Dexter Laundry DX16.5 User manual

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©2019 Dexter Axle Company | www.dexteraxle.com 059-Z01-06 2019.10 | 08197
INSTALLATION INSTRUCTIONS
DX16.5 Actuator (Formerly Model 16.5K) for 16,500 lbs Capacity Trailer Brakes
READ AND UNDERSTAND THE ENTIRE INSTRUCTION/ASSEMBLY
PROCEDURE BEFORE INSTALLATION.
The DX16.5 works by the “surge” or “push” of the trailer toward the
tow vehicle. This automatically synchronizes the trailer brakes with the
brakes on the tow vehicle. When the trailer pushes against the tow
vehicle, the actuator telescopes together and applies the force to the
master cylinder, supplying hydraulic pressure to the brakes. The built
in sealed and independent dampening shock absorber controls the
telescoping shock against the hitch.
Be sure to comply with regulations for brakes in your state. Brake laws
sometimes are minimum standards and you may wish to add additional
brakes to your trailer to meet minimum Gross Vehicle Weight Ratings
(G.V.W.R.). Note: G.V.W.R. is the Gross Vehicle Weight Rating which
includes the trailer and the load weight as a Total Gross Weight.
READ YOUR TOW VEHICLE OWNER’S MANUAL ON TOWING CAPACITY
AND OTHER TOWING RECOMMENDATIONS BEFORE INSTALLATION.
The DX16.5 Actuator is completely assembled and ready to bolt into
place (Tongue sizes: 3”x 4” & 3”x 5”, 9 ga. min.).
1. Bolt the actuator to the tongue using 5/8” diameter, 4” long grade
5 bolts. Attachment strength should equal or exceed 1-1/2 times
trailer G.V.W.R.
2. Hydraulic brake lines should be installed on the trailer as
described in the installation manual supplied with the brakes.
Note: Some disc brakes require the use of exible brake lines
at the connection point on the brake caliper. Follow brake
manufacturer instructions.
3. Use only DOT-3 brake uid in the DX16.5 actuator. Use a pressure
type brake bleeder to bleed brakes. Follow manufacturer’s directions.
Or, manually bleed the brakes using directions on page 3.
4. To bleed master cylinder and brakes, install bleeder hose on rst
# TDE Part # DX Part # Description
1A 70403K K68-523-21
Disc Brake DX16.5 Master
Cylinder Kit: master cylinder, cap
and 4 mounting screws
1A 70403KD K68-523-01
Drum Brake DX16.5 Master
Cylinder Kit: master cylinder, cap
and 4 mounting screws
1B 11286-BLK 054-240-00 Disc Brake Solenoid - used with
Disc brake actuators
1C 17028SA 052-017-00 Dampener Cylinder (each) 2
required
2 70404K K68-540-00 Wear Pad Kit: upper and lower
wear pads
3 70407K K68-532-00 Emergency Stop Lever and Spring
4 70408K K68-519-00 Actuator Pin Kit: 3 pins with
retainers and pin kit
5 48986A 068-572-00 Master Cylinder Cap with internal
bladder
6 50306 074-480-00 Safety Pin and Cable Assembly
7 50307K K68-529-00 Emergency Stop Cable with
Connector Link
8 70409K K74-571-00 Latch Kit
9 70405K 068-576-00 Emergency Stop Lever Cover and
Spring and 3 mounting screws
10 70406 068-560-00 Rear Cover
1A
1C
1
9
1A & 5
8
7
7
3
4
4
4
6
2
2
1B
10
wheel cylinder to be bled; if tandem axle trailer, bleed farthest axle
rst, and the farthest brake on that axle rst. Use a loose end of
hose from the bleeder valve submerged in a clear container of brake
uid to observe bubbling (hose must be submerged into clean brake
uid to keep air from traveling back into the brake cylinder). Loosen
the bleeder screw located in the wheel cylinder one turn; the system
is now open to the atmosphere. The bleeding operation for that brake
is complete when bubbling stops. Be sure to tighten bleeder screw
securely. Each wheel cylinder must be bled until all air is out of the
lines. Replenish the brake uid during the bleeding process so the
level does not fall below half full level in the master cylinder reservoir.
When bleeding and testing is completed, make sure master cylinder
is lled to approximately 3/8” below the top of the reservoir and
ller cap is securely in place.
5. Road test trailer a short distance to activate the actuator several
times. Check uid level again. Remember, low brake uid levels will
result in reduced braking or no braking at all.
6. When testing is complete, make sure master cylinder is lled to
approximately 3/8” below the top of the reservoir and ller cap is
securely in place. Road test again to make sure brakes work properly.

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©2019 Dexter Axle Company | www.dexteraxle.com 059-Z01-06 2019.10 | 08197
RATED CAPACITY:
Maximum Actuator Capacity: 16,500 lbs. Gross Load; 1,600 lbs.
maximum tongue load; minimum tongue weight is 5% of G.V.W.R.
The actual in-service rating is limited to that of the ball and hitch or
the least rated component on the tow vehicle or trailer being used or
the trailer manufacturer’s G.V.W.R. shown on the certication label,
whichever is lower (Note: G.V.W.R. is the Gross Vehicle Weight Rating
which includes the trailer and the load weight as a Total Gross Weight).
HITCHING TRAILER
1. The vehicle, towing hitch and ball must have a rating equal to or
greater than trailer G.V.W.R.
!
CAUTION
• A loose fit between the coupler and hitch ball can cause the
actuator and hitch ball to separate, causing serious damage,
injury or death. Check coupler every time prior to towing and at
each stop on long trips. Always make certain that coupler latch
safety pin is securely installed into coupler latch.
• After reverse maneuvering, always insert coupler latch safety
pin back into coupler latch. FAILURE TO REMOVE SAFETY PIN
FROM REVERSE LOCK OUT POSITION HOLE WILL PREVENT
FORWARD MOVEMENT BREAKING THAT CAN RESULT IN
SERIOUS PROPERTY DAMAGE, INJURY OR DEATH.
2. DX16.5 will accept 2-5/16” trailer hitch balls with a 16,500 lb.
capacity only. Trailer balls larger than 2-5/16” or out of round will
not t he coupler or may result in coupler failure. Balls smaller than
2-5/16” can cause shock loading and sudden disconnection. Make
certain ball latch is in correct position to retain the hitch ball. Push
latch lever down until safety latch engages the hitch ball. Always
insert safety pin into forward hole as a safety lock for the hitch ball
coupler prior to towing. Do not tow trailer if coupler is damaged.
3. Connect safety cables or chains using crossed pattern under
tongue, or follow trailer manufacturer’s directions.
!
CAUTION
• A minimum of 5% tongue weight and a maximum 10% tongue
weight of the trailer GVWR must be positioned over the hitch
ball. The Trailer tongue should be parallel to the ground. Too
much weight can cause premature brake actuation and loss
of control of the towing vehicle. Too little tongue weight can
cause the trailer to fishtail, resulting in loss of control of the
tow vehicle and trailer (total trailer weight GVWR includes
weight of the trailer plus load).
• AVOID sharp turns, which can cause the actuator to bind
or jackknife against the tow vehicle or cause a bend in the
tongue. Either can damage the actuator causing brake failure.
AVOID towing trailer across large bumps or dips that may over
stress the connection between the trailer and tow vehicle, as
this could result in damage to the actuator.
• Failure to install the hitch pin before towing can result in
accidental opening of the coupler hitch latch which can lead to
the trailer coming off of the hitch ball causing serious damage,
injury or death. If pin will not fit into the latch hole, the coupler
is not attached properly. Reset coupler on hitch ball.
4. Connect actuator breakaway cable carabiner to the tow vehicle
only. Do not connect to the safety cables or chains.
5. The breakaway system is designed to only operate after complete
separation from the trailer or if the tongue goes under the rear of
the tow vehicle. The breakaway is not a parking brake. Do not use
as such. If the breakaway is accidentally applied while un-hitching,
insert a at bladed screwdriver into the slot on either side of
the plastic cover on top of the actuator. The screwdriver blade
should go under the spring plate. Pry down on the handle of the
screwdriver to release the spring plate. The E-stop arm should fall
back and down when released.
CAUTION
When resetting the break away system keep hands and fingers
clear as you reset the mechanism, hydraulic pressure held in the
system may cause the assembly to snap back suddenly.
6. Any control devices that restrict operation of the actuator cannot
be used. This includes certain sway control devices. The actuator
must be free to telescope in response to braking requirements.
7. Equalizing or weight distributing hitches may be used, allow six
to eight inches free chain length. DANGER: Tongue weight outside
rating limits will interfere with performance of actuator, and braking
system, and the tow vehicle.
8. Automatic Free-Backing (backing-up without braking action) is
possible with this Actuator when supplied with an electrically operated
Reverse Lock-Out Solenoid or coupled with Free-Backing drum
brakes. To allow Free-Backing without either of those components
installed the Operator must manually Lock-Out the Actuator
movement while backing up. This is accomplished by placing a
7/16 X 5” long bolt (or comparable screwdriver) through the upper
hole provided through the actuator housing. DANGER: FAILURE TO
REMOVE THE BOLT/SCREWDRIVER AFTER BACKING WILL CAUSE
NO BRAKING ACTION IN NORMAL USE. REMEMBER TO ALWAYS
REMOVE THE BOLT/SCREWDRIVER AFTER BACKING THE TRAILER.
9. Important: The supplied, cable
tethered, “Safety Pin” must be
installed in the Coupler Latch hole
(see illustration at right) during
towing at all times.
MAINTENANCE
1. Always check the brake uid reservoir before using trailer. Make
sure it is at least half full. If not, rell to approx. 3/8” below the top
of the reservoir with DOT 3 brake uid. Check for leaks and repair
as required. Never reuse brake uid.
2. To extend coupler and ball life, coat both with a thin coating of
grease. Wipe clean and renew grease lm each time trailer is used.
A zerk tting is installed on the coupler to make this step easier.
3. Examine the actuator for bent parts or wear each time the trailer is
used. Replace parts as necessary.
4. There are no user adjustments on the actuator.
5. After excessive travel the brakes may need adjusted or bled, uid
added to the reservoir, and connections checked for leaks. Adjust
per instructions found in brake installation manual. In general,
back off the adjusters on drum brakes from locked position, as

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©2019 Dexter Axle Company | www.dexteraxle.com 059-Z01-06 2019.10 | 08197
required. Adjust Free-Backing brakes by rotating wheel in forward
direction only. Failure to adjust may result in loss of braking. Disc
brakes do not require adjustment, check for pad wear periodically.
!
CAUTION
The exterior of the actuator and brakes should always be flushed
with fresh water after using trailer in corrosive conditions. This
includes salt water, fertilizers and other corrosive materials.
Before storing trailer remove brakes and clean thoroughly. It
is also wise to repack the bearings at the same time. Failure
to properly and adequately maintain the actuator could cause
serious damage, injury or death.
6. While towing, if the actuator appears to be knocking against the
hitch ball while starting or stopping, check brake uid reservoir and
ll if below 3/8” full from the top.
PLEASE NOTE THE FOLLOWING IMPORTANT INFORMATION ABOUT
MAINTAINING AND OPERATING THE ACTUATOR.
Actuator models designed for disc brakes do not have a check
valve installed. Check valves are required for use with drum brakes.
DO NOT use any actuator designed for drum brakes on a trailer
with disc brakes installed.
Check all system components after breakaway system is used.
Replace any damaged parts with genuine Dexter parts only.
DO NOT REUSE BRAKE FLUID. Always use fresh DOT 3 brake uid
from a fresh container. Failure to maintain proper levels of uid in the
reservoir will cause brake failure. Never use silicone based brake uids.
BLEEDING THE BRAKES
Tools Required – a medium to large size at blade screwdriver, a 3/16”
& a 5/32” hex key wrench, a wrench to t the bleeder valves on your
brakes and brake uid DOT 3. Do not use silicone brake uids. This will
cause seal damage and void your warranty.
1. Secure trailer on level ground. Chock wheels and/or attach trailer
to the tow vehicle to keep the trailer from moving during the
bleeding process
2. Use the hex key wrenches to remove the 3 hex screws holding the
top black plastic cover on top of the actuator (Fig. 1 & 2).
Figure 1 Figure 2
3. Slide the rectangular metal E-stop spring catch backward several
inches (Fig. 3).
4. Fill master cylinder reservoir with DOT 3 brake uid. NEVER reuse
brake uid. Use only new DOT 3 brake uid. Never use silicone
based brake uids (Fig. 4).
Figure 3 Figure 4
5. Insert the at blade screwdriver in the Cable attachment loop, with
the blade of the screwdriver against the E-stop arm. Pull the handle
forward to pump the master cylinder (Fig. 5 & 6).
Figure 5 Figure 6
6. Repeat several times and hold to build pressure to bleed each of the
brakes. Follow manufacturer’s instructions for bleeding the brakes.
7. Check the master cylinder reservoir often. Do not allow the
reservoir to empty. When bleeding is completed, ll reservoir to
within 3/8” from the bottom of the threads. DO NOT OVER FILL.
8. Reassemble E-stop spring latch and cover (Fig. 7-11). Slide spring
catch back into position lining the holes in the plate with the holes in
the cover. Place plastic cover over the plate, apply Loctite® or thread
locker to threads and reinstall the 3 hex head screws.
Figure 7
Figure 8 Figure 9
Figure 10 Figure 11
9. Test brakes in a protected area such as a parking lot or side street.
EMERGENCY STOP CABLE OR E-STOP CABLE
The DX16.5 actuator is supplied with an emergency stop system that
applies the brakes in the unlikely situation were the trailer becomes
disconnected from the tow vehicle. The cable is PVC coated and coiled
for convenience. On one end the cable is connected to a lever arm on
top of the actuator. The other end of the cable has a hook to connect
to the tow vehicle. Should the trailer become disconnected from the
tow vehicle (both coupler and/or chains) the E-stop cable would pull
the lever and activate the master cylinder. A steel spring lock keeps the
pressure on the brakes until manually released.
1. When towing the vehicle, connect the end of the E-stop cable
to the tow vehicle. Never connect the E-stop cable to the safety
chains or cables.
2. Connection point should be a position on the tow vehicle that is
different from the safety cables or chains.

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©2019 Dexter Axle Company | www.dexteraxle.com 059-Z01-06 2019.10 | 08197
WARNING: IT IS POSSIBLE THAT THE E-STOP CAN BE ACTIVATED BY
PULLING ON THE CABLE IN VARIOUS WAYS.
1. Forgetting to disconnect the E-stop cable from the tow vehicle and
pulling tow vehicle away from the trailer. This would pull the lever
and activate the brakes.
2. Stepping on the E-stop cable with enough force to pull the lever
and activate the brakes.
3. Attaching the E-stop hook in a way that is too tight and causes the
cable to be pulled when making turns while towing the trailer.
4. Wrapping the E-stop cable around the actuator or trailer tongue
reducing the amount of free play in the cable.
5. Leaving the E-stop cable dragging on the ground, causing the cable
to grab an object on the road.
RELEASING THE E-STOP
Always check the position of the E-stop lever to make sure it is not in a
locked position. Lever should be able to touch the rear of the slot in the
plastic cover when not activated.
1. Figure 12 shows a released E-stop lever position. Figure 13 shows
an activated E-stop lever position.
Figure 12 Figure 13
2. To release, use a at bladed screwdriver to pry up the steel E-stop
spring (Fig. 14).
Place screwdriver
head under the
spring plate.
Figure 14
3. Insert at bladed screwdriver under the steel spring plate and push
the handle of the screwdriver down, prying the spring plate up to
release the E-stop lever (Fig. 15).
Figure 15
4. E-stop lever should move freely after release (Fig. 16).
Figure 16