TrailMax FWTD-50-T, Manual

Page 1: ...tenance 17 2 0 Periodic Maintenance 17 2 1 Structural Components 18 Sub Frame 18 Deck 18 2 2 Sub Assembly Components 18 Drawbar Eye 18 Binkley Jack 19 Cushion Cylinder 19 Deck Latch 19 Deck Hinge Assembly 19 2 3 Rear Impact Guard RIG 20 2 4 Running Gear 21 Suspension 21 AxleAlignment 23 Axle End Component Disassembly 23 Hub Inspection 23 Broken or Damaged Studs 23 Brake Drum Inspection 24 Brake Dr...

Page 2: ...st 35 Brake Lubrication 35 Section 3 Parts 36 3 1 Structural Components 36 Sub frame 36 Deck Assemblies 37 3 2 Major Sub Assemblies 37 Binkley Fifth Wheel Jack 38 Cushion Cylinder 40 Deck LatchAssembly 41 Deck HingeAssembly 42 3 3 Rear Impact Guard RIG Assembly 43 3 4 Running Gear 44 Brakes 44 Bearings and Hubs 44 Axle End Components 44 Suspension 44 3 5 Wheels and Tires 46 3 6 Electrical 48 Harne...

Page 3: ...and stability limits and how driver awareness and skill can help compensate for these factors This knowledge will assist you to safely enjoy the maximum utility and productivity from your trailer First and foremost DO NOT operate the trailer until you have read and fully under stand this instruction and operating manual It is also important that each and every person who operates the trailer be gi...

Page 4: ... not recommended to carry the full rated capacity of the trailer Extreme concentrated appli cations may require additional support for the load 1 4 Vehicle Load and Handling Limits Vehicle handling limits can be greatly affected by the weight of a load its place ment the amount of weight distributed over the axles and whether or not the load is secured properly Tow vehicle and trailer combinations...

Page 5: ...d trailer wheels will add significantly to the handling characteristics of the combination and allow the driver to utilize all the design responses of the vehicle to make evasive maneuvers in the safest manner Irregular terrain steep grades and crowned roads especially rural roadways free ways exit ramps curves bumps and depressions introduce forces into a tow vehicle trailer combination that coul...

Page 6: ... familiar the driver is with the vehicle and the road the less likely he will need to make abrupt emergency maneuvers which will take the vehicle to its limits Control and stability may be main tained if the driver knows his vehicle his load and the road Either braking or accelerating while cornering can significantly reduce the control lability and stability of the vehicle and should be avoided T...

Page 7: ...jury or death DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION CAUTION used withou...

Page 8: ...l roll freely until they are removed To remove the release tool assemblies use the following procedure see illustration on next page 1 Hook up trailer to tow vehicle and or put air to the air brake system on the trailer 2 Apply approximately 70 psi of air pressure to the brake system this should be sufficient to remove the spring pressure and loosen the release tool assemblies NOTE The release too...

Page 9: ... page 9 FWTD 50 T 17 5 Operation Spring Brake Chamber Rubber Seal Release Tool Assembly O P E R A T I O N Release Tool Assembly in storage position ...

Page 10: ... and if it finds that a safety defect exists in a group of vehicles it may pursue a remedy campaign and recall those vehicles However NHTSAcannot become involved in individual problems between you your dealer or Gem State Mfg Inc To contact NHTSA you may either call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safecar gov or write to Administrator NHTSA ...

Page 11: ... order to achieve the correct hitch height elevate the tongue of the trailer slightly 1 to 2 by adjusting the trailer hitch to compensate for settling of tow vehicle springs when loaded Always visually inspect hitch for unusual appearances such as bent components cracks in welds or chipped paint where stress cracks may appear from high loads Check tires for proper inflation Tire manufacturers reco...

Page 12: ...ng the jack under load and high gear for raising and lowering the leg when it is off the ground Check all safety chains and their attachment to both the trailer and the towing ve hicle Connect safety chains to tow vehicle using crossed pattern under tongue Allow slack for turning but avoid having chains drag on pavement Make certain that all attachment devices are properly installed and in good wo...

Page 13: ...n when it is not easy to calculate the total load or determine the load center of gravity A decal on the trailer similar to the one shown below indicates the correct placement of the load Load the trailer so that 60 of the total load weight is forward of the arrow and 40 is rearward of the arrow This will ensure that the proper load balance and tongue weight are achieved WARNING MAINTAIN 60 OF LOA...

Page 14: ...hs Prior to loading or unload ing it is very important that ramps are adjusted to proper spacing for equipment being transported When loading equipment onto deck drive slowly forward until appropriate tongue load is achieved Ramps are designed to support rear of trailer during loading and unloading Ramps must be in stored position during transport Trailers With Tilt Decks It is very important that...

Page 15: ...s to be used with chain slots When securing loads with chains the chains should not exceed angles shown in illus trations below Viewed from above chain should not be angled more than 45 degrees in either direc tion of chain slot In addition chain should not be angled more than 45 degrees above the trailer floor Operation ...

Page 16: ... page 16 FWTD 50 T 17 5 Operation THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 17: ...erify correct hitch height Check lights for correct operation Quarterly or 10 000 miles Check wheel flange nut torques see page 28 Check brakes for adjustment see page 32 Semi Annually or 25 000 miles Lubricate jack see page 19 Re torque suspension fasteners see page 22 Inspect and lubricate brakes and linings see page 35 Lubricate tilt deck hinges see page 19 Replace wheel bearing lubricant heavy...

Page 18: ...o sion If the trailer has been overloaded or in an accident inspect the tilt deck carefully It may be necessary to apply a new coat of wood preservative after decking has aged and become dry The best time to apply preservative is during warm weather for better penetration Replace decking when necessary Occasionally check for loose missing or broken deck screws 2 2 Sub Assembly Components Drawbar E...

Page 19: ... the cylinder has leaked or if the deck action has become jerky or sluggish Fully collapse the cylinder and then remove the filler plug and drain out the old fluid Add 10W hydraulic fluid until the cylinder is full and all the air has been expelled Deck Latch The latch assembly is designed with replaceable self lubricating bushings at the wear points See the appropriate pages of the Parts section ...

Page 20: ...ng the forces of an impact If they show any signs of deformity from having been impacted by the RIG pivot arms they should be replaced immediately In no case should the crush blocks be straightened or re paired in any way they both must be REPLACED if deformed by the RIG pivot arms Also check the deck beam flanges that the crush blocks bolt to for damage or bending The flanges may have to be strai...

Page 21: ...ts of the suspension have worked together for a very short period of time re torquing the bolts is necessary to insure that undue move ment which results in excessive suspension wear does not occur During the first maintenance check the trailers axle alignment should be examined and adjusted Alignment should also be checked following any maintenance or repair procedure performed on the suspension ...

Page 22: ...Item Oiled Torque Dry Torque 1 1 1 8 7 Rocker Bolt 590 lb ft 790 lb ft 2 5 8 18 Spring Retainer Bolt 35 lb ft 50 lb ft 3 1 14 Radius Rod Bolt 540 lb ft 720 lb ft 4 5 8 18 Radius Rod Clamp Bolt 130 lb ft 170 lb ft 5 7 8 14 Axle U bolt with pattern 350 lb ft 470 lb ft Rocker bolt may be of the Huck type and have a permanent clinch end instead of a nut If so no torquing is necessary 5 1st 2nd 4th 3rd...

Page 23: ...enever the hub equipment on your trailer must be removed for inspection or maintenance refer to the Meritor Maintenance Manual 14 Trailer Axles beginning with Section 2 Hub Inspection Clean the hub with a commercial solvent for inspection Check for cracks elon gated holes evidence of overheating or foreign object damage The hub is crucial to safe vehicle operation and any doubt about its condition...

Page 24: ...heat checks or other surface defects resulting from normal use The following should be noted when turning the brake drum 1 The maximum diameter cast into the back plate portion of the brake drum is the discard diameter If any portion of the brake drum exceeds the maximum diameter it must be replaced 2 When preparing to machine a drum allow at least 040 under the maximum diameter for further normal...

Page 25: ...BRAKE SYSTEM IM PROPER ADJUSTMENT OR INFERIOR LINING CHECK BRAKE DRUM LINING CONDITION AND BRAKE BALANCE AVOID CONDITIONS OR LOADS WHICH CREATE HIGH BRAKE TEMPERATURES BLUE OR DISCOLORED BRAKE SURFACE EXCESSIVE HEAT FROM DRAGGING BRAKES OR BRAKE IMBALANCE BETWEEN TRACTOR AND TRAILER MACHINE BRAKE DRUM CHECK RETURN SPRINGS AND FOR BINDING BRAKE ACTUATION SYSTEM NOISE CHATTER OR PULSATING BRAKE HEAT...

Page 26: ...BOLT HOLE WHEEL HITTING BRAKE DRUM INSTALLATION ON DIRTY HUB MOUNTING FLANGE SEPARATED FROM HOOP SECTION OF DRUM REPLACE DRUM CLEAN THE HUB PRIOR TO INSTALLING NEW DRUM INCORRECT APPLICATION REPLACE BRAKE DRUM WITH CORRECT PART HEAT SPOTTED OR HARD SPOTS IN BRAKE SURFACE HIGH LOCALIZED HEATING AND COOLING CYCLES GRIND HARD SPOT AND MACHINE DRUM BALANCE WEIGHT FALLEN OFF OR NOT A BALANCED DRUM OUT ...

Page 27: ...the wheels on your trailer be certain that the replacement units match the originals in the following regards 1 Type The disc wheels and capnuts on your trailer are of the hub pilot design 2 Material Do not mix aluminum and steel disc wheels or aluminum and steel disc wheel capnuts This may result in incorrect components being used to secure the wheels which can lead to loose wheels resulting in a...

Page 28: ...de with great force and can cause serious injury or death 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 The hand torque wrench or air wrench used to install the wheels must be periodi cally calibrated...

Page 29: ... tire mounting procedures as outlined by the Rubber Manufacturers Association or the tire manufacturer Inflation Pressure Correct tire inflation pressure for both the 215 75R 17 5 tires and the 255 70R 22 5 tires is 125 psi and is the most important factor in tire life Inflation pressure should be as recommended by the manufacturer for the load Pressure should be checked cold before operation Do n...

Page 30: ...ad per tire catalog Side Wear Loss of camber or over loading Adhere to load limits Have axle aligned Toe Wear Incorrect toe in Have axle aligned Cupping Loose bearing or out of balance Adjust bearing balance tires Flat spots Wheel lockup or tire skidding Adjust brakes avoid sudden stops Wear Pattern Cause Corrective Action Tire Wear Diagnostic Chart Maintenance ...

Page 31: ...voltage with a test lamp or volt meter to verify that the electrical system is functioning properly If it is then replace the lamp if not then trouble shoot the electrical system Junction Block The junction block requires no regular maintenance If an electrical problem devel ops check for corroded or loose terminals Seven Way Plug The plug should be kept clean and free of dirt If an electrical pro...

Page 32: ...r breathing dust 2 Avoid machining filing or grinding the brake linings 3 Do not use compressed air or dry brushing for cleaning Dust can be removed with a damp brush RISK OF PERSONAL INJURY Whenever it becomes necessary to jack the trailer it is up to you to ensure that the trailer or axle is supported securely Use blocks or jack stands on solid ground especially if you are going to be working un...

Page 33: ...ep b b Measure the free stroke Make the same two measurements as described above for measuring the applied stroke but instead of air pressure use a lever to move the slack adjuster arm until the brake shoes contact the drum This distance should be between 1 2 to 5 8 If the free stroke is good but the applied stroke is too long then there is a problem with the foundation brake Check the foundation ...

Page 34: ...pawl The pull pawl can be disengaged by prying up on it with a screwdriver at least 1 32 2 Turn the adjusting nut in the counterclockwise direction until the linings touch the drum and then turn the adjusting nut in the opposite direction clockwise 1 2 turn 3 Repeat the free stroke measurement procedure If it is necessary to adjust the stroke turn the adjusting nut 1 8 turn clockwise to lengthen t...

Page 35: ...ing the 22 turns then the slack adjuster is not working correctly and should be rebuilt or replaced 4 Reinstall the slack adjuster on the axle and check the free stroke length Adjust if necessary For more information regarding the slack adjuster refer to Meritor Maintenance Manual 4B Automatic Slack Adjuster Brake Lubrication Every six months or 50 000 miles the brake system should be lubricated w...

Page 36: ... 8 x 20 2 1 8x8 20 3 3 Deck Lumber 2 1 8 x 10 x 20 2 1 8x10 20 4 2 Deck Lumber 2 1 8 x 12 x 20 2 1 8x12 20 5 222 1 4 20 x 3 Torx Deck Screws 32523 6 2 Front Hanger 7701 01 7 4 Center Hanger 16180 01 8 2 Rear Hanger 7703 01 9 2 Lower Stationary Side Plate C 02024 10 1 Tool Box LidAssembly SA 14157 These items are included in Sub frameAssembly SA 03209 1 3 5 8 7 4 2 6 9 ...

Page 37: ...ption Part No 1 1 DeckAssembly SA 09188 2 2 StepAssembly SA 04069 3 2 Deck Lumber 2 1 8 X 8 24 4 5 Deck Lumber 2 1 8 X 10 20 5 1 Deck Lumber 2 1 8 X 10 24 6 2 TrailMax Mudflap B30PCB 7 2 Mudflap Bracket MFW 2375 8 246 Torx Deck Screws 1 4 20 x 3 32523 1 2 5 3 8 4 6 7 ...

Page 38: ...embly LG 75 4 001 1 1 Binkley 2 Speed Jack XAS84A001 2 1 Binkley Jack XAS94A001 3 1 Universal Crank XAV90 0 4 1 Coupler Shaft XAV1910 Note Kit names are bold type while component names are regular type kit com ponents are indexed under the kit name Kit component quantities are per kit other parts and kit quantities are per trailer 2 4 1 Parts 3 ...

Page 39: ... page 39 FWTD 50 T 17 5 Parts P A R T S THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 40: ... page 40 FWTD 50 T 17 5 Parts Cushion Cylinder Ref Quantity Description Part No 1 1 Cushion Cylinder 5 X 12 5012 1 ...

Page 41: ...Latch HandleAssembly SA 12547 5 3 Latch Pin C 06050 6 6 E clip SE 98ZD 10385 00128 7 9 Flanged Bushing GFI 1618 08 8 1 Roll Pin 3 8 x 2 64315 9 1 Bent Arm PinAssembly 2250 BENT 10 1 12 Lanyard Stainless Bracket 2250 L62N12 Note Kit names are bold type while component names are regular type kit compo nents are indexed under the kit name Kit component quantities are per kit other parts and kit quant...

Page 42: ...y SA 07099 3 2 Hinge Pin C 06179 4 2 Lock Nut 3 8 NF 37304 5 2 Bolt 3 8 x 3 1 2 Grade 8 NF 18846 2 Grease Fitting 60105 Note Kit names are bold type while component names are regular type kit com ponents are indexed under the kit name Kit component quantities are per kit other parts and kit quantities are per trailer Parts 1 4 5 3 2 6 ...

Page 43: ... 10198 7 2 Crush BlockAssembly SA 12368 8 1 Torsion BlockAssembly C 06128 9 1 Adjustable Radius Rod 16398 04 10 1 Torsion Block Pivot Pin C 12229 11 1 Linkage Pin Short C 12239 12 2 Linkage Pin Long C 12249 13 2 5 8 18 x 1 3 4 Cap Screw Gr 8 Zinc 18959 14 2 5 8 18 Flange Lock Nut Gr 8 Zinc 37246 15 6 1 2 20 x 1 1 4 Cap Screw Gr 5 Zinc 17207 16 6 1 2 20 Top Lock Nut Gr C 37308 Note Kit names are bo...

Page 44: ...us Rod 19 25 16398 04 6 8 Flanged Locknut 10562 00 7 8 Radius Rod Bolt 719 02 8 4 2 Leaf Medium Arch Spring TS 325 01 9 8 U bolt 7816 11 10 4 Bottom Plate 706 01 11 16 Washer 35 00 12 16 Hex Nut 34 04 1 Equalizer Bolt Kit 10287 00 13 4 Spacer sleeve 756 00 14 4 Spacer sleeve bolt 759 00 15 4 Hex lock nut 37 03 16 4 Air Brake Chamber Type 3030 12514 Note Kit names are bold type while component name...

Page 45: ... page 45 FWTD 50 T 17 5 Parts P A R T S 2 4 6 5 7 3 9 1 16 12 11 10 8 15 13 14 ...

Page 46: ... Quantity Description Part No 1 2 Tire 215 75R 17 5 2 2 Wheel 17 5 x 6 75HC P617 0778 B8 W4 3 2 Valve Stem 572 Note Tires are not available through Gem State Manufacturing contact your local equipment tire retailer for replacement parts Parts 2 4 1 3 ...

Page 47: ... page 47 FWTD 50 T 17 5 THIS PAGE LEFT BLANK INTENTIONALLY Parts P A R T S ...

Page 48: ... 7 5 Red clearance lamp sealed 10205R 8 4 Oval stop turn tail light sealed 60202R 9 4 Oval mounting grommet 60700 10 1 License plate lamp 26331 11 2 Boot Kit 2 connector 77850 1 Boot Kit 6 7 connector 77852 3 Boot Kit Filler 77853 1 Boot Kit 4 5 connector 77851 12 1 Junction Box 8 way 77808 1 Harness Clip 97011 Note Kit names are bold type while component names are regular type kit compo nents are...

Page 49: ... page 49 FWTD 50 T 17 5 P A R T S Parts 5 6 6 7 8 9 10 12 11 4 3 1 2 ...

Page 50: ...FWTD 50 T 17 5 Ref Quantity Description Part No 1 E 5 Electrical Kit K00061 1 1 Harness Marker 50358 2 2 Amber clearance lamp sealed 10205Y 3 2 Mounting grommet 10704 4 1 Boot Kit 2 connector 77850 1 4 2 3 Parts ...

Page 51: ... page 51 FWTD 50 T 17 5 Parts P A R T S THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 52: ...able OW4493280300 Note Kit names are bold type while component names are regular type kit com ponents are indexed under the kit name Kit component quantities are per kit other parts and kit quantities are per trailer These items are included in the AK A2 ABS air kit Electrical Receptacle Ref Quantity Description Part No 1 1 Seven Way Receptacle PL 15 720 Brown Tail and Marker Blue ECU Power Electr...

Page 53: ... page 53 FWTD 50 T 17 5 Junction Box shown for reference only 5 4 1 3 2 6 Parts ...

Page 54: ...Nylon Tubing Black NTPFT6BIN0E 10 1 Air Tank 1200 2800 cu in AT1211 11 4 Hose Assembly 3 8 x 3 8 x 30 TA32002 030 12 4 Hose Assembly 3 8 x 3 8 x 62 TA32002 062 13 3 Street Elbow 90 PB2202P 6 6 14 1 Drain Cock PBDC604 4 15 1 Allen Head Pipe Plug F1 3 4 16 1 Hose Assembly 3 8 x 3 8 x 28 TA32002 028 17 1 Electronic Control Unit ECU OW4005001030 18 1 Pipe Nipple OS60060E 19 1 Male Branch Tee 3 8 x 1 4...

Page 55: ... page 55 FWTD 50 T 17 5 Parts Detail shown on follow ing pages P A R T S 4 7 5 6 2 1 3 3 ...

Page 56: ... page 56 FWTD 50 T 17 5 Parts Hose end fitting included with 3 8 hose assemblies Hidden under tank 12 16 10 11 12 13 11 11 12 12 14 15 11 9 8 ...

Page 57: ... page 57 FWTD 50 T 17 5 Parts Hidden between ECU and tank P A R T S 13 5 20 22 18 17 4 21 13 6 19 15 ...

Page 58: ...tive in your immediate area If you do not have or can not find a representative in your area then contact the factory WarrantyAdministrator for as sistance 1 800 447 0213 4 Give a detailed description and nature of the problem Also leave contact name s phone no and or e mail address 5 A claim will be processed and reviewed for warranty approval The factory Warranty Administrator must authorize all...