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TrailMax GTD-20-FBR Manual

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Section 1.
Operation ............................................................................................... 3
1.0
Introduction ................................................................................... 3
1.1
Purpose ........................................................................................ 3
1.2
Rating............................................................................................ 3
1.3
Design and Safety Factors ........................................................... 4
1.4
Vehicle Load and Handling Limits ................................................ 4
1.5
Alert Symbols ................................................................................ 7
1.6
Reporting Safety Defects ............................................................. 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
Drawbar Eye ............................................................................. 14
Binkley Jack .............................................................................. 15
Cushion Cylinder ...................................................................... 15
Deck Latch ................................................................................ 15
Deck Hinge Assembly............................................................... 15
2.3
Rear Impact Guard (RIG) ........................................................... 16
2.4
Running Gear ............................................................................. 17
Suspension ............................................................................... 17
Axle Alignment .......................................................................... 19
Hubs and Drums ....................................................................... 20
Hub Inspection.......................................................................... 20
Broken or Damaged Studs ....................................................... 20
Brake Drum Inspection ............................................................. 21
Brake Drum Troubleshooting Chart .......................................... 22
Bearing Inspection .................................................................... 24
Bearing Lubrication .................................................................. 24
Seal Inspection and Replacement ........................................... 25
Hub Reinstallation and Bearing Adjustment ............................ 25
2.5
Wheels and Tires ........................................................................ 26
Wheels ..................................................................................... 26
Wheel Torquing Procedures ..................................................... 28
Tires .......................................................................................... 29
Inflation Pressure ..................................................................... 29
Tire Wear Diagnostic Chart ...................................................... 30
®

Table of Contents

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GTD-20-FBR
Table of Contents
Rev. C 04/21/06

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  • Page 1: Table Of Contents

    GTD-20-FBR Table of Contents Section 1. Operation ....................3 Introduction ................... 3 Purpose ..................3 Rating.................... 3 Design and Safety Factors ............4 Vehicle Load and Handling Limits ..........4 Alert Symbols ................7 Reporting Safety Defects ............. 8 Pre-Trip Inspection................ 9 Hook-Up Procedures ..............
  • Page 2 GTD-20-FBR Section 2. Maintenance ................continued Electrical ..................31 Harnesses and Lights ............... 31 Junction Block ................31 Seven-Way Plug ............... 31 Electric Brake System ..............32 Operation .................. 32 Using your Brakes Properly ............33 Synchronization ................ 34 Controllers ................35 Magnets ..................

  • Page 3: Operation

    GTD-20-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

    GTD-20-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 GTD-20-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 GTD-20-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

    GTD-20-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: Reporting Safety Defects

    GTD-20-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.

  • Page 9: Pre-Trip Inspection

    GTD-20-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 10: Hook-Up Procedures

    GTD-20-FBR 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

    GTD-20-FBR 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

    GTD-20-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 13: Maintenance

    GTD-20-FBR Section 2. Maintenance Periodic Maintenance New Trailer Break-in 50 to 100 miles- re-torque wheel nuts- see page 28. 1000 miles- check axle alignment and re-torque suspension fasteners- see page Pre-Trip Inspection Lube wear areas on hitch. Examine frame and tongue members for evidence of damage or cracked welds.

  • Page 14: Structural Components

    GTD-20-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 15: Binkley Jack

    GTD-20-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.

  • Page 16: Rear Impact Guard (Rig)

    GTD-20-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 17: Running Gear

    GTD-20-FBR Running Gear Suspension The suspension on your trailer is a heavy duty, leaf spring, underslung type. An eye is formed into the forward end of the longest leaf spring, while the aft end is free to float against the wear pads of the hangers and rockers. Adjustable spring seats are em- ployed to keep the axles in alignment.
  • Page 18 GTD-20-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. Ref.

  • Page 19: Axle Alignment

    GTD-20-FBR Axle Alignment Verify that the forward axle is centered on the trailer; W . Check the distance from the hitch center to the forward axle end on both sides, and adjust the spring seat adjusters if necessary so that X "...

  • Page 20: Hubs And Drums

    GTD-20-FBR Hubs and Drums Hub Removal- Whenever the hub equipment on your trailer must be removed for inspection or maintenance the following procedure should be utilized: 1. Jack up the wheel. Use a jack stand to support the axle. Only right hand thread wheel nuts and studs are used on your trailer.

  • Page 21: Brake Drum Inspection

    GTD-20-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 22: Brake Drum Troubleshooting Chart

    GTD-20-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 23: Brake Drum Troubleshooting Chart (Continued)

    GTD-20-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 24: Bearing Inspection

    GTD-20-FBR Bearing Inspection Wash all grease and oil from the bearing cone using a suitable solvent. Dry the bearing with compressed air or a lint-free cloth and inspect each roller completely. Also clean and inspect the cups (races) inside the hub. Any pitting, spalling, bluing (heat damage) or corrosion is cause for replacement.

  • Page 25: Seal Inspection And Replacement

    GTD-20-FBR 3. Reinstall the drain plug. 4. Remove the fill plug on the axle cap and add oil to the line on the cap. Reinstall the plug and check for leaks. Use a gear oil of API GL-5 performance level. SAE 90 weight oil is normally pre- ferred for most operating environments.

  • Page 26: Wheels And Tires

    GTD-20-FBR 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 27 GTD-20-FBR 7. Rim Contour. RIM CONTOURS! WARNING Use only the approved rim contours as shown in the Tire and Rim Yearbook or the tire manufacturers catalog. The use of other rim con- tours is dangerous. Failure to use the proper rim contour can result in explosive separation of the tire and wheel and could cause a serious accident.

  • Page 28: Wheel Torquing Procedures

    GTD-20-FBR Wheel Torquing Procedures 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 29: Tires

    GTD-20-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 30: Tire Wear Diagnostic Chart

    GTD-20-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 31: Electrical

    GTD-20-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 32: Electric Brake System

    GTD-20-FBR 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 33: Using Your Brakes Properly

    GTD-20-FBR 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 34: Synchronization

    GTD-20-FBR 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 35: Controllers

    GTD-20-FBR Controllers Start by making sure trailer brakes are properly adjusted. Some controllers have a gain control to vary the amount of current to the brakes, and a level control which sets the controller’s inertia sensor to sense deceleration. The level adjustment also can be used to vary when the trailer braking is felt.

  • Page 36: Brake Cleaning And Inspection

    GTD-20-FBR Brake Cleaning and Inspection Your trailer brakes must be inspected and serviced at yearly intervals or more often as use and performance requires. Magnets and shoes must be changed when they become worn or scored thereby preventing adequate vehicle braking.

  • Page 37: Electric Brake System Troubleshooting

    GTD-20-FBR 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 38 GTD-20-FBR 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 38...

  • Page 39: Measuring Amperage

    GTD-20-FBR 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 40: Manual Brake Adjustment

    GTD-20-FBR 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 41: Electric Brake System Troubleshooting Chart

    GTD-20-FBR 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 TEST AND CORRECT...

  • Page 42: Pre-Storage Maintenance

    GTD-20-FBR 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 43: Pre-Season Maintenance

    GTD-20-FBR 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 discrepancies.

  • Page 44: Parts

    GTD-20-FBR Section 3. Parts Structural Components Sub-frame Ref. Quantity Description................. Part No. Sub-frame Assembly ............A-08109 Safety Chain and Hook Assembly ........" ASSY Parts ® page 44...

  • Page 45: Deck Assemblies

    Deck Lumber ...............2" X 10" X 16' Deck Lumber ...............2" X 10" X 20' Deck Lumber ...............2" X 12" X 16' Deck Lumber ...............2" X 12" X 20' TrailMax Mudflap ..............B30PCB Mudflap Bracket .............. MFW 2375 Ramp Assembly ..............SA-08203 Ramp Springs, Pair ............. C-12210 Ramp Pin ................

  • Page 46: Major Sub-Assemblies

    GTD-20-FBR Major Sub-Assemblies Gooseneck Coupler Ref. Quantity Description................. Part No. Gooseneck Coupler ............LL2516ST Parts ® page 46...

  • Page 47: Binkley Jack

    GTD-20-FBR Binkley Jack Ref. Quantity Description................. Part No. Binkley Jack ................48000 Universal Crank ...............LG0083-01 Jack Handle Extension ............SA-04301 Parts ® page 47...

  • Page 48: Running Gear, 10K

    GTD-20-FBR Running Gear, 10K Suspension Ref. Quantity Description................. Part No. Axle Assembly, 10K Electric Brake ......10KE-SPR PKG Single Axle Hanger and Parts Kit ....... HAP-103-00 Front Hanger ............. 028-067-04 Rear Hanger ............. 030-066-01 Spring Eye Bolt ............007-169-00 Keeper Bolt ............... 007-095-00 Lock Nut ..............
  • Page 49 GTD-20-FBR Parts ® page 49...

  • Page 50: Axle End Components, 10K

    GTD-20-FBR Axle End Components, 10K Ref. Quantity Description................. Part No. Unitized Oil Seal ..............10-56 Inner Bearing Cone ..............395S Inner Bearing Cup ..............394A Drum Mounting Screw ............. 7-103 Brake Drum ................9-27-1 Hub with Cups and Studs, RH ..........8-214-5 Locating Pin ................
  • Page 51 GTD-20-FBR Parts ® page 51...

  • Page 52: Electric Brake Components, 10K

    GTD-20-FBR Electric Brake Components, 10K Ref. Quantity Description ................... Part No. Shoe and Lining Kit, LH ..............71-51 LH Primary ................40-108-1 LH Secondary ................. 40-109-2 Shoe Hold Down Washer ............5-107 Castle Nut ..................6-77 Cotter Pin..................19-12 Shoe and Lining Kit, RH ..............71-52 RH Primary ................
  • Page 53 GTD-20-FBR Parts ® page 53...

  • Page 54: Wheels And Tires

    GTD-20-FBR Wheels and Tires Ref. Quantity Description................. Part No. Tire ................. 245/75R 16 Wheel, 17.5 x 6.75 ............. 17-279-14 SP Valve Stem...................501 Clamp Ring ................33-52-1 Wheel Nut ................6-109 Note: Tires are not available through Gem State Manufacturing; contact your local equipment tire retailer for replacement parts.
  • Page 55 GTD-20-FBR THIS PAGE LEFT BLANK INTENTIONALLY Parts ® page 55...

  • Page 56: Electrical

    GTD-20-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 57 GTD-20-FBR Parts ® page 57...

  • Page 58: Electrical Plug

    GTD-20-FBR 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 Stop...

  • Page 59: Electric Breakaway System

    GTD-20-FBR Ref. Quantity Description................. Part No. E-6 Electrical Kit ..............51306 Harness, Electric Brake ...........512332 Connector Kit ..............77850 8" Electric Breakaway System Ref. Quantity Description................. Part No. Electric Breakaway Kit ............110898 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 assistance @ 1-800-447-0213.

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