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TrailMax 8012DT 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
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
2.6
®

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8012DT
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Revision A 02/18/05

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  • Page 1: Table Of Contents

    8012DT 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................ 9 Hook-Up Procedures ..............
  • Page 2 8012DT 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................28 Hydraulic Brakes ............... 28 Brake System Bleeding ............

  • Page 3: Section 1. Operation

    8012DT 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

    8012DT 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 8012DT 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 8012DT 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: Reporting Safety Defects

    8012DT 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 8: Alert Symbols

    8012DT 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

    8012DT 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

    8012DT 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

    8012DT 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.

  • Page 12: Trailers With Ramps

    8012DT 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

    8012DT 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 13. Examine frame and tongue members for evidence of damage or cracked welds. Check lights for correct operation.

  • Page 14: Structural Components

    8012DT 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

    8012DT 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.

  • Page 16: Running Gear

    8012DT 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

    8012DT 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.

  • Page 18: Standard Bearing Lubrication

    8012DT Standard Bearing Lubrication Bearings should be lubricated every 12 months or 12,000 miles. If the axles have been submerged, the bearings should be repacked immediately. Service the bearings with lithium grease meeting NLGI No. 2 standards. Use this procedure: 1.

  • Page 19: Seal Inspection And Replacement

    8012DT Note: The E-Z Lube feature is designed to allow immersion. If the hubs are removed from the axle, it is imperative that the grease seals be replaced. A worn or defective grease seal will allow brake lining contamination during the bearing greasing procedure.

  • Page 20: Wheels And Tires

    8012DT 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

    8012DT 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.

  • Page 22: Inflation Pressure

    8012DT 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

    8012DT 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 24: Electrical

    8012DT 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)

    8012DT 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.

  • Page 26: Brake Cleaning And Inspection

    8012DT 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

    8012DT 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

    8012DT 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

    8012DT 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. Fill the master cylinder in the surge actuator with fresh DOT 3 brake fluid. Re- move the two "...
  • Page 30 8012DT 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...

  • Page 31: Hydraulic Brake System Troubleshooting Chart

    8012DT 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

    8012DT 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.

  • Page 33: Synchronization

    8012DT 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

    8012DT 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...

  • Page 35: Electric Brake System Troubleshooting

    8012DT 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 8012DT 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...

  • Page 37: Measuring Amperage

    8012DT 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

    8012DT 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.
  • Page 39 8012DT 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...

  • Page 40: Pre-Storage Maintenance

    8012DT 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.

  • Page 41: Pre-Season Maintenance

    8012DT 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.

  • Page 42: Parts

    8012DT Section 3. Parts Structural Components Ref. Quantity Description................. Part No. Sub Frame ................. SA-12934 Dump Body ................ SA-12955 3-Way Tailgate Assembly ..........SA-13849 Ramp Assembly ..............SA-14056 Safety Chain and Hook Assembly ........" ASSY D-ring ..................B38W Tandem Hanger Kit ........ H202/AP216 PKG2 10429 Front Hanger .................
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  • Page 45: Major Sub-Assemblies

    8012DT Major Sub-Assemblies Binkley Jack Ref. Quantity Description ................. Part No. Dump Trailer Jack Assembly ......... SA-14093 Binkley Jack Drop Leg 12K ..........4800 Jack Drop Foot Extension ..........C-14059 Jack Plunger Extension ........... C-14058 Jack Handle Extension ............SA-14142 Universal Crank ..............

  • Page 46: Couplers

    8012DT Couplers Ref. Quantity Description................. Part No. " Lever Lock Coupler ..........07678-97 " -11 UNC x 1- " Hex Head Bolt Grade 5 ......04051 " -11 UNC Stover Lock Nut ..........03730 Parts ® page 46...
  • Page 47 8012DT Ref. Quantity Description ................. Part No. Pintle Eye ................09557-97 "-11 UNC x 4- " Hex Head Bolt Grade 5 ......02434 "-11 UNC Nylon Insert Lock Nut ..........02587 Note: Pintle Eye and associated hardware is an available option.

  • Page 48: Running Gear

    8012DT Running Gear Ref. Quantity Description................. Part No. Axle Assembly (hydraulic brakes) ......70865HFBSTEZ Axle Assembly (electric brakes)........70865ESTEZ Note: Axle assemblies include brakes, drums, slipper springs and u-bolt kits. 24" 3.5K Slipper Spring ........... 1203T3 U-Bolt Kit (3" round axle) ........... APUBR-8 U-bolt, "...
  • Page 49 8012DT Parts ® page 49...

  • Page 50: Hydraulic Brake Components

    8012DT Hydraulic Brake Components Ref. Quantity Description ................. Part No. Complete Brake Assembly- Right ........SB42028 Complete Brake Assembly- Left .......... SB42029 Back Plate Assembly ............ SB18496-30 Brake Shoe Kit (2 Front & 2 Rear) ........SB18498 Bleeder ................... 05431 Wheel Cyl. Assy-Right ............SB9776 Wheel Cyl.

  • Page 52: Electric Brake Components, 7K

    8012DT Electric Brake Components, 7K Ref. Quantity Description ................. Part No. LH Complete Brake Assembly......... 023-105-00 RH Complete Brake Assembly ........023-106-00 Backing Plate Assembly ..........036-089-05 LH Lever Actuating Arm ........... 047-107-00 RH Lever Actuating Arm ..........047-108-00 Wire Clip ................. 027-005-00 Retractor Spring ..............

  • Page 54: Axle End Components

    8012DT Axle End Components Ref. Quantity Description ................. Part No. Grease Seal ..............010-036-00 Inner Bearing Cone ............031-030-02 Inner Bearing Cup ............031-030-01 " Wheel Stud ..............007-262-00 Brake Drum (6 stud on 5.5" circle) ........008-201-09 Outer Bearing Cup ............031-029-01 Outer Bearing Cone ............

  • Page 55: Wheels And Tires

    8012DT Wheels and Tires Ref. Quantity Description................. Part No. Tire ................ST235/80R16 Wheel ................. 17-153-14 SP Wheel Nut, "-20, 60° ........... 006-080-00 Note: Tires are not available through Gem State Manufacturing; contact your local equipment tire retailer for replacement parts.

  • Page 56: Electrical

    8012DT Electrical Harnesses and Lights Ref. Quantity Description................. Part No. E-14 Electrical Kit ............... K01946 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 57 8012DT Parts ® page 57...

  • Page 58: Electrical Plug

    8012DT Electrical Plug Ref. Quantity Description ................. Part No. Seven Way RV Plug ............... 12-706 Options Seven Way Plug and Spring ..........PL 15-730 Six Way Plug ................S603 Not Wired Black- Brown- Accessories Tail and Marker Yellow- Green- Left Turn...

  • Page 59: Electric Brake Wiring

    8012DT 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 com- ponents, if itemized, are indexed under the kit name.

  • Page 60: Hydraulic System

    8012DT Hydraulic System Hydraulic Lines Ref. Quantity Description................. Part No. Surge Line Kit ..............0716-04 Brake Hose, 13" ............18013-FF Hose Bracket ..............25 x 15 Hose Clip................1457 Adapter Tee ................. 7900 Brake Line, 113" ............AG-16113-C Brake Line, 62" ............T-16062-C Brake Line, 71"...
  • Page 61 8012DT Parts ® page 61...

  • Page 62: Model Da20 Surge Actuator

    8012DT Model DA20 Surge Actuator Ref. Quantity Description ................. Part No. Inner Slider Tube Channel Centered ........11044-97 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 64: Power Unit Motor

    8012DT Power Unit Motor Parts ® page 64...
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  • Page 66: Power Unit Control Valve

    8012DT Power Unit Control Valve Parts ® page 66...

  • Page 67: Power Unit Control Valve Schematic

    8012DT Power Unit Control Valve Schematic Parts ® page 67...

  • Page 68: Gear Pump And Manifold Assembly Parts List

    8012DT Gear Pump and Manifold Assembly Parts List Parts ® page 68...

  • Page 69: Gear Pump And Manifold Assembly Parts Illustration

    8012DT Gear Pump and Manifold Assembly Parts Illustration Parts ® page 69...

  • Page 70: Tool Box

    8012DT Tool Box Ref. Quantity Description ................. Part No. Tool Box ................TM321 421 ® page 70...
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  • Page 72: 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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