Table of Contents
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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
Reporting Safety Defects ............................................................. 7
1.6
Alert Symbols ................................................................................ 8
1.7
Pre-Trip Inspection........................................................................ 9
1.8
Hook-Up Procedures .................................................................. 10
1.9
Loading and Unloading .............................................................. 11
Trailers With Ramps ................................................................. 12
Trailers With Tilt Decks ............................................................. 12
Section 2. Maintenance .............................................................................. 13
2.0
Periodic Maintenance ................................................................. 13
2.1
Structural Components ............................................................... 14
Sub-Frame ................................................................................ 14
Deck .......................................................................................... 14
2.2
Sub-Assembly Components ....................................................... 14
Coupling ................................................................................... 14
Jack .......................................................................................... 15
Cushion Cylinder ...................................................................... 15
Deck Latch ................................................................................ 15
Deck Hinge Assembly............................................................... 15
2.3
Running Gear ............................................................................. 16
Suspension ............................................................................... 16
Hubs and Drums ....................................................................... 16
Brake Drum Inspection ............................................................. 17
Bearing Inspection .................................................................... 17
Standard Bearing Lubrication ................................................... 18
E-Z Lube Bearing Lubrication .................................................. 18
Seal Inspection and Replacement ........................................... 19
Hub Reinstallation and Bearing Adjustment ............................ 19
2.4
Wheels and Tires ........................................................................ 20
Wheels ..................................................................................... 20
Tires .......................................................................................... 22
Inflation Pressure ..................................................................... 22
Tire Wear Diagnostic Chart ...................................................... 23
2.5
Electrical ..................................................................................... 24
Harnesses and Lights ............................................................... 24
Junction Block .......................................................................... 24
Electrical Plug ........................................................................... 24
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T-16-UT (4+16)
Table of Contents
page 1
Contents
Revision B 01/19/05
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Table of Contents
Troubleshooting
Related Manuals for TrailMax T-16-UT (4+16)
Summary of Contents for TrailMax T-16-UT (4+16)
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Page 1: Table Of Contents
T-16-UT (4+16) Table of Contents Section 1. Operation ..................3 Introduction ................... 3 Purpose ..................3 Rating.................... 3 Design and Safety Factors ............4 Vehicle Load and Handling Limits ..........4 Reporting Safety Defects ............. 7 Alert Symbols ................8 Pre-Trip Inspection................ - Page 2 T-16-UT (4+16) Brake System (Common to Hydraulic and Electric) ....25 Brake Adjustment ..............25 Brake Cleaning and Inspection ..........26 Brake Lubrication ..............26 Hydraulic Brake System .............. 27 Operation .................. 27 Surge Actuator Maintenance ............. 27 Corrosive Environment Warning ..........28 Hydraulic Lines................
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Page 3: Section 1. Operation
T-16-UT (4+16) 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
T-16-UT (4+16) 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 T-16-UT (4+16) 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 T-16-UT (4+16) 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.
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Page 7: Reporting Safety Defects
T-16-UT (4+16) 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. If NHTSA receives similar complaints it may open an investigation, and if it finds that a safety defect exists in a group of vehicles it may pursue a remedy campaign and recall those vehicles. -
Page 8: Alert Symbols
T-16-UT (4+16) Alert Symbols It is important that your 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 9: Pre-Trip Inspection
T-16-UT (4+16) 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 10: Hook-Up Procedures
T-16-UT (4+16) Hook-Up Procedures WARNING TRAILER HOOK-UP 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 11: Loading And Unloading
T-16-UT (4+16) The ‘surge’ or ‘push’ of the trailer toward the tow vehicle when the tow vehicle brakes are applied actuates the trailer brakes. Excessive surge actuator travel (over one inch) when brakes are applied indicates a need to adjust the trailer brakes. Should the breakaway be accidentally applied while unhitching, pry the breakaway locks apart to release lever. -
Page 12: Trailers With Ramps
T-16-UT (4+16) 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 dam- age 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 13: Section 2. Maintenance
T-16-UT (4+16) Section 2. Maintenance Periodic Maintenance Pre-Trip Inspection- Check brake fluid level- see ‘Surge Actuator Maintenance’ on page 27. Lube coupler- see ‘Coupling’ on page 14. Examine frame and tongue members for evidence of damage or cracked welds. Check lights for correct operation. Weekly-Weekly- Check cold tire pressures- see ‘Inflation Pressure’... -
Page 14: Structural Components
T-16-UT (4+16) 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 leaking brake fluid. If your application requires the hauling of corrosives then frequent washdowns are very important. -
Page 15: Jack
T-16-UT (4+16) Jack As necessary, grease the jack lead screw using the following procedure: 1. Fully extend the jack and apply grease to the lead screw through the grease port (hole) in the side of the jack body. 2. Cycle the jack up and down several times to distribute the grease on the screw. The following three sub-sections pertain to trailers with tilt decks- Cushion Cylinder The fluid in the cylinder should be changed if the cylinder has leaked or if the deck... -
Page 16: Running Gear
T-16-UT (4+16) Running Gear Suspension The suspension on your trailer is either a rubber torsion axle type or the slipper leaf spring type. Rubber torsion suspensions require no maintenance. Slipper springs have an eye formed in one end of the spring only with the other end formed into a reverse curve. -
Page 17: Brake Drum Inspection
T-16-UT (4+16) 4. Remove the cotter pin from the spindle nut. 5. Unscrew the spindle nut and remove the spindle washer. 6. Remove the hub from the spindle, being careful not to allow the outer bearing cone to fall out. The inner bearing cone should be retained by the grease seal. Brake Drum Inspection The critical surface of the brake drum is the contact area for the brake shoes during stopping. -
Page 18: Standard Bearing Lubrication
T-16-UT (4+16) Bearing Lubrication Wheel end lubricant should be replaced periodically as described earlier in this sec- tion. Follow these guidelines for lubricant replacement: 1. If possible, wash down the area around the wheel end thoroughly. 1. Place a clean container under the axle cap. 2. -
Page 19: Hub Reinstallation And Bearing Adjustment
T-16-UT (4+16) Hub Reinstallation and Bearing Adjustment The objective of this procedure is to attain 0.001" to 0.010" end play. 1. Place the hub (with inner bearing set and oil seal installed), outer bearing and adjust- ing nut (inner spindle nut) back on the spindle in the reverse order of removal. Rotate the hub assembly in both directions while tightening the adjusting nut to approximately 100 lbs.-ft. -
Page 20: Wheels And Tires
T-16-UT (4+16) Wheels and Tires Wheels Wheels are a very important and critical component of your running gear. Inspect them visually for cracks or elongated bolt holes whenever they are removed for any reason. If it becomes necessary to replace the wheels on your trailer, be certain that the replacement units match the originals in the following regards: 1. -
Page 21: Tires
T-16-UT (4+16) When installing the wheels, make sure that the hub and wheel mating surfaces are clean and free of rust, dirt and excess paint. The studs and threads must be clean, dry and in good condition for applying installation torque. Tighten the lug nuts in the following pattern in three steps- first to 20-25 lbs.-ft., next to 50-60 lbs.-ft., and then to the final torque of 275 to 325 lbs.-ft. -
Page 22: Inflation Pressure
T-16-UT (4+16) 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 23: Tire Wear Diagnostic Chart
T-16-UT (4+16) 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 Adhere to load over loading limits. -
Page 24: Electrical
T-16-UT (4+16) 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 connection at the light for voltage (with a test lamp or volt meter) to verify that the electrical system is functioning properly. -
Page 25: Brake System (Common To Hydraulic And Electric)
T-16-UT (4+16) Brake System (Common to Hydraulic and Electric) CAUTION ASBESTOS DUST HAZARD! Since some brake shoe friction materials contain asbestos, certain pre- cautions need to be taken when servicing brakes: 1. Avoid creating or breathing dust. 2. Avoid machining, filing or grinding the brake linings. 3. -
Page 26: Brake Cleaning And Inspection
T-16-UT (4+16) 5. Replace the adjusting hole cover and lower the wheel to the ground. 6. Repeat the above procedure on all brakes. Brake Cleaning and Inspection Your trailer brakes must be inspected and serviced at yearly intervals or more often as use and performance requires. -
Page 27: Hydraulic Brake System
T-16-UT (4+16) Hydraulic Brake System Operation The hydraulic brakes on your trailer are much like those on your car. The hydraulic brake fluid from a master cylinder is used to actuate the wheel cylinder which, in turn, applies force against the brake shoes and drum. The main difference between automo- tive hydraulic brakes and hydraulic trailer brakes is the actuation system which transfer the braking signal from the tow vehicle to the brakes. -
Page 28: Corrosive Environment Warning
T-16-UT (4+16) Corrosive Environment Warning CORROSIVE ENVIRONMENTS! WARNING Saltwater, granular fertilizers and other corrosive materials are destruc- tive to metal. To prolong the life of a braking system used under corrosive conditions the actuator should be flushed after use with a high pressure water hose. -
Page 29: Brake System Bleeding
T-16-UT (4+16) Brake System Bleeding The preferred method for bleeding air out of the brake hydraulic system is to use a pressure-type brake bleeder. Follow the manufacturers directions for using the bleeder. To bleed the brakes manually, proceed as follows: 1. - Page 30 T-16-UT (4+16) Hydraulic Brake System Troubleshooting Chart REMEDY CAUSES SYMPTOM CAUSES REMEDY BROKEN OR KINKED REPAIR OR REPLACE ADJUST BRAKES UNDERADJUSTMENT BRAKE LINE SEVERE ADJUST BRAKES LUBRICATE LACK OF LUBRICATION NO BRAKES UNDERADJUSTMENT BROKEN BRAKE MALFUNCTIONING TROUBLESHOOT SYSTEM REPLACE COMPONENTS NOISY BRAKES COMPONENTS ACTUATION SYSTEM...
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Page 31: Hydraulic Brake System Troubleshooting Chart
T-16-UT (4+16) Electric Brake System Operation The electric brakes on your trailer are similar to the drums brakes on your automo- bile. The basic difference is that your automotive brakes are actuated by hydraulic pressure while the electric brakes are actuated by an electromagnet. With all of the brake components connected into the system, the brake will operate as follows: 1. -
Page 32: Using Your Brakes Properly
T-16-UT (4+16) Increasing the current flow to the electromagnet causes the magnet to grip the armature surface of the brake drum more firmly. This results in increasing the pressure against the shoes and brake drums until the desired stop is accomplished. Using your Brakes Properly Your trailer brakes are designed to work in synchronization with your tow vehicle brakes. -
Page 33: Synchronization
T-16-UT (4+16) Synchronization To insure safe braking performance and synchronization, read the brake controller manufacturer’s instructions completely before attempting any synchronization proce- dure. ROAD SAFETY! CAUTION Before making road tests, make sure that the area is clear of vehicular and pedestrian traffic. The purpose of these tests is to adjust the brakes for safe operation, and therefore you should expect that initial braking action make be weak or irregular. -
Page 34: Magnets
T-16-UT (4+16) CONTROLLER PARAMETERS! CAUTION Do not adjust the brake controller outside the parameters outlined by the controller manufacturer’s instructions. Controller* Brake Timing Adjustment Brake Force Adjustment Tekonsha Level Gain (9010,20,30,55) Kelsey 81741A Level Gain Draw-Tite 5100 Sync Output *See manufacturer’s instructions Magnets Your electric brakes are equipped with high quality electromagnets that are de- signed to provide the proper input force and friction characteristics. -
Page 35: Electric Brake System Troubleshooting
T-16-UT (4+16) Electric Brake System Troubleshooting Most electric brake system malfunctions that cannot be corrected by either brake adjustments or synchronization adjustments can generally be traced to electrical sys- tem failure. Mechanical causes are ordinarily obvious, i.e. bent or broken parts, worn out linings or magnets, seized lever arms or shoes, scored drums, loose parts, etc. - Page 36 T-16-UT (4+16) From Trailer Harness VOLTMETER To measure VOLTAGE, measure across both brake magnet wires. From Trailer Harness AMMETER To measure AMPERAGE, measure between one open brake magnet wire. Maintenance ® page 36...
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Page 37: Measuring Amperage
T-16-UT (4+16) Measuring Amperage System amperage is the amperage being drawn by all the brakes on the trailer. The engine of the tow vehicle should be running when checking the amperage. One place to measure system amperage is at the BLUE wire of the controller which is the output to the brakes. -
Page 38: Electric Brake System Troubleshooting Chart
T-16-UT (4+16) Finding a system short is a matter of isolation. If the high amperage reading drops to zero by unplugging the trailer, the short is in the trailer. If the amperage reading remains high with all the brake magnets disconnected, the short is in the trailer wiring. All electrical troubleshooting procedures should start at the controller. - Page 39 T-16-UT (4+16) Electric Brake System Troubleshooting Chart REMEDY CAUSES SYMPTOM CAUSES REMEDY WRONG MAGNET LEAD FIND AND CORRECT OPEN CIRCUITS CORRECT WIRE COLOR SEVERE ADJUST BRAKES NO BRAKES INCORRECT ADJUSTMENT ADJUST UNDERADJUSTMENT BRAKES PULL TO GREASE OR OIL ON CLEAN OR REPLACE TEST AND CORRECT FAULTY CONTROLLER ONE SIDE...
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Page 40: Pre-Storage Maintenance
T-16-UT (4+16) Pre-Storage Maintenance If your trailer is to be stored for an extended period of time or over the winter, it is important that the trailer be prepared properly. 1. Give the trailer a thorough wash down and let it dry completely. 2. -
Page 41: Pre-Season Maintenance
T-16-UT (4+16) 2.10 Pre-Season Maintenance Before removing the trailer from the jack stands: 1. Remove all wheels and hubs (brake drums). Note which spindles the drums were removed from so that they can be reinstalled in the same location. 2. Inspect the suspension for wear and corrosion and correct any discrepencies. 3. -
Page 42: Parts
T-16-UT (4+16) Section 3. Parts Structural Components Ref. Quantity Description................. Part No. Safety Chain and Hook Assembly ........" ASSY Fender Assembly .............. SA-05139 Right Hand Tail Light Bracket ..........SA-12779 Left Hand Tail Light Bracket ..........SA-14218 D-ring ..................B-48 ®... - Page 43 T-16-UT (4+16) Parts ® page 43...
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Page 44: Major Sub-Assemblies
T-16-UT (4+16) Deck Surface Wood Deck Ref. Quantity Description ................. Part No. Deck Lumber, 1-1/2” x 10” x 16’ ........1 1/2x10 16’ Deck Lumber, 1-1/2” x 12” x 16’ ........1 1/2x12 16’ Torx Deck Screws, -20 x 2- "... -
Page 45: Hammerblow Drop Leg Jack
T-16-UT (4+16) Hammerblow Drop Leg Jack Ref. Quantity Description ................. Part No. Jack Assembly with Crank ............. 182304 Inner Ram and Drop Leg Assembly ........701165 Screw and Nut Assembly ............712216 Crank Assembly Kit ............800075 Screw, Nut, and Bearing Replacement Kit ....... 500220 Note: Kit names are bold type while component names are regular type;... -
Page 46: Couplers
T-16-UT (4+16) Couplers Ref. Quantity Description ................. Part No. " Coupler ................. 75074 Parts ® page 46... - Page 47 T-16-UT (4+16) Ref. Quantity Description ................. Part No. Pintle Eye ................BDB 1250 Note: Pintle Eye and associated hardware is an available option. Parts ® page 47...
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Page 48: Deck Latch Assembly
T-16-UT (4+16) Deck Latch Assembly Ref. Quantity Description ................. Part No. Foam Grip Latch Handle ............. 9282K19 Latch Handle Assembly ............ SA-01090 " x 1- " Roll Pin ..............64311 " Bail Pin ..............10385-00164 4" x 4" x " Slider Block ............C-01170 "... -
Page 49: Cushion Cylinder
T-16-UT (4+16) Cushion Cylinder Ref. Quantity Description................. Part No. Cushion Cylinder ..............30x12 Parts ® page 49... -
Page 50: Running Gear
T-16-UT (4+16) Running Gear Suspension, 8K Ref. Quantity Description................. Part No. 8000# Rubber Torsion Axle ..........7800127 Parts ® page 50... - Page 51 T-16-UT (4+16) THIS PAGE LEFT BLANK INTENTIONALLY Parts ® page 51...
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Page 52: Hydraulic Brake Components, 8K
T-16-UT (4+16) Hydraulic Brake Components, 8K Ref. Quantity Description................. Part No. LH Complete Brake Assembly FSA US ......023-418-00 RH Complete Brake Assembly FSA US ......023-419-00 *Dust Shield ..............036-115-20 Retainer ................069-053-00 LH Shoe & Lining Kit Containing: 1 #040-199-01 LH Prim. - Page 53 T-16-UT (4+16) Parts ® page 53...
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Page 54: Electric Brake Components, 8K
T-16-UT (4+16) Electric Brake Components, 8K Ref. Quantity Description................. Part No. LH Complete Brake Assembly......... 023-434-00 RH Complete Brake Assembly ........023-435-00 LH Shoe & Lining Kit Containing: 1 #040-350-01 LH Prim. Shoe & Lining 1 #040-351-02 LH Sec. Shoe & Lining ......K71-499-00 RH Shoe &... - Page 55 T-16-UT (4+16) Parts ® page 55...
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Page 56: Axle End Components
T-16-UT (4+16) Axle End Components Ref. Quantity Description................. Part No. Oil Seal ................010-063-00 Inner Bearing Cone ............031-030-02 Inner Bearing Cup ............031-030-01 Wheel Stud ..............007-232-00 Brake Drum (8 stud on 6.5" circle) ........008-285-10 Oil Filler Plug ..............046-052-00 Outer Bearing Cup ............ -
Page 57: Wheels And Tires
T-16-UT (4+16) Wheels and Tires Ref. Quantity Description................. Part No. Tire................215/75R 17.5 Wheel ..................17-240 Wheel Nut, "-20, 60° ............... 6-58 Note: Tires are not available through Gem State Manufacturing; contact your local equipment tire retailer for replacement parts. Parts ®... -
Page 58: Electrical
T-16-UT (4+16) Electrical Harnesses and Lights Ref. Quantity Description ................. Part No. E-7 Electrical Kit (Special) ..........K01928A Red Clearance Lamp, sealed .......... 10205R Mounting Grommet ............10704 Amber Clearance Lamp, sealed ........10205Y Oval Stop/Turn/Tail Light, sealed ........60202R Oval Mounting Grommet ............. 60700 License Plate Lamp ............ - Page 59 T-16-UT (4+16) Parts ® page 59...
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Page 60: Electrical Plug
T-16-UT (4+16) Electrical Plug Ref. Quantity Description ................. Part No. Seven Way RV Plug ............... 12-706 Black (Electric Brake Only)- Accessories Brown- Tail and Marker Yellow- Green- Left Turn Right Turn White- Red- Ground Stop Black (Surge Brakes Only)- Vehicle Back Up Lights Note: For surge brake equipped trailers - Wire from tow vehicle back up lights must be connected to center post of vehicle’s mating plug end. -
Page 61: Electric Brake Wiring
T-16-UT (4+16) Electric Brake Wiring Ref. Quantity Description ................. Part No. E-8 Brake Harness Kit ............K00769 Brake Harness ............51362 0012 Brake Harness ............51362 0096 Magnet Pigtail ..............94619 Note: Kit names are bold type while component names are regular type; kit compo- nents, if itemized, are indexed under the kit name. -
Page 62: Hydraulic System
T-16-UT (4+16) Hydraulic System Hydraulic Lines Ref. Quantity Description................. Part No. Surge Line Kit ..............0716-001 Brake Hose, 13" ............18013-MF Brake Hose, 13" ............18013-FF Hose Bracket ..............25 x 15 Hose Clip ................1457 Adapter Tee ................7900 Union Tee with Bracket ............7812 Brake Line, 126"... - Page 63 T-16-UT (4+16) ® Parts page 63...
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Page 64: Model Da20 Surge Actuator
T-16-UT (4+16) Model DA20 Surge Actuator Ref. Quantity Description................. Part No. Flat Mount Inner Slide Tube ..........11043-97 Top Wear Pad ................. 10962 Bottom Wear Pad ..............10963 Spacer Block................10964 Damper Shock ..............SB12426 Front Shock Pin ..............03409-95 Outer Case ................ 03412-97 Connecting Pin .............. -
Page 66: Free Backing Solenoid
T-16-UT (4+16) Free Backing Solenoid Ref. Quantity Description................. Part No. Free Backing Solenoid Kit ............. 5404 EDPM Black Tubing ............04594 Solenoid Valve ..............05561 Brass Fitting Str. .2 HB X 10-32 NF Crimp Clamp ..............10374 Straight Nipple 1/8” MPT X 1/8” MPT ......... 10375 Brass Elbow1/8”... -
Page 67: 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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