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TrailMax TD-40-T Manual

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Section 1. Operation .................................................................................... 3
1.0 Introduction .......................................................................... 3
1.1 Purpose ............................................................................... 3
1.2 Rating .................................................................................. 3
1.3 Design and Safety Factors .................................................. 4
1.4 Vehicle Load and Handling Limits ....................................... 4
1.5 Alert Symbols ...................................................................... 7
1.6 Uncaging Air Brakes ............................................................ 8
1.7 Reporting Safety Defects ................................................... 10
1.8 Pre-Trip Inspection ............................................................ 11
1.9 Hook-Up Procedures ......................................................... 12
1.10 Loading and Unloading ..................................................... 13
Trailers With Ramps ........................................................ 14
Trailers With Tilt Decks ..................................................... 14
Securing Loads With Chains ............................................ 15
Section 2.
Maintenance .............................................................................. 17
2.0
Periodic Maintenance......................................................... 17
2.1
Structural Components ....................................................... 18
Sub-Frame ....................................................................... 18
Deck ................................................................................ 18
2.2
Sub-Assembly Components ............................................... 18
Drawbar Eye .................................................................... 18
Binkley Jack ..................................................................... 19
Cushion Cylinder .............................................................. 19
Deck Latch ....................................................................... 19
Deck Hinge Assembly ...................................................... 19
2.3
Rear Impact Guard (RIG) .................................................... 20
2.4
Running Gear ..................................................................... 21
Suspension ...................................................................... 21
Axle Alignment .................................................................. 23
Axle End Component Disassembly ................................... 23
Hub Inspection .................................................................. 23
Broken or Damaged Studs ............................................... 23
Brake Drum Inspection ..................................................... 24
Brake Drum Troubleshooting Chart ................................... 25
Axle End Component Assembly ........................................ 27
Wheel Bearing Adjustment ................................................ 27
®

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TD-40-T
Table of Contents
Rev. F 06/01/05

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Summary of Contents for TrailMax TD-40-T

  • Page 1: Table Of Contents

    TD-40-T Table of Contents Section 1. Operation ..................3 1.0 Introduction ................3 1.1 Purpose ................3 1.2 Rating .................. 3 1.3 Design and Safety Factors ..........4 1.4 Vehicle Load and Handling Limits ........4 1.5 Alert Symbols ..............7 1.6 Uncaging Air Brakes ............
  • Page 2 TD-40-T Section 2. Maintenance ..............Continued Wheel Bearing Lubrication ..........27 Wheels and Tires ..............27 Wheels ................27 Wheel Torquing Procedures ..........28 Tires ................. 29 Inflation Pressure .............. 29 Tire Wear Diagnostic Chart ..........30 Electrical ................31 Harnesses and Lights ............

  • Page 3: Section 1. Operation

    TD-40-T Section 1. Operation Introduction This section describes how trailers can have different operational characteristics based on design, load configuration, gross weights, suspension characteristics, articu- lation and extreme differences between loaded and unloaded weights. Trailers have safe operating limits just as automobiles, airplanes, and other ve- hicles.

  • Page 4: Design And Safety Factors

    TD-40-T Design and Safety Factors The safety factor is a ratio between the design stress imposed by the load sitting static on the trailer and the minimum yield stress of the steel used in construction of that trailer structure. For example, if the structure is built using 50,000 psi minimum yield strength steel and the load sitting on it causes a stress level of 25,000 psi then a 2:1 safety factor would exist.
  • Page 5 TD-40-T Overloading a vehicle should never be permitted. Overloading results in tire blow- outs, spring breakage, frame damage, diminished braking capacity, and will severely alter the vehicle’s normal handling characteristics. All vehicles are designed with a maximum load capability. To best utilize these vehicles in the safest manner the loads as shown on the certificate label should not be exceeded.
  • Page 6 TD-40-T Weather conditions can be a major factor in the cause of accidents. Rain, ice, snow, high winds and visibility combined with excessive speed, sudden lane changes, or other factors that put lateral forces into a tow vehicle trailer combination contribute significantly to an accident.

  • Page 7: Alert Symbols

    TD-40-T Alert Symbols It is important that you know the meaning of the following symbols that are used throughout this document. SAFETY ALERT! This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

  • Page 8: Uncaging Air Brakes

    TD-40-T Uncaging Air Brakes Air brakes are designed with a safety feature called a spring brake, so that if no air pressure is present in the system springs will apply force to the brake system linkages and apply the brakes. To allow the trailer to be moved during shipping a release tool assembly is installed in each of the spring brake cans to prevent the brakes from being applied.
  • Page 9 TD-40-T Spring Brake Chamber Rubber Seal Release Tool Assembly (in storage position) Release Tool Assembly Operation ® page 9...

  • Page 10: Reporting Safety Defects

    TD-40-T Reporting Safety Defects If you believe that your vehicle has a defect that could cause a crash, injury, or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Gem State Mfg., Inc.

  • Page 11: Pre-Trip Inspection

    TD-40-T Pre-Trip Inspection There are some items on every vehicle combination that can be and should be inspected prior to every trip that require no special knowledge, training, or sophisti- cated equipment. Before beginning a trip, make a thorough visual inspection of the trailer for cracks in the structure, or bent components such as the tongue or frame.

  • Page 12: Hook-Up Procedures

    TD-40-T Hook-Up Procedures TRAILER HOOK-UP WARNING The consequences of not properly hooking the trailer to the tow vehicle can be very serious. Failure to adhere to information in this section could lead to the trailer becoming detached, the trailer brakes and/or lights not working correctly, or other unsafe situations which could result in an acci- dent causing property damage, bodily injury or death.

  • Page 13: Loading And Unloading

    TD-40-T 1.10 Loading and Unloading TRAILER LOADING PRACTICES CAUTION The consequences of ignoring proper trailer loading practices can be very serious. Failure to adhere to the information in this section could lead to unsafe handling, diminished braking capacity, or other unstable trailer characteristics which could result in an accident causing property damage, bodily injury or death.

  • Page 14: Trailers With Ramps

    TD-40-T Always use extreme caution when loading and unloading equipment on trailer. Make sure road surface is level. Loading and unloading on an uneven surface may cause damage to the trailer frame and create unsafe loading conditions. Always set brakes on tow vehicle and trailer before loading and unloading and use chock blocks as an added safety precaution.

  • Page 15: Securing Loads With Chains

    TD-40-T Securing Loads With Chains NOTE: Only 5/16” or 3/8” Grade 70 Transport Chain is to be used with chain slots When securing loads with chains, the chains should not exceed angles shown in illus- trations below. Viewed from above, chain should not be angled more than 45 degrees in either direc- tion of chain slot.
  • Page 16 TD-40-T THIS PAGE LEFT BLANK INTENTIONALLY ® page 16...

  • Page 17: Maintenance

    TD-40-T Section 2. Maintenance Periodic Maintenance New Trailer Break-in 50 to 100 miles- re-torque wheel flange nuts- see page 28. 1000 miles- check axle alignment and re-torque suspension fasteners- see page Pre-Trip Inspection Lube wear areas on hitch. Examine frame and tongue members for evidence of damage or cracked welds.

  • Page 18: Structural Components

    TD-40-T Structural Components Sub-Frame Other than for periodic or special inspections the trailer sub-frame requires no regular maintenance other than washing. Keeping the trailer clean will help you notice other things such as cracked welds or corrosion. If your application requires the hauling of corrosives then frequent washdowns are very important.

  • Page 19: Binkley Jack

    TD-40-T Binkley Jack Every six months, lubricate the jack in the following manner: 1. Extend the leg approximately 2 inches from the fully retracted position. 2. Add pound molybdenum grease (with a temperature rating suitable for your operating conditions) to each of the grease fittings. For 2-speed jacks there are two on the gear leg, one on the swivel pad and one on the gear box.

  • Page 20: Rear Impact Guard (Rig)

    TD-40-T Rear Impact Guard (RIG) Your trailer may be fitted with an energy absorbing RIG system that retracts auto- matically when the deck is tilted for loading and unloading. An elastomeric torsion block assembly is part of the system and absorbs the excess travel of the retraction hardware.

  • Page 21: Running Gear

    TD-40-T Running Gear Suspension The suspension on your trailer is a heavy duty, leaf spring, underslung type. The leaf springs are not directly attached to the trailer, but are free to float against the wear pads of the hangers and rockers. Adjustable radius rods are employed to keep the axles in alignment.
  • Page 22 TD-40-T TORQUE REQUIREMENTS! WARNING Follow all torque requirements! Do not use any component with visibly worn or damaged threads. Failure to follow these safety alerts can lead to loss of vehicle control, property damage, serious personal injury or death. Item...

  • Page 23: Axle Alignment

    TD-40-T Axle Alignment Verify that the forward axle is centered on the trailer; W . Check the distance from the coupler or faceplate center to the forward axle end on both sides, and adjust the left radius rod if necessary (the right radius rod is of fixed length) so that X...

  • Page 24: Brake Drum Inspection

    TD-40-T Brake Drum Inspection Clean and inspect the brake drums whenever relining the brakes. To be suitable for further service, the brake drum should pass the following checks: 1. The brake surface should be free of scoring, excessive heat checks and free of cracks.

  • Page 25: Brake Drum Troubleshooting Chart

    TD-40-T Brake Drum Troubleshooting Chart PROBLEM CAUSE REMEDY REPLACE SEAL. CLEAN OIL STAINED DRUMS LEAKING SEAL DRUMS & REPLACE LININGS. LIGHT HEAT CHECK NORMAL CONDITION MACHINE EXCESSIVE HEAT FROM MACHINE BRAKE DRUM. DRAGGING BRAKES OR BLUE OR DISCOLORED CHECK RETURN SPRINGS...

  • Page 26: Brake Drum Troubleshooting Chart (Continued)

    TD-40-T Brake Drum Troubleshooting Chart (continued) PROBLEM CAUSE REMEDY ABRASIVE FOREIGN MACHINE OR REPLACE MATERIAL OR POOR BRAKE DRUM AND QUALITY BRAKE LINING REPLACE LINING FINE GROOVES LOOSE RIVETS OR BOLTS MACHINE OR REPLACE OR FOREIGN MATERIAL BRAKE DRUM. USE RIVET IN RIVET HOLES HOLE PLUGS.

  • Page 27: Axle End Component Cleaning And Inspection

    TD-40-T Axle End Component Cleaning and Inspection Refer to the Meritor Maintenance Manual 14, Trailer Axles, Section 3. Axle End Component Assembly Refer to the Meritor Maintenance Manual 14, Trailer Axles, Section 4. Wheel Bearing Adjustment Refer to the Meritor Maintenance Manual 14, Trailer Axles, Sections 8 and 9.

  • Page 28: Wheel Torquing Procedures

    TD-40-T 6. Offset. This refers to the relationship of the center line of the tire to the hub face of the axle. Care should be taken to match a replacement wheel with the same offset wheel as originally equipped. Failure to match offset can result in reduced carrying capacity of your axle.

  • Page 29: Tires

    TD-40-T Tires Before mounting tires onto 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 30: Tire Wear Diagnostic Chart

    TD-40-T Tire Wear Diagnostic Chart Wear Pattern Cause Corrective Action Center Wear Over inflation Adjust pressure to particular load per tire catalog Edge Wear Under inflation Adjust pressure to particular load per tire catalog Side Wear Loss of camber or...

  • Page 31: Electrical

    TD-40-T Electrical Harnesses and Lights The electrical harnesses in the trailer run within the frame members and require no maintenance. The oval stop/turn/tail lights and the round clearance lights are all of the sealed type and do not have a separately replaceable bulb. If a light stops working, first check the plug at the light for voltage (with a test lamp or volt meter) to verify that the electrical system is functioning properly.

  • Page 32: Brake System

    TD-40-T Brake System An air brake system is installed on your trailer. The front and rear axles (tandem) or center and rear axles (triple) have brake cylinders with spring brake chambers. Vehicle safety is enhanced through the use of an Anti-Lock Braking System (ABS) that controls the brakes on the front axle (tandem) or center axle (triple).
  • Page 33 TD-40-T a. Measure the applied stroke. Using a ruler, measure the distance from the face of the air chamber to the center of the large pin in the clevis. (Another method is to mark the shaft where it exits the chamber). Make a 100 psi brake application and allow the chamber pushrod to travel to its maximum stroke.

  • Page 34: Manual Brake (Free Stroke) Adjustment

    TD-40-T Manual Brake (Free Stroke) Adjustment DISENGAGING THE PAWL! CAUTION You must disengage a pull pawl or remove a conventional pawl before rotating the manual adjusting nut, or you will damage the pawl teeth. A damaged pawl will not allow the slack adjuster to automatically adjust brake clearance.

  • Page 35: Slack Adjuster Function Test

    TD-40-T Slack Adjuster Function Test 1. Remove the slack adjuster from the axle. 2. Using a torque wrench that measures in lb-in., rotate the adjusting nut counter- clockwise 22 turns. This is enough turns of the adjusting nut to rotate the camshaft gear 1 full revolution.

  • Page 36: Parts

    TD-40-T Section 3. Parts Structural Components Sub-frame Ref. Quantity Description................. Part No. Sub-frame Assembly ............SA-02107 Safety Chain and Hook Assembly ........" ASSY *Front Hanger ............... 7701-01 *Rocker Hanger ..............16319-01 *Rear Hanger ............... 7703-01 *Lower Latch Side Plate ............C-04019 Tool Box Lid Assembly ............

  • Page 37: Deck Assemblies

    Deck Lumber ..............2-1/8 X 8 24' Deck Lumber ...............2-1/8 X 10 10' Deck Lumber ...............2-1/8 X 10 24' Deck Lumber ...............2-1/8 X 12 10' TrailMax Mudflap ..............B30PCB Mudflap Bracket ............... MFW 2375 Torx Deck Screws, -20 x 3 ........... 32523 *Upper Latch Assembly .............

  • Page 38: Major Sub-Assemblies

    TD-40-T Major Sub-Assemblies Drawbar Eye Ref. Quantity Description................. Part No. Premier 300 Drawbar Eye ............300 “ x 2- “ Bolt Grade 8 NF .............18992 “ Lock Washer ..............33632 “ Hex Nut Grade 8 NF ............36466 Parts ® page 38...

  • Page 39: Binkley 2-Speed Jack

    TD-40-T Binkley 2-Speed Jack Ref. Quantity Description................. Part No. Binkley 2-Speed Jack ............LG4701-72 Universal Crank ...............LG0083-01 Jack Handle Extension ............SA-04291 Parts ® page 39...

  • Page 40: Cushion Cylinder

    TD-40-T Cushion Cylinder Ref. Quantity Description................. Part No. Cushion Cylinder, 5 X 12 ............5012 Parts ® page 40...
  • Page 41 TD-40-T THIS PAGE LEFT BLANK INTENTIONALLY Parts ® page 41...

  • Page 42: Upper & Lower Latch Assemblies

    TD-40-T Deck Latch Assembly Ref. Quantity Description ................. Part No. Upper Latch Assembly " x 1- " Adjusting Bolt ............ 15359 Latch Hook ..............C-04109 Glide Latch Bearing ..........GFI-1618-08 Latch Pin ................ C-06050 E-clip SE 982 D ............10385-00128 Lower Latch Assembly Latch Arm Assembly ............
  • Page 43 TD-40-T Upper Latch Assembly Lower Latch Assembly ® page 43...

  • Page 44: Deck Hinge Assembly

    TD-40-T Deck Hinge Assembly Ref. Quantity Description................. Part No. Deck Hinge Assembly ............SA-04027 Hinge Bracket Assembly ........... SA-07099 Hinge Pin ................C-06179 3/8-24 Top Lock Nut Gr. C Zinc ..........37304 3/8-24 x 3 1/2 Cap Screw Gr. 8 Zinc ........18846 Grease Fitting .................

  • Page 45: Rear Impact Guard (Rig) Assembly

    TD-40-T Rear Impact Guard (RIG) Assembly Ref. Quantity Description ................. Part No. Rear Impact Guard Assembly ........SA-09248 RIG Light Bracket Assembly ......... SA-14534 Hinge Pin Assembly ............. SA-12382 RIG Pushrod ..............SA-12514 Pushrod Bolt ( " x 3” shackle bolt) ..........B-3 Pushrod Nut ( shackle bolt) ............

  • Page 46: Running Gear

    TD-40-T Running Gear For: Brakes Bearings and Hubs Axle End Components Refer to the Meritor Maintenance Manual 14, Trailer Axles and call Gem State Manufac- turing at 1-800-447-0213. Suspension Ref. Quantity Description ................... Part No. Axle Assembly, Front (ABS) ..........TN4271QH6815 Axle Assembly, Rear (non ABS) .........
  • Page 47 TD-40-T Parts ® page 47...

  • Page 48: Axle End Components

    TD-40-T Axle End Components, 17.5 Ref. Quantity Description ................. Part No. RH Camshaft..............2210D6166 LH Camshaft ..............2210C6165 Camshaft Repair Kit ................... Kit 8048 Camshaft Spacer Washer .......... 1229-X-3318 Spider Seal ............... 1205-V-1452 Camshaft Retainer Washer .......... 1229-J-868 Retaining Ring ............1229-X-1116 Bracket Assembly ............
  • Page 49 TD-40-T Parts ® page 49...

  • Page 50: Brakes

    TD-40-T Brake Components, 17.5 Ref. Quantity Description ................. Part No. Brake Shoe and Lining ............E-3491-88 Brake Repair Kit..................Kit 8004 Roller ..............2297-C-5021 Roller Pin ..............1246-F-1020 Snap Ring ............... 1229-T-3166 Anchor Pin ..............1259-N-274 Anchor Pin Bushing ........... 1225-B-496 Return Spring Pin ............

  • Page 51: Bearings And Hubs

    TD-40-T Bearing and Hub Components, 17.5 Ref. Quantity Description ................. Part No. Oil Seal ................... 46300 Inner Bearing Cone ............HM218248 Inner Bearing Cup ............HM218210 Wheel Stud ................E-5997 Wheel Hub, Non-ABS ..........Hayes 450002 Wheel Hub, ABS ..........Webb 20271CW3T-80 Brake Drum..............

  • Page 52: Wheels And Tires

    TD-40-T Wheels and Tires Ref. Quantity Description................. Part No. Tire ................215/75R 17.5 Wheel, 17.5 x 6.75HC ......... P617-0778-B8-W4 Valve Stem .................. 572 22mm x 1.5 Wheel Nut ............R005991 Note: Tires are not available through Gem State Manufacturing; contact your local equip- ment tire retailer for replacement parts.
  • Page 53 TD-40-T THIS PAGE LEFT BLANK INTENTIONALLY Parts ® page 53...

  • Page 54: Electrical

    TD-40-T Electrical Harnesses and Lights Ref. Quantity Description................. Part No. E-18 Electrical Kit ..............K02863 Harness, Front Main ............88776 Harness, Main Feed ............88774 Harness, Center Main ..........88775 0344 Harness, Rear Impact Guard ..........95582 Harness, Stationary Deck Marker ........88356 Harness, Marker ............88355 0140...

  • Page 56: Electrical Plug

    TD-40-T Electrical Plug Ref. Quantity Description................. Part No. Seven Way Plug and Spring ..........PL 15-730 White- Blue- Ground ECU Power/Electric Brakes Black- Brown- Accessories Tail and Marker Yellow- Green- Right Turn Left Turn Red- Stop Parts ® page 56...
  • Page 57 TD-40-T THIS PAGE LEFT BLANK INTENTIONALLY Parts ® page 57...

  • Page 58: Air Brake System

    TD-40-T Air Brake System Because of the complexity of the air brake system, the components are displayed graphically over the next several pages. Ref. Quantity Description................. Part No. Tandem Axle Air Kit/ABS ........AK-A2 ABS-PC Service Gladhand ............PL12-006 Emergency Gladhand ........... PL12-008 Hose Assembly, 1 /2"...
  • Page 59 TD-40-T Detail shown on follow- ing pages. Parts ® page 59...
  • Page 60 14 15 Hose end fitting (Hidden under tank) included with " hose assemblies.
  • Page 61 (Hidden between ECU and tank)

  • Page 62: Warranty Claim Procedure

    (Digital photo’s can be sent via e-mail to customerservice@trailmax.com in *.jpg or *.jpeg format.) 3. Contact a TrailMax representative in your immediate area. If you do not have or can not find a representative in your area, then contact the factory Warranty Administrator for as- sistance @ 1-800-447-0213.

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