Nev-R-Lube™ bearings are comprised of opposed tapered roller bearing cones sealed inside of a precision ground, one piece double cup arrangement. These bearings are designed with a small amount of axial end play. This end play is essential to the longevity of the bearings service life.
Page 96: Bearing Inspection
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 unexpectedly and cause serious injury or death.
Page 97: Nev-R-Lube™ Bearing End Play Inspection
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.
Page 98: Bearing Replacement And Drum Installation
Bearing Replacement and Drum Installation 1. Once the drum and bearing assembly is removed from the axle, remove “internal” snap ring from the bearing bore that retains bearing. 2. Using an arbor press and mandrel, press the bearing out of the drum. Bearing will exit on the wheel side of the drum.
Page 99 Nut should be torqued to 145-155 lb.-ft. (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.
Page 100: Suspension Systems
Suspension Systems The suspension systems incorporated into Dexter axles are designed to provide the trailer owner three basic functions: 1. Attach the axle to the trailer 2. Dampen the effects of road shock 3. Cushion the cargo or load All Dexter suspension systems are available in single and multiple axle configurations.
Page 101: Grease Lubricated Suspension Bushings
Grease Lubricated Suspension Bushings Dexter Axle offers an optional heavy duty attaching parts kit for double eye leaf spring suspensions up to 7,000 lb. 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.
Page 102: Inspection And Replacement
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.
Page 103 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 unexpectedly and cause serious injury or death.
Page 104: Torflex® Suspension
1. With both axles blocked up, remove the spring eye bolt, shackle bolt, and equalizer bolt from the equalizer to be repaired or replaced. 2. Take the equalizer to suitable work surface and remove the worn bushings using a suitable drift punch. 3.
Page 105: Airflex™ Suspension
surrounded by four natural rubber cords encased in the main structural member of the axle beam. 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.
Page 106 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.
Page 107 4. Re-measure A and B, as before, to assure that “A” and “B” dimensions are within " of each other. If dimensions are not to specification, then repeat adjustment procedure. Figure 1 -64-...
Page 108 Tandem Axle Adjustment 1. Adjust the second axle using it’s left hand spring seat adjusters to assure distances “C” and “D” are within tolerance. 2. Measure the distances “C” and “D” between the front and rear tandem axles. These distances must be within "...
Page 109: Wheels
Wheels Wheel Selection Wheels are very important and critical components of your running gear system. When specifying or replacing your trailer wheels it is important that the wheels, tires, and axle are properly matched. The following characteristics are extremely important and should be thoroughly checked when replacement wheels are considered.
Page 110: Torque Requirements
CAUTION 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.
Page 111: Wheel Torque Requirements
Be sure to use only the fasteners matched to the cone angle of your wheel (usually 60 or 90 ). The proper procedure for attaching your wheels is as follows: 1. Start all bolts or nuts by hand to prevent cross threading. 2.
Page 112: Maximum Wheel Fastener Torque
Maximum Wheel Fastener Torque The wheel mounting studs used on Dexter axles 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 Max.
Page 113: Tires
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.
Page 114: Tire Wear Diagnostic Chart
Tire Wear Diagnostic Chart Cause Wear Pattern Action Adjust pressure to Center Wear Over Inflation particular load per tire catalog Adjust pressure to Edge Wear Under Inflation particular load per tire catalog Make sure load doesn't Side Wear Loss of camber exceed axle rating.
Page 115: Replacement Parts/Kits
Replacement Parts/Kits Magnet Replacement Kits Brake Magnet Kit No. Wire Nut Torque Size (one magnet per kit) Color Brake Mounting 7 x 1 K71-057-00 White 45-70 10 x 2 K71-104-00 Green 45-70 12 x 2 K71-105-00 White 25-50 12 x 2 K71-125-00 (7K) Black 25-50...
Page 116: Bearing Replacement Chart
Bearing Replacement Chart Brake Dexter Kit Industry Part # Axle Size Size Bearings Number Cup /Cone Capacity 7 x 1 4 or 5 Inner K71-306-00 L44610 / L44649 Bolt Outer K71-306-00 L44610 / L44649 10 x 1 4 or 5 Inner K71-307-00 LM67010 / LM67048...
Page 117: Storage
Storage Storage Preparation If your trailer is to be stored for an extended period of time or over the winter, it is important that the trailer be prepared properly. 1. Remove the emergency breakaway battery and store inside, out of the weather. Charge the battery at least every 90 days.
Page 118: After Prolonged Storage - Inspection Procedures
After Prolonged Storage - Inspection Procedures 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.
Page 119: Trip Preparation Checklist
Trip Preparation Checklist There are a number of simple rules to follow in caring for your trailer axle assembly that can add to its life and in the case of some of these rules, you may be protecting your own life as well. Using the following checklist before starting a trip with your trailer is highly recommended.
Page 120: Maintenance Schedule
Maintenance Schedule 6 Months 3 Months or 12 Months Item Function Required Weekly or 6000 3000 Miles or 12000 Miles Miles Brakes Test that they are At Every operational. Brake Adjust to proper Adjustment operating clearance. Brake Inspect for wear and Magnets current draw.
Page 121: Dexter Axle Limited Warranty
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 in material and workmanship for a period of two (2) years from the date of first sale of the trailer incorporating such components.
Page 122 EXCLUSIONS These warranties do not extend to or do not cover defects caused by: The connecting of brake wiring to the trailer wiring or trailer wiring to the towing vehicle wiring. The attachment of the running gear to the frame. Hub imbalance, or any damage caused thereby.
Page 123 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.
Page 124 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.
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 Genuine Dexter axles and components are available nationwide from our plant locations listed below or through our network of distributors. Check our website for the distributor nearest you. Visit us online at: www.dexteraxle.com Dexter Axle Dexter Axle Road 75 East 11870 N.
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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