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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Table of Contents
page 1
T-12-T
Contents
Rev A 6/1/06
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Table of Contents
Troubleshooting
Related Manuals for TrailMax T-12-T
Summary of Contents for TrailMax T-12-T
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Page 1: Table Of Contents
T-12-T 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 T-12-T 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-12-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
T-12-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 T-12-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 T-12-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.
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Page 7: Reporting Safety Defects
T-12-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 8: Alert Symbols
T-12-T 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-12-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 10: Hook-Up Procedures
T-12-T Hook-Up Procedures Connect the tow vehicle to the trailer and check that the coupler is completely latched. Be sure that a safety pin is inserted to ensure coupler will not unlatch during transport. Connect the electrical plug from the trailer’s harness to the receptacle of the tow vehicle. -
Page 11: Loading And Unloading
T-12-T 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 12: Trailers With Ramps
T-12-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 13: Section 2. Maintenance
T-12-T 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. -
Page 14: Structural Components
T-12-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 leaking brake fluid. If your application requires the hauling of corrosives then frequent washdowns are very important. -
Page 15: Jack
T-12-T 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
T-12-T 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-12-T 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
T-12-T 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
T-12-T Note: The E-Z Lube feature is designed to allow immersion. If the hubs are re- moved 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
T-12-T 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 T-12-T 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.
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Page 22: Tires
T-12-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 23: Tire Wear Diagnostic Chart
T-12-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 24: Electrical
T-12-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 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-12-T 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
T-12-T 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-12-T 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 28: Corrosive Environment Warning
T-12-T 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 29: Brake System Bleeding
T-12-T 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 30: Magnets
T-12-T 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 31: Hydraulic Brake System Troubleshooting Chart
T-12-T 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 32 T-12-T 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 32...
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Page 33: Measuring Amperage
T-12-T 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 34 T-12-T 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.
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Page 35: Electric Brake System Troubleshooting
T-12-T 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 36: Pre-Storage Maintenance
T-12-T 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 37: Pre-Season Maintenance
T-12-T 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 38: Parts
T-12-T Section 3. Parts Structural Components Sub Frame Ref. Quantity Description ................. Part No. Sub Frame Assembly ............SA-14321 Parts ® page 38... -
Page 39: Deck Surface
T-12-T Deck Assembly Ref. Quantity Description ................. Part No. Deck Assembly ..............SA-14322 Step Assembly ..............SA-04069 Hinge Pins ................C-06179 Bolt, " x 3- " Grade 8 NF ........... 18846 Lock Nut, " NF ..............37304 Parts ® page 39... -
Page 40: Major Sub-Assemblies
T-12-T Major Sub-Assemblies 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 41: Couplers
T-12-T Couplers Ref. Quantity Description ................. Part No. " Coupler ................. 75074 Parts ® page 41... - Page 42 T-12-T Ref. Quantity Description ................. Part No. Pintle Eye ................BDB 1250 Note: Pintle Eye and associated hardware is an available option. Parts ® page 42...
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Page 43: Deck Latch Assembly
T-12-T Deck Latch Assembly Ref. Quantity Description ................. Part No. " x 1- " Adjusting Bolt ............ 17359 Hook ................C-04109 Latch Arm Assembly ............ SA-12552 Grooved Pin ..............C-06050 E-clip SE 982 D ............10385-00128 Flanged Bushing ............GFI-1618-08 Latch Handle .............. -
Page 44: Cushion Cylinder
T-12-T Cushion Cylinder Ref. Quantity Description................. Part No. Cushion Cylinder ..............30X12 Parts ® page 44... -
Page 45: Running Gear
T-12-T Running Gear Suspension, 7K Ref. Quantity Description................. Part No. 7000# Rubber Torsion Axle ....12TF0865EEZ0815063501 Parts ® page 45... -
Page 46: Electric Brake Components, 7K
T-12-T 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 ..........036-089-10 LH Lever Actuating Arm ..........047-107-00 RH Lever Actuating Arm ..........047-108-00 Wire Clip ................ 027-009-00 Retractor Spring ............. -
Page 48: Axle End Components
T-12-T Axle End Components Ref. Quantity Description ................. Part No. Grease Seal ..............010-010-00 Inner Bearing Cone ............031-030-02 Inner Bearing Cup ............031-030-01 " Wheel Stud ............... 007-122-00 Brake Drum (8 stud on 6.5" circle) ......... 008-219-13 Outer Bearing Cup ............031-017-01 Outer Bearing Cone ............ -
Page 49: Wheels And Tires
T-12-T 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 50: Electrical
T-12-T Electrical Harnesses and Lights Ref. Quantity Description ................. Part No. E-11 Electrical Kit ..............K01433B Harness, Main Feed ............93738 Harness, Rear Impact Guard ..........93737 Harness, Stationary Deck Marker ........50393 Harness, Marker ..............50358 Amber clearance lamp, sealed ........10205Y Mounting grommet ............. - Page 51 T-12-T Parts ® page 51...
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Page 52: Electrical Plug
T-12-T Electrical Plug Ref. Quantity Description ................. Part No. Seven Way RV Plug .............. 12-706 Seven Way Plug and Spring ..........PL 15-730 Not Wired Black- Brown- Accessories Tail and Marker Yellow- Green- Left Turn Right Turn White- Blue- Ground... -
Page 53: Electric Brake Wiring
T-12-T 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 54: 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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