DEXTER AXLE E/H 1000 Manuale utente
SERVICE MANUAL
DEXTER AXLE
E/H 1000 & 1600
BRAKE ACTUATORS
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Introduction
This manual has been provided to guide you through the process of
installing, operating, and maintaining your Dexter E/H 1000 or E/H 1600
hydraulic brake system actuator. This electrically powered unit has been
designed and manufactured to give safe, reliable power to your hydraulic
trailer brakes.
Before proceeding, make sure that the unit is appropriate for your particular
brakes. The E/H 1000 produces 1000 psi, typically used for duo-servo
hydraulic drum brakes, while the E/H 1600 produces 1600 psi for most
hydraulic disc brakes. Please refer to your brake manufacturer for proper
operating pressures.
This new Dexter actuator is compatible with many electric brake controllers,
but the best performance will be achieved using an inertial type controller
such as the Dexter Predator DX2. The electronic timer type of controller is
not recommended because these units use a fixed control that does not
sense varying brake requirements.
For all your running gear needs...
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www.dexteraxle.com
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Contents
Installation Instructions ............................................................. 3
Getting Started .................................................................. 3
Electrical Installation Requirements .........................................6
Wire Colors and Function.................................................. 6
Test Electrical Operation .......................................................... 9
Bleeding and Brake Adjustment ............................................. 10
Testing and Adjustment of Controller Unit .............................. 12
Troubleshooting Guide ........................................................... 13
Warranty ................................................................................. 16
Table of Contents
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!
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.
Actuator Installation Instructions
Getting Started
The following materials are required to properly install the Dexter
E/H unit. If your trailer is not already equipped with brake lines,
you will need enough 3/16"diameter automotive brake line to
connect the trailer brakes to the unit. Where possible, steel tubing
is preferred.
• Four 1/4" threaded fasteners to mount the unit to the trailer.
• One quart of DOT 3 or DOT 4 brake fluid (from a new
sealed container).
• One emergency breakaway kit - must include a 12 volt,
9 amp hour (minimum) battery.
• Wire (see Electrical Installation Requirements for proper
wire size).
Location of the Dexter E/H actuator is at the discretion of the
vehicle owner. When selecting the location, the following items
should be considered:
1. The shorter the wiring between the unit and the electrical
power source, the smaller the voltage drop.
2. The unit should be located so that the electrical wiring and
brake lines can be neatly routed directly to the towing
vehicle and trailer brakes. Special care should be taken to
minimize the number of bends and fittings in the brake line
circuits.
3. An emergency breakaway kit must be located on the trailer
so that the trailer breakaway cable can be easily attached
to the towing vehicle.
Installation Instructions
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4. The Dexter E/H actuator is powered from the electrical
system on the tow vehicle. In order for the unit to function
properly, it must have adequate electrical power (see
Electrical Installation Requirements).
5. The Dexter E/H unit should not be placed in an area where
it is susceptible to damage from trailer loads, road debris,
or from being stepped on. Failure to protect the actuator
from damage can cause the unit to malfunction and void
the Dexter Axle warranty.
Mounting consideration should be given to the following:
1. The unit must be level, with the filler neck up.
2. It is the responsibility of the customer to provide necessary
fasteners for attachment of the actuator to the trailer.
CAUTION
The Dexter E/H actuator contains sensitive electronics
that must be protected. Drilling additional holes in the
housing, electrostatically painting, or welding anywhere
on the unit will damage the unit making it inoperable and
will void the manufacturer’s warranty. Always remove
the unit from the trailer before doing any welding repair
or modifications to the trailer structure.
Connect the trailer brake lines to the actuator as follows:
1. Remove the red plastic plug from the 3/16"inverted flare
brake port.
2. Brake line must be compatible with DOT 3 & DOT 4 brake
fluid.
3. Flush existing brake system and lines with DOT 3 or DOT 4
brake fluid prior to connecting to the Dexter E/H unit.
4. Connect the brake line from the trailer brakes to the 3/16"
inverted flare fitting on the actuator.
Fill the unit with DOT 3 or DOT 4 brake fluid to the bottom of the
reservoir filler neck. When putting the filler cap back on it should
be turned clockwise until snug.
Installation Instructions
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CAUTION
Always use new DOT 3 or DOT 4 brake fluid from a
sealed container. Never attempt to reuse old or dirty
fluid. Do not overfill the unit. Take care to protect painted
surfaces from contact with the brake fluid. Wash off any
spilled brake fluid.
Mount the emergency breakaway switch and emergency
breakaway battery on the trailer, as detailed in the instruction
sheets provided with the emergency breakaway kit.
Installation Instructions
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Electrical Installation Requirements
CAUTION
Undersized wire will increase electrical resistance and
will prevent proper operation of this unit.
Wire Colors and Function
BLACK – 30 amp 12 volt Supply From Tow Vehicle*
BLUE – Output From In-Cab Electronic Brake Controller
WHITE – Trailer and Tow Vehicle Ground
YELLOW – Cold side of breakaway switch
YELLOW
ORANGE/BLACK
MINIMUM
9 AMP HR BATTERY
It is critical that the BLACK power lead and WHITE ground lead
from the tow vehicle to the input of the actuator are sized and
properly terminated (i.e. dedicated 25-40* amp circuit on the tow
vehicle – 12 gauge wire minimum). 10-gauge wire is
recommended to optimize performance. Consult the SAE wiring
guidelines for proper trailer electrical harness design.
* Low temperature applications below 0° F require a
40-amp circuit.
Electrical Requirements
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Electrical Requirements
The blue wire from the in-cab electronic brake control is
connected to the blue wire on the actuator. The yellow wire from
the actuator is connected to the cold side of the trailer emergency
breakaway switch. Under no circumstances should the blue
wire and the yellow wire be connected together, nor should
the blue wire ever be grounded.
Requires an In-Cab Electronic Control – The Dexter E/H
actuator is intended to be used with an in-cab electronic brake
controller. The unit will operate with a wide variety of controllers
but provides optimum performance when used with a Dexter
electronic brake controller. The in-cab controller must have an
output capacity of at least 5 amps for proper operation of the
Dexter E/H actuator.
CAUTION
It is the responsibility of the end user to ensure that their
in-cab electronic controller is compatible with the Dexter
E/H actuator. Dexter Axle attempts to provide
compatibility with most controllers available, but is
unable to anticipate design changes that might be
introduced by the various controller manufacturers.
Electrical Connections – Make sure all electrical connections
are clean, dry, weather tight, and secure to prevent damage to
the wiring from dragging or becoming entangled with foreign
objects. A dedicated ground connection between the tow vehicle
and trailer is also required.
Breakaway Battery Requirement – To comply with federal
requirements, the trailer must be equipped with a breakaway
switch and battery. The breakaway battery needs to have a
minimum capacity of 9 amp hours and needs to be maintained in
a fully charged condition at all times. The breakaway battery
should be checked for proper charge level before every use.
Charging the Breakaway Battery – The breakaway battery must
be kept fully charged at all times in order to function properly. Use
only those breakaway battery kits that include a charging device.
Do not attempt to charge the breakaway battery directly from the
tow vehicle without the appropriate charging device.
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Note: If the Dexter E/H unit is wired to an on-board trailer
battery instead of a conventional breakaway battery, the unit
will draw a small amount of current even when not in use.
Prolonged periods of non-use (with no recharging) can
deplete an on-board battery. If the vehicle is to be stored, it
is recommended that the battery be disconnected to avoid
being depleted.
Electrical Requirements
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Test Electrical Operation
1. Attach the trailer to the towing vehicle. Do not connect
trailer plug to tow vehicle until step #2 is completed.
2. Pull the breakaway switch. The Dexter E/H unit should run.
If the unit does not run, check breakaway battery condition
and system wiring. Reset the breakaway switch, which will
turn the unit off.
Note: When the unit is running, the motor will generate
a “hum” that changes pitch as the unit builds pressure.
This is normal.
3. Connect trailer plug to tow vehicle.
4. Turn the ignition switch on and turn the in cab electronic
brake controller on. The Dexter E/H unit should run
whenever the brake pedal is depressed. If the unit does not
run, check system wiring.
5. Apply the controller manual slide. The Dexter E/H unit
should run and brake lights come on.
!
CAUTION
Testing the Dexter E/H unit confirms that it is operating.
It DOES NOT confirm that the brakes are operating
properly. Regular inspection, adjustment, and
maintenance of the brakes, lines, hoses, drums, discs,
fluid, and other associated components is necessary to
ensure proper brake operation.
6. Some brake controllers will not produce a high enough
signal voltage to actuate the trailer brakes when the vehicle
is at a standstill. Minimal trailer brake force is produced
when the controller voltage output to the E/H actuator is at
least 3 VDC. Maximum trailer brake force is achieved at 12
VDC.
Test Electrical Operation
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