LIT-012-00 – Heavy Duty Suspension System – DEXTER

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OPERATION MAINTENANCE SERVICE MANUAL
HEAVY DUTY SUSPENSION SYSTEM
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DEXTER
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. Since
1960, Dexter’s experience in the design, testing, and manufacturing of trailer axles has
resulted in the most complete product line in the industry. The Dexter running gear system
consists of axles, suspensions, and braking systems which are engineered to provide you
the finest towing and stopping performance available today.
Two Dexter philosophies are at work to provide you the best product available and have
enabled us to maintain our position of leadership. First, we operate on the theory that
“there is always a better way” for a product to operate, to be manufactured, and/or to be
serviced. We are constantly striving to find that better way.
Secondly, we maintain the highest quality control standards in the industry and adhere to
ISO 9001:2015. Dexter has operated with detailed documented processes and procedures
long before completing ISO Certification, continually placing quality and customer service
as the focus. This ensures that critical components including axle beams, hubs, drums,
spindles, and braking systems are manufactured to the highest quality standards so
that we can provide our customers with dependable products, the most comprehensive
product offering and reliable, consistent customer service.
Trusting is hard. Knowing who to trust even harder. Through vertical integration we engineer,
design, manufacture and test virtually every part in-house to ensure superior quality trailer
running gear. We fuss over details, so you don’t have to. Trust Dexter.
Visit us online at www.dexteraxle.com.
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Contents
Introduction ……………………………………………………………………………………… 3
Important Safety Notice ……………………………………………………………….. 3
Operating Procedures …………………………………………………………………………. 3
Axle Clamp Group and Springs ……………………………………………………… 5
Track Arms (Radius Rods) …………………………………………………………….. 6
Rocker Bushings …………………………………………………………………………. 6
Hangers …………………………………………………………………………………….. 7
Alignment Procedures ………………………………………………………………….. 8
Limited Warranty ……………………………………………………………………………… 11
Dexter Video Gallery …………………………………………………………………………. 14
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Important Safety Notice
Appropriate service methods and repair procedures are essential for the safe,
reliable operation of all running gear as well as the personal safety of the
individual doing the work. This manual provides general directions for performing
service and repair work with tested, effective techniques. Following these
guidelines will help assure reliability.
There are numerous variations in procedures, techniques, tools, parts for
servicing axles, as well as in the skill of the individual doing the work. This
manual cannot possibly anticipate all such variations and provide advice or
cautions as to each. Anyone who departs from the instructions provided in this
manual must first establish that they neither compromise their personal safety
nor the vehicle integrity by their choice of methods, tools, or parts.
Refer to your vehicle manufacturer’s owners manual for additional procedures,
techniques, and warnings prior to performing any maintenance or repairs.
& CAUTION
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.
Dexter strongly emphasizes that each of the maintenance procedures discussed
has a significant safety purpose. Failure to maintain proper torque values on
each of the suspension components can result in a malfunction of suspension
components. Further, use of any visibly worn component can result in a
malfunction. Any of these malfunctions can result in loss of vehicle control and
personal injury or death. Safety is the number one concern at Dexter. We urge
you to follow the maintenance procedures set out in these written instructions.
The first maintenance check should be performed after an initial break-in
period at 1,000 miles. A visual inspection of all suspension components and
attachment welds should be performed to reveal any obvious problems, such as
cracks or unexpected wear.
Operating Procedures
During the “walk-around”, it is essential to also check the torque on all
suspension fasteners. In the course of the initial 1,000 mile period in which
the components of the suspension “seat-in”, as much as 25% of the original
clamp load on the bolted joints can be lost. After the parts of the suspension
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have worked together for a very short period of time, re-torquing the bolts
is necessary to ensure that undue movement, which results in excessive
suspension wear, does not occur.
During the first maintenance check, the trailer’s axle alignment should
be examined and adjusted to comply with the Dexter trailer alignment
procedure (shown on page 8). Alignment should also be checked following
any maintenance or repair procedure performed on the suspension. Visual
inspections and re-torquing are maintenance procedures that are performed
every four months throughout the life of the trailer.
Begin each inspection with a review of the Dexter torque decal (shown below)
for the appropriate torque values for each suspension fastener. The oiled torque
values listed are for new fasteners with lubricated threads. For maintenance
checks on fasteners that have been in service, use the higher dry torque
values. It is important that you check all bolts and nuts to ensure that the
recommended torque values are being maintained.
~ CAUTION
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You cannot rely on visual inspection to detect loose fasteners.
USE A CALIBRATED TORQUE WRENCH!
The Dexter torque decal label should be installed on the side of the trailer in a
visible location. Decals can be obtained free of charge by contacting Dexter.
Now let’s look closely at the maintenance requirements for each of the
suspension’s main component groups.
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Axle Clamp Group and Springs
1. Check the torque on the U-BolVTie Plate nuts by alternately tightening
opposing corners of the clamp assembly (see Figure 1).
A. U-Bolts are 3/ 4″-10 and the nuts should be torqued to a dry level of
200 Ft. Lbs.
U-BoltNuts
UNDERSLUNG (shown above)
OVERSLUNG (shown above)
Figure 1
Adjustable Track Arm
sts·-11 Clamp Nut
Always carefully inspect the spring and axle clamp components for any signs of
wear or cracks, and replace if visible wear or cracks are present.
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Track Arms (Radius Rods)
1. The 1 “-8 UNC nut for track arm attachment bolts at the hangers and
tie-plates should be tightened to a dry level of 350 Ft. Lbs. of torque for
adjustable and non-adjustable track arms (see Figure 1).
Loose operation of this bolt can result in wear requiring that new
components be installed to avoid structural damage. During your visual
inspection, if you observe any visible wear or loosening in the bushing,
it is imperative that you immediately replace the track arm, and the
bushing and bolt assembly. Failure to replace these components will
result in damage to the hanger, spring seat, and/ or track arm.
2. Next, check the 5/8″-11 UNC adjustable track arm clamp nut and
tighten to a dry level of 150 Ft. Lbs. of torque (see Figure 1). If the
clamp bolt has not been properly maintained, then wear between the
track arm threads and the eye end may be observed. If so, then the
entire track arm must be replaced. Simply retightening or replacing the
clamp bolt will not correct this problem.
Rocker Bushings
1. The recommended torque values for the rocker bushing clamp bolts are
different for each model.
A. If you are working on the Dexter Double Slipper Spring (DSS) model
suspension, the single 1 1/8″-7 UNC rocker nut should be tightened
to a dry level of 815 Ft. Lbs. of torque (see Figure 2).
Rocker (Equalizer) Bushing
Clamp 1-1/8#-7 Lock Nut
Spring Retainer (Keeper) Nut
0 UNDERSLUNG (shown above)
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1-1/8″-7 Lock Nut
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OVERSLUNG (shown above)
Figure 2
During your check, if the bolts are loose, a detailed inspection of the rocker is
important to ensure that no structural damage has occurred. One way this can
be done is by raising the trailer until the trailer weight is taken off the springs.
If the rocker is displaced, or if the joint is loose, then the rocker should be
removed and the rocker equalizer should be replaced. Again, visually inspect
the condition of all rocker or rocker hanger assembly components and replace if
visible wear is present.
Hangers
1. Check all of the spring retainer bolts found in the rockers and rear
hangers. A dry value of 50 Ft. Lbs. of torque should be maintained on all
of these bolts (see Figure 2).
Loose fasteners that are allowed to operate for any period of time will
result in irreversible suspension damage and possible loss of vehicle
control. Remove and replace loose or damaged fasteners. Retightening a
worn fastener will not correct a situation created by loose operation.
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Heavy Duty Suspension System
Axle Alignment
To align a four (4) spring suspension, there is one adjustable track arm (rod) on
each axle. These will typically be on the road (left) side.
Release the clamps at each end of the adjustable rod (see Figure 1). Align front
axle with the king pin and adjust each axle thereafter parallel to the front axle.
Be sure to secure the clamps on the adjustable track arm (rod) after alignment
(see Figure 1).
Alignment Procedure (Figure 3)
Before taking axle alignment measurements, make sure the trailer is unloaded
and free the suspension of any binds by pushing the trailer backwards and then
pulling the trailer forward. While pulling the trailer forward on a level floor, apply
the brakes and release. The trailer MUST be level from side to side as well as
from front to rear.
Note: Neither service nor parking brakes should be applied during the
measurement procedure.
Ensure the king pin is at the correct height. Use axle and extenders (or remove
outer wheels and any obstructions) to achieve a straight line for measuring from
king pin to the axle ends/centers.
UNDERSLUNG (shown above)
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OVERSLUNG (shown above)
Figure 3
Measuring
1. Lateral Centerline (E). Determine lateral centerline of trailer body and
axles by measuring distance E between trailer and axle centerlines first, and
correct so that distance E is 1/ 4″ or less for each axle.
2. Thrust Angle (A, B). Measure distances A (curbside) then B (roadside)
from the king pin to the front of the axle. These must be equal to within 0.1
degree or 1/8″ of each other (A = B ± 1/8″). Ensure the lateral tension
(pulling force) applied to the measuring tape is the same for both A and B
measurements. Use a tensioning device scale or optical (laser) to ensure
accuracy.
3. Scrub Angle (C, D). Measure distances C (curbside) then D (roadside)
between axles, measuring from front of axle extension to front of axle
extension (same as center to center). These also must be equal to within
1/16″ of each other (C = D ± 1/16″). This measurement should be as
close to zero as possible. The smaller the offset, the lower the rolling
resistance and the better the fuel economy.
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Figure 4
Adjusting
1. Loosen the adjustable track rod clamp bolts (see Figure 1) and turn the
center rod to adjust as necessary (see torque min/max table).
2. After adjusting, tighten the adjustable track rod clamp nuts (see Figure 1)
to proper torque (see torque min/max table) and recheck measurements.
Precautions
1. Always measure to the front axle ends for accurate alignment.
2.
3.
Avoid measuring to rims, suspension brackets, hub cap vent holes,
brake drums, etc. This can result in improper alignment. For accurate
measurements, use extenders.
Always align any succeeding axles with the front axles, not the kingpin.
-10-
Dexter Axle Limited Warranty
What Products Are Covered
All Dexter Axle Company (“Dexter”) trailer axles, suspensions, and brake control
systems manufactured on or after September 1, 2016, excluding Dexter 6000
series Manufactured Housing Axles. Additional exclusions include the following
brands: UFP by Dexter, AL-KO (IAC), Titan Brakes and Actuators by Dexter, and
BrakeRite by Dexter products, which are covered under separate warranties.
Limited 1 Year Warranty
As specified in Dexter’s current publication “Operation Maintenance Service
Manual”, grease and oil seals FOR ALL PRODUCTS have a one (1) year limited
warranty to the original purchaser from the date of first sale of the trailer
incorporating such components. Except as to grease and oil seals, the
following four other warranties are available.
Limited 2 Year Warranty
Dexter warrants to the original purchaser that its electric/hydraulic brake
actuators shall be free from defects in material and workmanship for a period
of two (2) years from the date of first sale of the trailer incorporating such
components.
Limited 5 Year Warranty
Dexter warrants to the original purchaser that its axles, suspension systems
and Genuine Replacement Parts shall be free from defects in material and
workmanship for a period of five (5) years. The warranty period shall begin from
the date of the original purchase of the trailer and/or Genuine Replacement
Parts.
Limited 7 Year Warranty
Dexter 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.
Limited 10 Year Warranty
Dexter warrants to the original purchaser that the suspension components of
its Torflex· axles shall be free from defects in material and workmanship for a
period of ten (10) years from the date of first sale of the trailer incorporating
such suspension components.
Exclusive Remedy
Dexter will, at its option, repair or replace the affected components of any
defective axle, repair or replace the entire defective axle, or refund the lesser
of the original purchase price and the then-current list price of the axle or
components. In all cases, a reasonable time period must be allowed for
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warranty repairs to be completed. Allowance will only be made for installation
costs specifically approved by Dexter.
What You Must Do
In order to make a claim under these warranties:
1. You must be the original purchaser of the trailer in which the sprung
suspension axles orTorflex· axles or components were originally installed.
2. You must promptly notify Dexter after detection of any defect, but in any
case within the applicable warranty period of such defect, and provide us
with the axle or applicable component serial number and any substantiation
of such defect which may include, but is not limited to, the return of part(s)
that we may reasonable request.
3. The axles, suspensions and components must have been installed and
maintained in accordance with good industry practice and any specific
Dexter recommendations, including those specified in Dexter’s current
publication “Operation Maintenance Service Manual”.
Exclusions
These warranties do not extend to and 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. Parts not supplied by Dexter.
4. Any damage whatsoever caused by or related to any alteration of the axle
including welding supplemental brackets to the axle.
5. Use of an axle on a unit other than the unit to which it was originally
mounted.
6. Normal wear and tear.
7. Improper alignment.
8. Improper installation.
9. Unreasonable use (including failure to provide reasonable and necessary
maintenance as specified in Dexter’s current publication “Operation
Maintenance Service Manual including required maintenance after
“Prolonged Storage”} .
10. Improper torque values and torqueing of wheel nuts. (The proper torqueing
procedure and torque values are contained in Dexter’s current publication
“Operation Maintenance Service Manual”).
11. Cosmetic finish or corrosion .
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Limitations
1. In all cases, Dexter reserves the right to fully satisfy its obligations
under the Limited Warranties by refunding the lesser of the original
purchase price and the then-current list price of the defective axle
(or, if the axle has been discontinued, of the most nearly comparable
current product).
2. Dexter reserves the right to furnish a substitute of replacement component
or product in the event an axle or any component of the axle is discontinued
or is otherwise unavailable.
3. These warranties are nontransferable.
General
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER
WARRANTIES EXCEPT THAT OFTITLE, WHETHER WRITTEN, ORAL OR IMPLIED,
IN FACT OR IN LAW (INCLUDING ANY WARRANTY AGAINST INFRINGEMENT OR
OF MERCHANTABILITY OR RTNESS FOR A PARTICULAR PURPOSE).
These warranties give you specific legal rights, and you may also have other
rights which vary from state to state.
DEXTER HEREBY EXCLUDES INCIDENTAL AND CONSEQUENTIAL DAMAGES,
INCLUDING LOSS OFTIME, INCONVENIENCE, LOSS OF USE, TOWING FEES,
TELEPHONE CALLS, COST OF MEALS OR LODGING, FOR ANY BREACH OF ANY
EXPRESS OR IMPLIED WARRANTY.
Some states do not allow limitations on how long an implied warranty lasts, or
the exclusion or limitation if incidental or consequential damages, so the above
exclusion or limitation may not apply to you.
Inquiries regarding these warranties should be sent to:
Dexter Axle Company
P.O. Box 250
Elkhart, IN 46515
Note: Current publication “Operation Maintenance Service Manual” can be found at
www.dexteraxle.com.
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Dexter Video Gallery
In keeping with our continual commitment to industry safety and the development of
innovative products, please feel free to view our ongoing video gallery at
www.dexteraxle.com/resources/videos or scan the following QR codes. We are
confident these videos will help educate and promote the Dexter product line that you,
as our customer, are investing in.
Bearing
Maintenance
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System
~ -Manual Bleed
Hydraulic Disc
Removable
Spindle
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Installation
Genuine Brakes
Medium Duty
Axles
~~ -Sway Control
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Electric Brakes
Genuine
Replacement Parts
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Brakes
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Suspension Axles
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Suspension
Leaf Spring
Axles
Power Bleed
Hydraulic Disc
Dexter Online Parts Store
From magnets and seals to complete brake and hub kits, Dexter offers a complete line
of genuine replacement parts for your trailer. Most products are available in-stock and
ready to ship within 24 hours direct to you from the factory. With dedicated customer
support and quick turnaround, the Dexter Online Parts Store helps keep your trailer
going.
· Hub Components
· Brake Components ,.. ·: l/111
, DEXTER .
· Suspension Components
· Complete Hub Kits
GENUINE
· Brake Assemblies & Kits
· Brake Controllers & Actuators
Ready for Immediate Shipment
Direct to Your Door
FIVE VEAR
WARRAtHY
Visit us online at www.dexteraxle.com
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DEXTER
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.
Dexter – Pit 12
301 West Pearl Street
Fremont, Indiana 46737
Phone: 260-495-5100
Fax: 260-495-1701
Dexter – Pit 23
5600 Bucknell Drive SW
Atlanta, Georgia 30336
Phone: 404-4 77-6899
Fax: 470-443-1715
Dexter – Pit 51
34 7 King Street West
Ingersoll, Ontario N5C 3K6
Phone: 519-485-2210
Fax: 519-485-2163
www.ingersollaxles.com
Dexter – Headquarters
2900 Industrial Parkway East ■ Elkhart, Indiana 46516
Phone: 574-295-7888 ■ Fax: 574-295-8666
www.dexteraxle.com
Dexter – Pit 13
500 South 7th Street
Albion, Indiana 46701
Phone: 260-636-2195
Fax: 260-636-3030
Dexter – Pit 24
135 Sunshine Lane
San Marcos, California 92069
Phone: 760-744-1610
Fax: 760-744-1616
Dexter – Pit 52
5885 51 Steet SE
Calgary, Alberta T2C 3V2
Phone: 587-323-8411
Fax: 587-327-0129
Dexter – Pit 15
500 Southeast 27th Street
El Reno, Oklahoma 73036
Phone: 405-262-6700
Fax: 405-262-9089
Dexter – Pit 25
1041 Baxter Lane
Winchester, Tennessee 37398
Phone: 931-967-5101
Fax: 931-967-1828
Dexter – Pit 61
21611 Protecta Drive
Elkhart, Indiana 46516
Phone: 574-294-6651
Fax: 574-295-6626
Dexter – Pit 21
199 Perimeter Road
Monticello, Georgia 31064
Phone: 706-468-6495
Fax: 706-468-2966
Dexter – Pit 39
902 South Division Street
Bristol, Indiana 46507
Phone: 574-848-4491
Fax: 574-848-4825
www.ventllne.com
Dexter – Pit 62
301 North Kennedy Street
Shawnee, Oklahoma 74801
Phone: 405-273-9315
Fax: 405-273-1054
NO PART OF THIS CATALOG MAY BE REPRODUCED WITHOUT DEXTER’S PERMISSION.
ALL PART NUMBERS, DIMENSIONS AND SPECIRCATIONS IN THIS CATALOG ARE SUBJECT
TO CHANGE WITHOUT NOTICE.
GEARED FOR INNOVATION SINCE 1960
www.dexteraxle.com
2900 Industrial Parkway East ■ Elkhart, Indiana 46516
Phone: 574-295-7888 ■ Fax: 574-295-8666
ISO 9001:2015 Certified
2018.05 © 2016-2018 Dexter Axle Company. UT-012-00