TrailMax TRD-54-FBR Manual
  1. Manuals
  2. Brands
  3. TrailMax Manuals
  4. Utility Vehicle
  5. TRD-54-FBR
  6. Manual

TrailMax TRD-54-FBR Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
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
Section 2. Maintenance .............................................................................. 15
2.0 Periodic Maintenance ........................................................ 15
2.1 Structural Components ...................................................... 16
Sub-Frame ....................................................................... 16
Deck ................................................................................ 16
2.2 Sub-Assembly Components .............................................. 16
Drawbar Eye .................................................................... 16
Binkley Jack..................................................................... 17
Cushion Cylinder ............................................................. 17
Deck Latch ....................................................................... 17
Deck Hinge Assembly ...................................................... 17
2.3 Rear Impact Guard (RIG) .................................................. 18
2.4 Running Gear .................................................................... 19
Suspension ...................................................................... 19
Axle Alignment ................................................................. 21
Axle End Component Disassembly ................................. 21
Hub Inspection ................................................................. 21
Broken or Damaged Studs............................................... 21
Brake Drum Inspection .................................................... 22
Brake Drum Troubleshooting Chart ................................. 23
Axle End Component Assembly ....................................... 25
Wheel Bearing Adjustment .............................................. 25
Wheel Bearing Lubrication .............................................. 25
®

Table of Contents

page 1
TRD-54-FBR
Table of Contents
Rev. D 06/01/06

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the TRD-54-FBR and is the answer not in the manual?

Questions and answers

Related Manuals for TrailMax TRD-54-FBR

Summary of Contents for TrailMax TRD-54-FBR

  • Page 1: Table Of Contents

    TRD-54-FBR 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 TRD-54-FBR Section 2. Maintenance ..............Continued Wheels and Tires ..............25 Wheels ................25 Wheel Torquing Procedures ..........26 Tires ................. 27 Inflation Pressure .............. 27 Tire Wear Diagnostic Chart ..........28 Electrical ................29 Harnesses and Lights ............29 Junction Block ..............

  • Page 3: Section 1. Operation

    TRD-54-FBR 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

    TRD-54-FBR 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 TRD-54-FBR 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 TRD-54-FBR 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

    TRD-54-FBR 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

    TRD-54-FBR 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 TRD-54-FBR Spring Brake Chamber Rubber Seal Release Tool Assembly (in storage position) Release Tool Assembly Operation ® page 9...

  • Page 10: Reporting Safety Defects

    TD-54-FBR 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 11: Pre-Trip Inspection

    TRD-54-FBR 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

    TRD-54-FBR 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 13: Loading And Unloading

    TRD-54-FBR 1.10 Loading and Unloading CAUTION TRAILER LOADING PRACTICES 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

    TRD-54-FBR 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: Section 2. Maintenance

    TRD-54-FBR Section 2. Maintenance Periodic Maintenance New Trailer Break-in 50 to 100 miles- re-torque wheel flange nuts- see page 26. 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 16: Structural Components

    TRD-54-FBR 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 17: Binkley Jack

    TRD-54-FBR 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 18: Rear Impact Guard (Rig)

    TRD-54-FBR 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 19: Running Gear

    TRD-54-FBR 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 20 TRD-54-FBR 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 21: Axle Alignment

    TRD-54-FBR 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 22: Brake Drum Inspection

    TRD-54-FBR 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 23: Brake Drum Troubleshooting Chart

    TRD-54-FBR 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 24: Brake Drum Troubleshooting Chart (Continued)

    TRD-54-FBR 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 25: Axle End Component Cleaning And Inspection

    TRD-54-FBR 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 26: Wheel Torquing Procedures

    TRD-54-FBR 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 27: Tires

    TRD-54-FBR 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 28: Tire Wear Diagnostic Chart

    TRD-54-FBR 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 29: Electrical

    TRD-54-FBR 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 30: Brake System

    TRD-54-FBR 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 31 TRD-54-FBR 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 32: Manual Brake (Free Stroke) Adjustment

    TRD-54-FBR 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 33: Slack Adjuster Function Test

    TRD-54-FBR 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 34: Parts

    TRD-54-FBR Section 3. Parts Structural Components Sub-frame Ref. Quantity Description ................. Part No. Deck and Sub-frame Assembly ......... SA-14391 Safety Chain and Hook Assembly ........" ASSY *Front Hanger ............... 7701-01 *Center Hanger ..............16180-01 *Rear Hanger ............... 7703-01 Tool Box Lid Assembly ............SA-01144...
  • Page 35 TRD-54-FBR THIS PAGE LEFT BLANK INTENTIONALLY Parts ® page 35...

  • Page 36: Deck Assemblies

    Deck Lumber ............... 2 1/8 X 12 10' Deck Lumber .............. 2 1/8 X 12 24' Torx Deck Screws, -20 x 3 ........... 32523 TrailMax Mudflap ..............B30PCB Mudflap Bracket ............... MFW 2375 Ramp Assembly ..............SA-14569 Ramp Springs, Left ............... C-14495 Ramp Springs, Right ............
  • Page 37 TRD-54-FBR ® page 37...

  • Page 38: Major Sub-Assemblies

    TRD-54-FBR 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

    TRD-54-FBR 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: Running Gear

    TRD-54-FBR Running Gear For: Brakes Bearings and Hubs Axle End Components Refer to the Meritor Maintenance Manual 14, Trailer Axles and call Gem State Manu- facturing at 1-800-447-0213. Suspension Ref. Quantity Description ................... Part No. Axle Assembly, Front and Rear (non ABS)......TN4270QH6458 Axle Assembly, Center (ABS) ..........
  • Page 41 TRD-54-FBR 20 18 Parts ® page 41...

  • Page 42: Axle End Components

    TRD-54-FBR 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 43 TRD-54-FBR Parts ® page 43...

  • Page 44: Brakes

    TRD-54-FBR 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 45: Bearings And Hubs

    TRD-54-FBR 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 46: Wheels And Tires

    TRD-54-FBR 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 47 TRD-54-FBR THIS PAGE LEFT BLANK INTENTIONALLY Parts ® page 47...

  • Page 48: Electrical

    TRD-54-FBR Electrical Harnesses and Lights Ref. Quantity Description................. Part No. E-4 Electrical Kit ..............K00060 Harness, Rear Clearance Lights ........50301 Harness, Marker ..............50393 Harness, Stop/Turn/Tail w/Clearance, RH ....50210 0192 Harness, Stop/Turn/Tail w/Clearance, LH ....50211 0192 Amber clearance lamp, sealed ........10205Y Mounting grommet .............10704...
  • Page 49 TRD-54-FBR Parts ® page 49...
  • Page 50 TRD-54-FBR Ref. Quantity Description ................. Part No. E-5 Electrical Kit ..............K00061 Harness, Marker ..............50358 Amber clearance lamp, sealed ........10205Y Mounting grommet ............. 10704 Boot Kit, 2 connector ............77850 Parts ® page 50...
  • Page 51 TRD-54-FBR THIS PAGE LEFT BLANK INTENTIONALLY Parts ® page 51...

  • Page 52: Electrical Plug

    TRD-54-FBR 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 Green- Yellow- Right Turn Left Turn Red- Stop ABS Electrical Ref. Quantity Description ................. Part No.
  • Page 53 TRD-54-FBR Parts ® page 53...

  • Page 54: Air Brake System

    TRD-54-FBR Air Brake System Because of the complexity of the air brake system, the components are displayed over the next several pages. For Air Brake Chambers, see section 3.4 - Running Gear. Ref. Quantity Description .................. Part No. Tandem Axle Air Kit/ABS ..........AK-A2 ABS-PC Service Gladhand ..............
  • Page 55 TRD-54-FBR Detail shown on follow- ing pages. Parts ® page 55...
  • Page 56 TRD-54-FBR Parts ® page 56...
  • Page 57 TRD-54-FBR Parts ® page 57...
  • Page 58 TRD-54-FBR Parts ® page 58...
  • Page 59 TRD-54-FBR Parts ® page 59...

  • Page 60: 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.

Table of Contents