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 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
Brake Drum Troubleshooting Chart (continued) .............. 24
Axle End Component Cleaning and Inspection ............... 25
Axle End Component Assembly ....................................... 25
Wheel Bearing Adjustment .............................................. 25
Wheel Bearing Lubrication .............................................. 25
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TRD-50-T (22.5)
Table of Contents
page 1
Table of Contents
Rev. C 11/08/01
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Related Manuals for TrailMax TRD-50-T
Summary of Contents for TrailMax TRD-50-T
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Page 1: Table Of Contents
TRD-50-T (22.5) 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-50-T (22.5) Section 2. Maintenance ..............Continued 2.5 Wheels and Tires .............. 25 Wheels ................25 Wheel Torquing Procedures ..........26 Tires ................. 27 Inflation Pressure ............27 Tire Wear Diagnostic Chart ..........28 2.6 Electrical ................29 Harnesses and Lights ............29 Junction Block ..............
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Page 3: Section 1. Operation
TRD-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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: Alert Symbols
TRD-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) Spring Brake Chamber Rubber Seal Release Tool Assembly (in storage position) Release Tool Assembly Operation ® page 9...
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Page 10: Reporting Safety Defects
TD-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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 13: 1.10 Loading And Unloading
TRD-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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.
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Page 21: Axle Alignment
TRD-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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-50-T (22.5) 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.
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Page 32: Manual Brake (Free Stroke) Adjustment
TRD-50-T (22.5) 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-50-T (22.5) 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: Section 3. Parts
TRD-50-T (22.5) Section 3. Parts Structural Components Sub-frame Ref. Quantity Description................. Part No. Sub-frame Assembly ............A-06039 Safety Chain and Hook Assembly ........" ASSY Deck Lumber ...............2" X 12" X 20' Parts ® page 34... -
Page 35: Deck Assemblies
Deck Lumber ............... 2" X 10" x 16' Deck Lumber ............... 2" X 10" x 20' Deck Lumber ...............2" X 10" X 24' Deck Lumber ...............2" X 12" X 16' TrailMax Mudflap ..............B30PCB Mudflap Bracket .............. MFW 2375 Parts ®... -
Page 36: Major Sub-Assemblies
TRD-50-T (22.5) 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 36... -
Page 37: Binkley 2-Speed Jack
TRD-50-T (22.5) 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 37... -
Page 38: Cushion Cylinder
TRD-50-T (22.5) Cushion Cylinder Ref. Quantity Description................. Part No. Cushion Cylinder, 5 X 12 ........... SA-03197 Parts ® page 38... -
Page 39: Deck Latch Assembly
TRD-50-T (22.5) Deck Latch Assembly Ref. Quantity Description................. Part No. Latch Assembly .............. SA-03114 Roll Pin, " x 2"..............64315 Flanged Bushing ............. GFI-1618-08 E-clip SE 982 D ............10385-00128 Groove Pin ..............C-06050 Safety Pin Assembly ............ 10385-00161 Note: Kit names are bold type while component names are regular type; kit com- ponents are indexed under the kit name. -
Page 40: Deck Hinge Assembly
TRD-50-T (22.5) Deck Hinge Assembly Ref. Quantity Description................. Part No. Deck Hinge Assembly ............. SA-04027 Hinge Bracket Assembly ..........SA-07099 Hinge Pin ............... C-06179 Lock Nut, " NF ..............37304 Bolt, " x 3- " Grade 8 NF ..........18846 Grease Fitting ..............60105 Note: Kit names are bold type while component names are regular type;... -
Page 41: Rear Impact Guard (Rig) Assembly
TRD-50-T (22.5) Rear Impact Guard (RIG) Assembly Ref. Quantity Description................. Part No. Rear Impact Guard Assembly .........SA-10098 RIG Light Bar ............... SA-10198 RIG Pushrod ..............SA-12515 Torsion Block Assembly ..........C-06128 Adjustable Radius Rod ..........16398-04 Torsion Block Pivot Pin ..........C-12229 Linkage Pin, Short ............ -
Page 42: Running Gear
TRD-50-T (22.5) 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) ......TN4670QH Axle Assembly, Center (ABS) ........... - Page 43 TRD-50-T (22.5) Parts ® page 43...
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Page 44: Wheels And Tires
TRD-50-T (22.5) Wheels and Tires Ref. Quantity Description................. Part No. Tire ................255/70R 22.5 Wheel, 22.5 x 8.25 ..............28408 Valve Stem...................572 Note: Tires are not available through Gem State Manufacturing; contact your local equipment tire retailer for replacement parts. Parts ®... - Page 45 TRD-50-T (22.5) THIS PAGE LEFT BLANK INTENTIONALLY Parts ® page 45...
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Page 46: Electrical
TRD-50-T (22.5) Electrical Harnesses and Lights Because of the complexity of the electrical kit, the components are displayed graphi- cally over the next several pages. Ref. Quantity Description................. Part No. E-17 Electrical Kit ..............E-17 Harness, Front Main ............88776 Harness, M/C ‘T’ style 2 plug ..........88355 Harness, Center Main ............88775... - Page 47 TRD-50-T (22.5) Parts ® page 47...
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Page 50: Air Brake System
TRD-50-T (22.5) Air Brake System Because of the complexity of the air brake system, the components are displayed graphically over the next several pages. For Air Brake Chambers, see section 3.4 - Running Gear. Ref. Quantity Description ................... Part No. - Page 51 TRD-50-T (22.5) Detail shown on follow- ing pages. Parts ® page 51...
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Page 56: 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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