9,000-15,000 lbs. Capacity

Transcription

1 HEAVY DUTY UTILITY AXLES 9,000-5,000 lbs. Capacity

2 Introduction This information is intended as a guide for the proper specification and application of Dexter Axle running gear, associated components and accessories. Dexter offers a full line of trailer axles that can be used in many different applications. When specifying any pre-engineered components such as axles, it is the responsibility of the trailer designer to insure compatibility with the vehicle and all of its sub systems. Information The information presented is meant to assist trailer manufacturers in the specification of their running gear components. Dexter Axle does not warrant that the information given constitutes an approved trailer design or application. Dynamic loading, travel requirements unique to the trailer design, unusual service conditions, trailer configurations, unequal load distribution, hitch or coupler arrangements and towing vehicle suspension characteristics can significantly affect the performance of any trailer axle and/or suspension systems. It remains the responsibility of the trailer manufacturer to evaluate, specify and test their trailer/running gear combination before production and to certify it as such. While the information presented at the time of this writing is current, it is subject to change as designs and components evolve over time. Disclaimer of Warranty and Limitation of Liability All users of this product catalog acknowledge that the information presented is significantly affected by factors within the exclusive knowledge of the user including, among other things, service conditions, trailer configurations, load distributions, hitch and coupler arrangements and tow vehicle suspension characteristics, that the users have independently investigated these factors and have solely relied on those investigations when using this catalog, and that it is the responsibility of the user to adequately specify, evaluate and test its trailer/running gear combinations. DEXTER AXLE DISCLAIMS ALL WARRANTIES, WHETHER WRITTEN, ORAL OR IMPLIED, IN FACT OR IN LAW (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), ASSOCIATED WITH THE USE OF THE CATALOG AND WITH ANY INFORMATION PRESENTED BY THIS CATALOG. Dexter Axle shall not be liable in damages (whether compensatory, punitive, direct, indirect, special, incidental or consequential) to any user of this catalog under contract, tort, strict liability or any other theory of liability, and any user agrees to indemnify and hold Dexter Axle harmless from any and all claims, actions or other proceedings (including attorney fees and court costs) arising out of the use of this catalog to the extent said claims, actions or other proceedings do not arise out of the sole and exclusive negligence of Dexter Axle. Load Ratings The maximum load carrying capacity of any assembly is limited to the lowest load rating of any individual component selected. For instance, the load rating of a pair of wheels may be lower than other axle components selected. If this is the case, the load carrying capacity of the axle assembly is reduced accordingly. As a specific example, if a pair of wheels is rated at 500 pounds each and is used with other components rated at 4000 pounds per axle, the maximum load capacity is limited to 3000 pounds. If two tires are rated at 400 pounds each and are used on this assembly, the maximum load carrying capacity is limited to 800 pounds. Axle Orientation When working with trailer running gear, it is important to understand the various features and descriptions of the equipment. Most trailer axles are directional by nature, that is, it is imperative that they be installed onto the trailer in the proper manner to ensure brake functioning and correct wheel alignment. The front of the axle must be oriented toward the front of the trailer. The convention used to define right and left is based on viewing the trailer from the rear and facing in the direction of forward travel. Features to help identify the front of the axle: Electric brake wires exit brake backing plates toward the rear of the axle. ¹ ₄" hydraulic brakes have view ports through the dust shield on the back of the assembly. Where the brake lining is visible in the view port, that will indicate the rear or secondary shoe which is always oriented toward the rear of the axle.

3 Introduction Slipper springs have the spring eye at the front of the axle. Leaf spring axles with inner wiring have the wires exit the tube toward the rear of the axle. Torflex axles have the wheel center trailing behind the axle tube. Axles using ³ ₄" spherical ball seat wheel nuts will have right and left handed threads. The right handed thread must be on the right end or curb side of the axle while the left handed thread will be on the left end or road side of the axle. Stub Axle Disclaimer A stub axle is described as a trailer axle spindle, welded to a short length of tubing. Stub axles may be specified and purchased as plain spindle/tube weldments or they may be fully assembled wheel end units, with or without trailer brakes. These incomplete axles are sold to manufacturers who wish to incorporate them into a variety of applications such as specialty vehicular axles, belt tensioning devices, machinery pivot points, etc. Dexter Axle has no control of the design intent of these special applications and therefore cannot apply a rating or capacity to these components. The spindle/tube connection has been designed for suitable stress levels when used in a trailer axle, mounted to an approved suspension system and loaded to no more than the stated capacity. The use of all or part of the product for applications other than its intended purpose may not be appropriate. It is the customers responsibility to determine the efficacy and safety of their particular application. Torflex axles can also be purchased as stub axles. This type of axle incorporates a self-contained suspension system. They can be specified as stub assemblies that will be rated for capacity when fitted with approved mounting brackets. The stated capacity will be based on the lowest rated component in each assembly. These stub assemblies are essentially half axles that are intended to be mounted to the trailer chassis independent of each other. The trailer manufacturer must assume responsibility for the integrity of the attachment as well as the final wheel alignment since independent mounting puts these critical aspects out of Dexter s control. If used in pairs of unequal capacity, the trailer manufacturer should assign a Gross Axle Weight Rating of not more than two times the capacity of the lower rated sub assembly.

4 Table of Contents Required Axle Dimensions Spring Suspensions... 4 Required Axle Dimensions Torflex Suspensions... 5 Heavy Duty Utility Axle Beam Features... Torflex Axle Beam Features... Torflex Application Information K, 0K, and 3G GD One-Piece Hub Group K, 0K, and 3G GD Two-Piece Hub Group ,000 Lb. Wheel and Hub Assembly... 0,000 Lb. Wheel and Hub Assembly... 5,000 Lb. Wheel and Hub Assembly... 0K, K, 5K, and 3D Hub Groups... 0,000 &,000 Lb. Hydraulic Disc Brake... 3 Hydraulic Disc Brake Parts... 3 Forward Self-Adjusting Electric Brake... 4 Electric Brake Parts Stamped Backing Plate... 5 Electric Brake Parts Cast Backing Plate... Forward Self-Adjusting Hydraulic Brake... 7 Hydraulic Brake Parts... 8 Electric Brake Wiring Diagram... 9 Air Brake System Diagram... 9 S Cam Air Brake... 0 Air Brake Parts PQ Style... Electric Hydraulic Brake System Diagram... Wheels and Tires... 3 Axle Overhang... 3 Oil Lubrication Specification... 4 Bearing Adjustment... 4 Axle Suspension System... 5 Cross Hanger Reinforcement... 5 Attaching Parts Suspension Kits... Limited Warranty... 9 A complete line of heavy duty utility axle systems is now available from Dexter, the leader in innovative running gear design. This manual provides information and technical data for incorporating 9,000, 0,000,,000 and 5,000 pound heavy duty axles into existing and future vehicle design. Versatility, rugged reliability, and serviceability are some of the bonus features engineered into these new high performance axle systems. The heavy duty utility axle systems have been exhaustively tested by subjecting them to a full spectrum of operating conditions exceeding the predicated end uses of the axles. Dexter Axle Company CAN NOT guarantee that components manufactured by others will be compatible with Dexter products. It is the responsibility of the user to ensure proper fit and function. 3

5 Required Axle Dimensions Options for Spring Suspension Axles Hubface Track Width Spring Center Wheel Offset Axle Front Hanger Center Hanger Rear Hanger Min. Recommended Tire Static Bump Tire Center Tire Height Ground Static Loaded Overall Tire Height Front Axle Location Front Axle Rear Axle 4

6 Required Axle Dimensions Options for Torflex Suspension Axles Bracket Orientation Standard Orientation Top Mount Reverse Orientation Side Mount Bracket Profile 5

7 Dexter Heavy Duty Utility Axle Beam Features Highest strength axle tube generally available for utility vehicle axles. Materials used allow a stiffer and stronger axle beam with no camber required. The backing plate of the Dexter electric or hydraulic brake mounts on piloted axle brake flange. This assures that brakes will perform effectively. Brake Flanges are machined to assure perpendicularity and concentricity. Spindles are made of forged carbon steel. High Strength Axle Tube. Spindle is friction forged onto axle tube for strength and alignment. Precision Machined Spindles. Replaceable Unitized Oil Seal. Spindle Detail Precision Machined Bearing Journals. Torflex Axle Beam Features #3G General Duty #3D Heavy Duty Inspected for proper alignment Dexter manufactured brakes & hubs Totally cushioned in rubber for a smooth, quiet ride Independent suspension Forged torsion arm for maximum strength Heat-treated solid steel bar CAUTION: Triple axles assemblies are not recommended for Torflex axles.

8 Torflex Application Information 9,000-0,000 Lbs. 3 Articulation Dimensions Dimensions are for high profile, top mount only. Side mount is.3" higher. Allow 3" bump clearance from full load. No Load Full Load Shock Load Start Angle Bracket Profile H L H L H L 45 down Hi DEXTER H.5 down Hi down Hi Hi up Hi up Hi Overhang Per Side Spindle Min. Max. Brake 3D.5" 7.0" ¹ ₄" x 4" 3G one-piece 0." 7.0" ¹ ₄" x 3³ ₈" 3G two-piece.35" 7.0" ¹ ₄" x 3³ ₈" Note: Dual wheel not available for 3G one-piece. 3 Note: Positive numbers in the H column indicate the spindle is BELOW the top of the bracket. Conversely, negative numbers are ABOVE the top of the bracket. Full Load Dimensions Dimensions are for high profile, top mount only. Side mount is.3" higher. Allow 3" bump clearance from full load. L C H E C H E C H E B D B D B D 0 o, 0 o down 0 o,.5 o up.5 o, 45 o down Start Angle * * * 45 Down.5 Down 0 Down 0 0 Up.5 Up Tire D E H B C H B C H B C H B C H B C H B C 0R7.5HC /75R LT LT R 7.5 HC Columns D and E are dimensional examples only: * D Static Loaded ** E Inflated #3D & #3G Bracket Dimensions A. B 3.3 C 0.5 D 0.5 E 3.00 F 5.50 G.50 J.5 L 7. P.00 Q.00 Bolt Size ⁵ ₈" bolt Tube Size 3.88 Q E D / F A C L High Profile B P G J A For Wiring Access Bolt Size Side Mount Hanger 7

9 9K, 0K, and 3G General Duty One-Piece Hub Group K_3G_Hubs_pc_ Note: Dual wheel cannot be used with 3G 9 Standard Oil Lube Parts Item Part No. Description Oil Seal A Inner Bearing Cone A Inner Bearing Cup Outer Bearing Cup Outer Bearing Cone Spindle Nut () Spindle Washer Tang Washer Oil Cap O Ring Oil Cap Plug ⁵ ₈-8 Wheel Stud Brake Mounting Bolt Brake Mounting Nut ns Lockwasher Hub & Drum Item Part No. Description Hub & Drum Assembly ns Hub & Drum Assembly - ABS ¹ ₄" x 3³ ₈" Brakes Item Part No. Description 0 K /K LH/RH Elecric, FSA K /K LH/RH Hydraulic, FSA, Duo-Servo K3-0-00/K3--00 LH/RH Hydraulic, RSA, Du-Servo w/park ns K3-4-00/K LH/RH Hydraulic, FSA, Single-Servo ns K /K LH/RH Hydraulic, Manual Adjust Single-Servo w/park ABS Components Item Part No. Description Sensor, Straight Sensor Block Sensor Clip Tone Ring ns Tone Ring Screws Studs and Wheel Nuts Item Part No. Description Nut Torque 8* ⁵ ₈-8 90 Cone Nut 00 lbs.-ft 9* Clamp Ring ⁵ ₈-8 Flange Nut 300 lbs.-ft ⁵ ₈-8 Press-in Stud * Must use the 90 cone nut with the clamp ring. Alternate fastener is just the flange nut. 8

10 9K, 0K, and 3G General Duty Two-Piece Hub Group K_GD Hubs_ Standard Oil Lube Parts Item Part No. Description Oil Seal A Inner Bearing Cone A Inner Bearing Cup Outer Bearing Cup Outer Bearing Cone Spindle Nut () Spindle Washer Tang Washer Oil Cap O Ring Oil Cap Plug ⁵ ₈-8 Wheel Stud Drum Mounting Screw Brake Mounting Bolt Brake Mounting Nut ns Lockwasher Hub & Drum Item Part No. Description Oil Hub w/cups and Studs Drum - Machined ns Drum - for ABS ns Oil Hub and Drum w/cups and Studs ¹ ₄" x 3³ ₈" Brakes Item Part No. Description 0 K /K LH/RH Elecric, FSA K /K LH/RH Hydraulic, FSA, Duo-Servo K3-0-00/K3--00 LH/RH Hydraulic, RSA, Du-Servo w/park ns K3-4-00/K LH/RH Hydraulic, FSA, Single-Servo ns K /K LH/RH Hydraulic, Manual Adjust Single-Servo w/park ABS Components Item Part No. Description Sensor, Straight Sensor Block Sensor Clip Tone Ring Studs and Wheel Nuts Item Part No. Description Nut Torque 8* ⁵ ₈-8 90 Cone Nut 00 lbs.-ft 9* Clamp Ring ⁵ ₈-8 Flange Nut 300 lbs.-ft ⁵ ₈-8 Press-in Stud * Must use the 90 cone nut with the clamp ring. Alternate fastener is just the flange nut. Hub & Rotor Available on 3G Not Offered on D90 or D00G Item Part No. Description ns Oil Hub w/cups and Studs ns Brake Rotor ns Rotor Mounting Nut ns - not shown 9

11 0,000 Lb. Wheel & Hub Assembly Unitized Seal Seals internally within the seal, with two sealing lips and press fitted to the spindle for improved performance. Tapered roller bearings Computer matched to Dexter Axle system Outer: (38A) cup, (387A) cone Inner: (394A) cup, (395S) cone 0kassy.eps Hardened spindle washer. ¼ x 4" high performance hydraulic brake. Electric and air brake, parking feature and uni-servo hydraulic brakes are also available. Two piece hub and drum design permits replacement of brake drum without the need to replace hub. Cast brake drum with integral brake armature. Alloy selected for both brake energy (heat) absorption and good magnetic braking characteristics. Finned outer surfaces in braking area for maximum cooling. Dual and single wheel design. Axle designed for oil bath lubrication of bearings with SAE 80W-90 hypoid gear oil. This lubrication method assures long bearing life with proper maintenance of oil level. When using clamp ring and 90 cone nuts, tighten wheel nuts to a torque of 00 lb-ft. Bearing adjustment nuts with tang locking washer keyed to spindle to maintain precision bearing adjustment. Removable rubber oil filler plug for ease of maintenance. Transparent polycarbonate oil cap with oil level indicator mark to allow visual checking for adequate lubricant. Cast hub with precision machined bearing and wheel mounting surfaces. 0

12 ,000 Lb. Wheel & Hub Assembly Unitized Seal Seals internally within the seal, with two sealing lips and press fitted to the spindle for improved performance. Tapered roller bearings Computer matched to Dexter Axle system. Outer: (8) cup (88) cone Inner: (390) cup (3984) cone *K Low profile hub is available for use with 4.5" diameter dual wheels. Tighten wheel nuts to a torque of 00 lb-ft. Hardened spindle washer. kassy_-09.eps ¼ x 5" high performance hydraulic brake. Electric and air brake, parking feature and uni-servo hydraulic brakes are also available. Bearing adjustment nuts with tang locking washer keyed to spindle to maintain precision bearing adjustment. Removable rubber oil filler plug for ease of maintenance. Transparent poly-carbonate oil cap with oil level indicator mark to allow visual checking for adequate lubricant. Two piece hub and drum design permits replacement of brake drum without the need to replace hub. Cast brake drum with integral brake armature. Alloy selected for both brake energy (heat) absorption and good magnetic braking characteristics. Finned outer surfaces in braking area for maximum cooling. Axle designed for oil bath lubrication of bearings with SAE 80W-90 hypoid gear oil. This lubrication method assures long bearing life with proper maintenance of oil level. Cast hub with precision machined bearing and wheel mounting surface. *Note: K Hi profile hub is available for use with and.5" diameter dual wheels and tires, or 7.5" diameter single wheel and tire. 5,000 Lb. Wheel & Hub Assembly Unitized Seal Seals internally within the seal, with two sealing lips and press fitted to the spindle for improved performance. Tighten wheel nuts to a torque of lb-ft. Tapered roller bearings Computer matched to Dexter Axle system. Outer: (8) cup (88) cone Inner: (390) cup (3984) cone Hardened spindle washer. Bearing adjustment nuts with tang locking washer keyed to spindle to maintain precision bearing adjustment. ¼ x 5" high performance hydraulic brake. Electric, air brake, parking feature, and ABS brakes are also available. Removable rubber oil filler plug for ease of maintenance. Transparent polycarbonate oil cap with oil level indicator mark to allow visual checking for adequate lubricant. Cast hub with precision machined bearing and wheel mounting surface. Axle designed for oil bath lubrication of bearings with SAE 80W-90 hypoid gear oil. This lubrication method assures long bearing life with proper maintenance of oil level.

13 0K, K, 5K, and 3D Hub Groups hub_-08 5A 7 Item Description 0K, 3D 8 on.50 0K, 3D Disc 8 on.50 K Low-Profile 8 on.50 K Hi-Profile 8 on.50 K Disc 8 on.50 5K 8 on 75 mm Unitized Oil Seal Inner Bearing Cone (395S) 4 Inner Bearing Cup (394A) (395S) (394A) (3984) (390) (3984) (390) (3984) (390) (3984) (390) 5 Brake Drum Brake Drum-ABS A Brake Rotor A Brake Rotor-ABS Wheel Mounting Stud Hubs w/cups & Studs Outer Bearing Cup (38A) 9 Outer Bearing Cone (387A) (38A) (387A) (8) (88) (8) (88) (8) (88) (std) (long) (std stud) (long stud) (8) (88) 0 Spindle Washer Spindle Nut Tang Washer Oil Cap "O" Ring Oil Cap Oil Cap Plug Wheel Clamp Ring Wheel Nut Flange Nut (swivel) Drum Mounting Screw Rotor Mounting Stud Rotor Mounting Nut

14 0,000 and,000 Lb. Hydraulic Disc Brake Caliper Pistons (underneath housing) are larger, for greater brake torque. Dual Pistons per caliper. Corrosion-Resistant Bolts. Universal Caliper and Universal Brake Pads eliminate the need to stock right-hand and left-hand parts. Brake Shoes of heavy steel are bonded to brake linings for extended lining life. Linings are truck type for improved stopping force and extended service life. Two-Piece Hub and Rotor Design allows rotor replacement without requiring new hub. Dexter Ventilated Disc Rotors. High grade alloy iron to prevent heat checking and distortion. Ventilation provides great heat dissipation. Hydraulic Disc Brake Parts Item Description Qty/Brake 0K, K, 3D, 3G Anchor Yoke Assembly (includes of item #) Caliper Assembly (includes items #, 3, 9, 0) 3 Caliper Piston Shoulder Screw ⁵ ₈ x Hex Screw ⁷ ₁₆-0 x Flange Nut Hex Nut ⁷ ₁₆ Rotor Mounting Stud ABS Sensor (straight) ABS Sensor Retaining Clip ABS Tone Ring Caliper Repair Kit Contains: K "O" Ring Bleeder Screw Caliper Seal Dust Boot Disc Brake Replacement Pad Kit Contains: K Brake Pad Anti-Rattle Spring "O" Ring Hex Locknut Installation Tool Hyddisc_-08 Recommend hose with banjo fiting. ⁷ ₁₆-0 threaded hole for fitting. Note: ABS not available on 3D or 3G. 3

15 Forward Self-Adjusting Electric Brake Anchor post of high strength steel to accept high torques of heavy duty brake service. Backing Plate is a cast spider from high strength ductile iron designed for long life under heavy duty braking conditions. Adjuster Spring holds heel ends of brake shoes engaged with adjuster link. Heavy Duty Actuating Lever with oil impregnated bushing for long trouble-free operation. Adjuster Link transmits braking forces between brake shoes. Length is adjusted during normal vehicle forward and reverse operation to maintain close brakes shoe-to-drum relation for maximum braking efficiency and service-free operation. Adjuster Pawl is cable actuated when brake is applied while vehicle is operating in forward or reverse. Brake Linings are truck type for improved stopping force and extended service life. Linings are bonded to brake shoes for more useable lining life. Electromagnet, powdered metal body with large, friction wear surface. Spring on actuating lever pin positions electromagnet positively against drum armature surface. Brake Shoes are fabricated out of heavy gauge steel to completely support brake linings under service conditions without warping. The shoes assure adequate strength to withstand high forces needed for more efficient braking. Electric Brakes Size Capacity Part No. LH Part No. RH ¹ ₄" x 3³ ₈" 9K, 0K, 3G GD K K ¹ ₄" x 4" 0K, 3D K K ¹ ₄" x 5" K K K ¹ ₄" x 5" 5K K K

16 Electric Brake Parts Stamped Backing Plate Prior to April x3e_ Item Description Qty Per Brake LH Shoe & Lining Kit Contains: LH Primary LH Secondary Shoe Hold Down Washer Lock Nut RH Shoe & Lining Kit Contains: RH Primary RH Secondary Shoe Hold Down Washer Lock Nut ¹ ₄" x 3³ ₈" 9K, 0K, 3G GD Part No. K K ¹ ₄" x 4" 0K, 3D Part No. K K ¹ ₄" x 5" K Part No. K K ¹ ₄" x 5" K Part No. K K Backing Plate Assembly Shoe Return Spring (rear-black) Shoe Return Spring (front-green) LH Actuator Arm Assembly RH Actuator Arm Assembly Wire Clip LH Arm/Shoe Retainer RH Arm/Shoe Retainer Flange Nut Magnet Kit Contains: Magnet Retainer Clip Magnet Assembly Magnet Mounting Spring K K K K Adjuster Cable LH Adjuster Lever RH Adjuster Lever 3 LH Adjuster Lever Spring RH Adjuster Lever Spring Adjuster Spring LH Adjuster Assembly RH Adjuster Assembly Dust Shield Brake Mounting Screw Wire Grommet Adjuster Clip (thread end) Adjuster Clip (barrel end) Brake Mounting Nut Brake Mounting Lockwasher

17 Electric Brake Parts Cast Backing Plate After April x4efsacast_ Item Description Qty Per Brake LH Shoe & Lining Kit Contains: LH Primary LH Secondary RH Shoe & Lining Kit Contains: RH Primary RH Secondary ¹ ₄" x 3³ ₈" 9K, 0K, 3G GD Part No. K x4efsacast.eps K Revised 3/5/ by Neil Bough New graphic saved as x4efsacast_3-04.eps ¹ ₄" x 4" 0K, 3D Part No. K K ¹ ₄" x 5" K Part No. K K ¹ ₄" x 5" K Part No. K K Backing Plate Assembly LH Actuator Arm Assembly RH Actuator Arm Assembly Wire Clip LH Arm/Shoe Retainer RH Arm/Shoe Retainer Flange Nut Magnet Kit Contains: Magnet Retainer Clip Magnet Assembly Magnet Mounting Spring K K K K Centering Spring Adjuster Cable LH Adjuster Lever RH Adjuster Lever Adjuster Spring LH Adjuster Assembly RH Adjuster Assembly Dust Shield Brake Mounting Screw Wire Grommet Adjuster Clip (thread end) Adjuster Clip (barrel end) Brake Mounting Nut Brake Mounting Lockwasher Return Spring

18 Forward Self-Adjusting Hydraulic Brake Anchor post of high strength steel to accept high torques of heavy duty brake service. Retractor Spring assures uniform return of both brake shoes after stop. Spider Assembly is high strength ductile iron with integral cast hydraulic cylinder. Designed for long life under heavy duty braking conditions. Positive Brake Shoe Hold-Down for smooth brake shoe movement. Adjuster Spring holds heel ends of brake shoes engaged with adjuster link. Dust Shield (not shown) protects brake from foreign material, thus allowing trouble-free operation. Adjuster Link transmits braking forces between brake shoes. Length is adjusted during normal vehicle forward and reverse operation to maintain close brake shoe-to-drum relation for maximum braking efficiency and service-free operation. Brake Linings are truck type for improved stopping force and extended service life. Linings are bonded to brake shoes for more useable lining life. Adjuster Pawl is cable actuated when brake is applied while vehicle is operating in forward or reverse. Note: Hydraulic brakes equipped with parking feature adjust ONLY when the brake is applied while vehicle is operating in reverse. Brake Shoes are fabricated out of heavy gauge steel to completely support brake linings under service conditions without warping. The shoes assure adequate strength to withstand high forces needed for more efficient braking. Hydraulic Brakes Size Capacity Part No. LH Part No. RH ¹ ₄" x 3³ ₈" 9K, 0K, 3G GD K K Duo-Servo ¹ ₄" x 3³ ₈" 9K, 0K, 3G GD K K Uni-Servo ¹ ₄" x 3³ ₈" 9K, 0K, 3G GD K K3--00 Duo-Servo w/park* ¹ ₄" x 4" 0K, 3D K K Duo-Servo ¹ ₄" x 4" 0K, 3D K K Uni-Servo ¹ ₄" x 4" 0K, 3D K K Duo-Servo w/park* ¹ ₄" x 4" 0K, 3D K3--00 K Uni-Servo w/park** ¹ ₄" x 5" K K K Duo-Servo ¹ ₄" x 5" K K K Uni-Servo ¹ ₄" x 5" K K K3--00 Duo-Servo w/park* ¹ ₄" x 5" 5K K K Duo-Servo ¹ ₄" x 5" 5K K3--00 K Duo-Servo w/park* * Duo-Servo brake with park is equipped with a rear self-adjusting feature. ** Uni-Servo brake with park is equipped with a manual adjusting feature. 7

19 Hydraulic Brake Parts x3hfsa_ ¹ ₄" x 3³ ₈" ¹ ₄" x 4" ¹ ₄" x 5" ¹ ₄" x 5" 9K, 0K, 3G GD 0K, 3D K 5K Item Description Qty Per Brake Part No. Part No. Part No. Part No. Dust Cover Retainer LH Shoe & Lining Kit Contains: K K K K LH Primary x3h90fsa.eps LH Secondary Hold Down Washer Revised 3/5/ by Hold Down Locknut Neil Bough K7--00 New graphic saved K as x3hfsa_3-04.eps RH Shoe & Lining Kit Contains: RH Primary RH Secondary Hold Down Washer Hold Down Locknut K K Show Hold Down Screw Adjuster Cable Wheel Cylinder Kit Contains: Cylinder Spring Cylinder Boot Cylinder Piston Cylinder Cup Bleeder Screw K K K K Cylinder Push Rod Spider Assembly Retractor Spring LH Adjuster Lever RH Adjuster Lever LH Adjuster Lever Spring RH Adjuster Lever Spring Cable Attachment Bracket FSA Extension Spring Adjuster Clip (barrel end) LH Adjuster Assembly RH Adjuster Assembly Brake Mounting Bolt Piston Stop Adjuster Clip (thread end) Brake Mounting Nut Lockwasher Optional ABS Parts: 0 ABS Sensor (straight) ABS Sensor Mounting Block ABS Sensor Retaining Clip ABC Tone Ring in Drum

20 Typical Electric Brake Wiring Diagram V Battery for Breakaway Switch Brake Controller Breakaway Switch Stoplight Wire Towing Vehicle Trailer Connection Battery Power Wire Brake Wire Ground Wire Hookup Wire Size Copper Recommended Note: Actual installation will vary depending on controller system used. Number of Brakes Hitch-to-Axle Distance (in feet) No. AWG No. AWG 4 Under 30 No. 0 AWG No. 0 AWG Under 30 8 No. 8 AWG Current 3 Amperes/Brake Typical Air Brake System Diagram Air Compressor - Tow Vehicle Reservoir 3 - Actuation Valve 4 - Control Gladhand 5 - Supply Gladhand - Trailer Reservoir 7 - Relay Valve 8 - Air Chambers Control Plumbing Supply Plumbing K K, K Hi-Profile, 5K Air chamber Size Type 0 Type 4 Air Chamber Full Stroke Volume 53 cu. 00 PSIG 3 cu. 00 PSIG Spring Brake Type Type 0-4 Combination Type 4-30 Combination Spring Brake Volume (caged) 7.4 cu. 00 PSIG 9.8 cu. 00 PSIG 9

21 Dexter S Cam Brake Lubricated Cam-Shaft Bushing. Minimizes friction and wear. Automatic Slack Adjusters offer precise adjustment for brake shoe clearance. Standard Air Chamber Mounting Brackets are provided. Hardened "S" Cam for extended life. Optional cam lengths available for special applications. Knurled Shoe Roller for positive rotation to prevent excessive wear. Size ¹ ₄" x 4" ¹ ₄" x 5" Capacity 0K, 3D K, 5K Service Air Chambers with forged clevis matched to the braking capacity of the axle. (Springbrake option available.) Heavy Duty Forged Spider welded to the axle beam for long life under heavy duty braking conditions. Hi-Performance Truck Type Brake Blocks for optimum stopping force and extended service life. Blocks are riveted for ease of replacement. Anchor Pins are hardened and plated for extended service life. Small S Head Hi-Rise 8 Spline Part No. A B C LH RH For.50 dia. shaft For.50 dia. shaft For.50 dia. shaft For.50 dia. shaft For.50 dia. shaft For.50 dia. shaft For.50 dia. shaft For.50 dia. shaft For.50 dia. shaft For.50 dia. shaft For.50 dia. shaft + No extra charge for these lenghts. 0

22 Air Brake Parts PQ Style 5A&5B A&B Airbrk_no hubs_ ABS parts 0-5K Item Description Qty Per Brake ¹ ₄" x 4" 0K, 3D Part No. ¹ ₄" x 5" K, 5K Part No. A Camshaft LH* xx xx B Camshaft RH* xx xx Air Chamber Bracket Shoe & Lining Assembly A Shoe & Roller Assembly RH B Shoe & Roller Assembly LH "D" Washer, Camshaft Grease Seal Camshaft Bushing Washer-Camshaft Spider End Camshaft Washer-8 Spline Retainer-Camshaft Retainer-Camshaft End Camshaft Support Bushing Automatic Slack Adjuster-8 Spline Manual Slack Adjuster - 8 Spline Grease Fitting Air Chamber w/hardware Air Chamber w/spring Brake Plate - Camshaft Support Bracket Plate, Bushing Retainer Bolt, Retainer Plate Lock Washer Nut Brake Spider * For camshaft with part no. xx, see page 0. Item Description Qty Per Brake ¹ ₄" x 4" 0K, 3D Part No. ¹ ₄" x 5" K, 5K Part No. Brake Shoe Repair Kit Contains: K K ns Bushing-Spider Anchor Pin Anchor Pin Roller Roller Pin Roller Pin Retainer Roller Pin Spacer Retractor Spring Retainer Pin Shoe Keeper Spring Instruction Sheet not used Brake Block Kit Contains: K K Brake Block Anchor Brake Block Cam Rivet ABS Components: 34 ABS Sensor Retaining Clip ABS Lower Sensor Mounting Block ABS Sensor ABS Tone Ring in Drum ABS Upper Sensor Mounting Block Mounting Screw Upper Block ns - not shown + Note: is required for 0K shoes with ¹ ₄" shoe web thickness. Not required for ⁵ ₁₆" shoe web thickness. Used only on ¹ ₄" x 4" shoes with ¹ ₄" webs.

23 Typical Electric Hydraulic Brake System Diagram Breakaway Battery Hydraulic lines to trailer brakes Breakaway Switch E/H Actuator Dexter hydraulic drum brake or disc brake Electric Wires Electric Brake Controller Trailer Plug Dexter Axle E/H Units Model E/H 000 P/N K for Drum Brakes Only Model E/H 00 P/N K for Disc Brakes Only Hydraulic System Installation Suggestions. Use ³ ₁₆" steel tubing having 000 PSI working pressure rating for all hardline connections between the actuator and take-off to axle. All tubing must have double flare connection at joints.. Anchor hydraulic tubing securely to frame and axle. 3. Use inverted flare fittings having 8 included angle. 4. Use D.O.T. high pressure hydraulic hose for flex connection(s) (frame to axle). WARNING: It is the brake system installer s responsibility to insure compatibility between towing vehicles and trailer actuation systems. Various combinations of Air/Hydraulic, E/H, or Vacuum/Hydraulic and tow vehicle systems can allow normal working pressure to exceed 000 PSI on drum brakes. Pressures in excess of 000 PSI on drum brakes increase lining wear and can lead to component failure. Make certain your system has the correct peak pressure to activate brakes properly. Axle Capacity Maximum Operating Pressure (PSI) Total Fluid Displacement Required per Axle 9K, 0K, K, 3D, 3G Drum Brakes ¹ ₄" Diameter Cylinder* cu. in. 0K, K, 3D Disc Brakes ¹ ₂" Diameter Piston (Quantity )** cu. in 5K Drum Brakes ³ ₈" Diameter cylinder* cu. in. * Use ³ ₈-4 flare nut fitting on ³ ₁₆" tube or hose to connect to back of brake. ** Use ⁷ ₁₆-0 straight thread inlet to connect to brake.

24 Wheels and Tires Dexter 9K-K hubs are designed to accept hub-piloted single or dual wheels that have an 8 on.50" bolt circle and a 4.75" bore. Single wheels should have a wheel offset between ¹ ₂" outset and ³ ₁₆" inset for maximum bearing life. The Dexter 5K hub is designed to accept hub-piloted dual wheels that have an 8 on 75mm bolt circle and a mm bore. Wheel Dia. Rim Width Contour Tire Size Description SLR Tire Width Capacity Single/Dual PSI Single/Dual R.5LT, F / R.5LT, E / R.5LT, F / R.5LT, E / K LT35/85R, D /38 5 K LT35/85R, E / K LT35/85R, G / K R7.5HC, G / / HC 45/70R7.5HC, H / HC 5/75R7.5HC, H / R.5, G / MH 9-4.5LT, F / MH 9-4.5LT, E / Axle Overhang Per Side For Dual Wheel Applications For Single Wheel Applications Axle Model Min. Max. Axle Model Min. Max. D D D00GD D00GD D00HD D00HD D0 Lo Profile D0 Lo Profile D0 Hi Profile D0 Hi Profile D D To determine frame height, ground clearance, recommended fender height, and center of tire in reference to the frame based on your axle specifications, contact your local Dexter sales representative or Dexter distributor to run ProSpec. 3

25 4 Recommended Oil Lubrication Specification Use: Service Designation: Axle hubs with tapered roller bearing API-GL-5 Viscosity: SAE 80W-90 Pour Point: Additives: Compatability: Approved Sources: Company -8 C (0 F) Maximum Corrosion and oxidation inhibitors, foam inhibitors, EP additives Must be compatable with nitrile and neoprene seals and polycarbonate plastic oil caps Product Description Ashland Oil Valvoline Dura Blend Ashland Oil Valvoline Power Lube CITGO Petroleum Company CITGO Premium Gear Oil MP CITGO Petroleum Company Mystik JT-7 CITGO Petroleum Company Mystik Power Lube Exxon Company U.S.A. Gear Oil GX 80W-90 Kendall Refining Company Kendall NS-MP Hypoid Gear Lube Lubriplate Division / Fiske Brothers Refining Lubriplate APG 90 Mobil Oil Corporation Mobilube SHC Mobil Oil Corporation Mobil Synthetic Gear Lube Phillips Petroleum Superior Multi-Purpose Gear Oil Phillips Petroleum Philguard Gear Oil Phillips Petroleum Philsyn Gear Oil Pennzoil Products Company Gear Plus 80W-90 GL-5 Pennzoil Products Company Gear Plus Super 75W-90 Pennzoil Products Company Gear Plus Super EW 80W-90 Pennzoil Products Company Multi-Purpose 409 Gear Lube Oil Center Research Liquid-O-Ring 750 GX Sun Refining and Marketing Company Sonoco Ultra Sun Refining and Marketing Company Sonoco Dura Gear Shell Oil Company Spirax A Shell Oil Company Spirax G Shell Oil Company Spirax HD Shell Oil Company Spirax S Texaco Oil Company Multigear EP Texaco Oil Company Multigear SS Troco Division / Royal Manufacturing Multigear Select Gear Oil Union Oil Company Unocal MP Gear Lube Union Oil Company 7 Triton Syn Lube EP Bearing Adjustment 9K & 0K General Duty, 0K-5K Heavy Duty Axles: Correct adjustment for all bearings is.00 to.00 end play.. Rotate hub assembly slowly while tightening the inner lock nut to 00 lb-ft. to seat the bearings.. Loosen the inner lock nut to remove pre-load torque. Do not rotate the hub. 3. Finger tighten the inner lock nut and snug. 4. Back inner lock nut out ¹ ₄ to ³ ₈ turn. 5. Install tang washer and outer lock nut. Bend two tangs over inner lock nut. Torque outer lock nut to lb-ft., insuring that the inner lock nut does not turn. Bend tangs over flats on outer lock nut to secure.

26 Dexter Axle Suspension System (0K-5K HD) (9K) (0K GD) Optional, Adjustable Spring Seat. High Strength Steel "U" Bolts have rolled threads for greater strength. Heavy Duty Hanger Brackets and Equalizers are reinforced for rugged service reliability. Equalizer and Spring Eye Bolts are tightened so that all movement is absorbed by the rubber. High Strength Steel Reinforced Tie Plates. Hex Locknuts give positive retention of spring to axle beam. A Single Suspension Eye is formed into the forward end of the first (longest) leaf of the spring (0K-5K HD) (9K) (0K GD) A Replaceable, Rubber Bushing is used to absorb motion to prevent bolt wear. Two Multi-Leaf Slipper Type Springs per single axle. Individual leaves are shot peened to increase fatigue life for long trouble-free service (0K-5K HD) (9K) (0K GD) Cross Hanger Reinforcement 5

27 Suspension Dimensions Kits for " Wide Springs Single Hanger Min. Recommended Tire 3.00" tandem Front Hanger Rear Hanger Min. Recommended Tire 3.00" Height Height Front Front Axle Location Tire Center Axle Location Static Bump Front Hanger Static Bump Ground 9K Single Axle HAP Part No. Qty Description Front Hanger Rear Hanger Spring Eye Bolt Keeper Bolt Locknut Locknut Instruction Sheet 9K Single Axle HAP Front Hanger.9 Static Bump. Tire Center 5. Axle Location 3.7 TRIple Front Axle Tire Static Loaded Center Hanger Tire Center Overall Tire Height Ground Rear Axle Rear Hanger 9K 38" Triple Axle HAP-05-0 HAP-05-0 HAP Front Hanger Center Hanger Rear Hanger Static Bump Tire Center Axle Location Front Axle Rear Axle K Axle Assemblies 38" 4.5" 48.50" For single axle assemblies use () HAP Tandem () HAP () HAP-05-0 () HAP () HAP-05-0 () HAP () HAP Triple () HAP () HAP-05-0 () HAP () HAP-05-0 () HAP () HAP Note: All dimensions are for underslung spring orientation only. Tire Static Loaded Height Front Static Bump Axle Location Min. Recommended Tire 3.00" Overall Tire Height Ground Axle Tire Center Tire Static Loaded Overall Tire Height 9K Tandem Axle HAP-05-0 HAP-05-0 HAP Front Hanger Rear Hanger Static Bump Tire Center Axle Location Front Axle K 38" Multi-Axle Conversion Kit HAP-05-0 Part No. Qty Description Center Hanger Equalizer Spring Eye Bolt Keeper Bolt Equalizer Bolt Locknut Locknut Locknut Instruction Sheet 9K 4.5" Multi-Axle Conversion Kit HAP-05-0 Part No. Qty Description Center Hanger Equalizer Spring Eye Bolt Keeper Bolt Equalizer Bolt Locknut Locknut Locknut Instruction Sheet 9K 48.5" Multi-Axle Conversion Kit HAP Part No. Qty Description Center Hanger Equalizer Spring Eye Bolt Keeper Bolt Equalizer Bolt Locknut Locknut Locknut Instruction Sheet

28 Suspension Dimensions Kits for ¹ ₂" Wide Springs ³ ₄" Spring Eye Bolts Single Hanger Min. Recommended Tire 3.00" TANDEM Front Hanger Rear Hanger Min. Recommended Tire 3.00" Height Front Tire Center Axle Location Static Bump Ground 0K GD Single Axle HAP Part No. Qty Description Hanger Rear Hanger Spring Eye Bolt Locknut Instruction Sheet Tire Static Loaded Overall Tire Height Height Front Static Bump Axle Location Ground Axle Tire Center Tire Static Loaded Overall Tire Height 0K GD Tandem Axle HAP-58-0 HAP-58-0 HAP Front Hanger Rear Hanger Static Bump Tire Center Axle Location Front Axle K GD Single Axle HAP Front Hanger 7.4 Static Bump.9 Tire Center 5.0 Axle Location 4.0 TRIple 0K GD Triple Axle HAP-58-0 HAP-58-0 HAP Front Hanger Center Hanger Rear Hanger Static Bump Tire Center Axle Location Front Axle Rear Axle K GD Axle Assemblies 38" 4.5" 48.50" For single axle assemblies use () HAP Tandem () HAP () HAP-58-0 () HAP () HAP-58-0 () HAP () HAP Triple Height Front Static Bump Axle Location Front Hanger () HAP () HAP-58-0 Front Axle () HAP () HAP-58-0 Center Hanger Tire Center Ground () HAP () HAP Note: All dimensions are for underslung spring orientation only. Rear Axle Rear Hanger Tire Static Loaded Min. Recommended Tire 3.00" Overall Tire Height 0K GD 38" Multi-Axle Conversion Kit HAP-58-0 Part No. Qty Description Locknut Locknut Spring Eye Bolt Equalizer Bolt Equalizer Center Hanger Instruction Sheet 0K GD 4.5" Multi-Axle Conversion Kit HAP-58-0 Part No. Qty Description Locknut Locknut Spring Eye Bolt Equalizer Bolt Equalizer Center Hanger Instruction Sheet 0K GD 48.5" Multi-Axle Conversion Kit HAP Part No. Qty Description Locknut Locknut Spring Eye Bolt Equalizer Bolt Equalizer Center Hanger Instruction Sheet 7

29 Suspension Dimensions Kits for 3" Wide Springs Single Hanger Min. Recommended Tire 3.00" TANDEM Front Hanger Rear Hanger Min. Recommended Tire 3.00" 8 Height Height Front Front Tire Center Axle Location Axle Location Static Bump Front Hanger Static Bump Ground 0-5K Single Axle HAP Part No. Qty Description Front Hanger Rear Hanger Spring Eye Bolt Keeper Bolt Locknut Locknut Instruction Sheet 0-5K Single Axle HAP Front Hanger 7.4 Static Bump.9 Tire Center.0 Axle Location 4.0 TRIple Front Axle Tire Static Loaded Center Hanger Tire Center Overall Tire Height Ground Rear Axle Rear Hanger 0-5K Triple Axle HAP-03-0 HAP-03-0 HAP Front Hanger Center Hanger Rear Hanger Static Bump Tire Center Axle Location Front Axle Rear Axle K Axle Assemblies 38" 4.5" 48.50" For single axle assemblies use () HAP Tandem () HAP () HAP-03-0 () HAP () HAP-03-0 () HAP () HAP Triple () HAP () HAP-03-0 () HAP () HAP-03-0 () HAP () HAP Note: All dimensions are for underslung spring orientation only. Tire Static Loaded Height Front Static Bump Axle Location Min. Recommended Tire 3.00" Overall Tire Height Ground Axle Tire Center Tire Static Loaded Overall Tire Height 0-5K Tandem Axle HAP-03-0 HAP-03-0 HAP Front Hanger Rear Hanger Static Bump... Tire Center Axle Location Front Axle K 38" Multi-Axle Conversion Kit HAP-03-0 Part No. Qty Description Center Hanger Equalizer Spring Eye Bolt Keeper Bolt Equalizer Bolt Locknut Locknut Locknut Instruction Sheet 0-5K 4.5" Multi-Axle Conversion Kit HAP-03-0 Part No. Qty Description Center Hanger Equalizer Spring Eye Bolt Keeper Bolt Equalizer Bolt Locknut Locknut Locknut Instruction Sheet 0-5K 48.5" Multi-Axle Conversion Kit HAP Part No. Qty Description Center Hanger Equalizer Spring Eye Bolt Keeper Bolt Equalizer Bolt Locknut Locknut Locknut Instruction Sheet