TrailMax S-5-UT, Manual

Page 1: ...3 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...

Page 2: ...eshooting 35 Measuring Voltage 35 Measuring Amperage 37 Electric Brake System Troubleshooting Chart 38 2 9 Pre Storage Maintenance 40 2 10 Pre Season Maintenance 41 Section 3 Parts 42 3 1 Structural C...

Page 3: ...er 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...

Page 4: ...d 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 gre...

Page 5: ...cantly 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...

Page 6: ...liar 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 t...

Page 7: ...hat 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 St...

Page 8: ...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...

Page 9: ...sting 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 whe...

Page 10: ...er gency to tow vehicle Shut off petcock s on air tank s or if already shut open to exhaust all moisture then shut off It is very important that the air system be drained of moisture after each use to...

Page 11: ...t 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 place ment of the load Load the trailer so that 6...

Page 12: ...ding 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...

Page 13: ...t of cargo should never exceed XXX kg or XXX lbs on your vehicle s placard See figure 1 1 2 This figure equals the available amount of cargo and luggage load capacity 3 Determine the combined weight o...

Page 14: ...nance activities can also Improve vehicle handling Help protect you and others from avoidable breakdowns and accidents Improve fuel economy Increase the life of your tires This booklet presents a comp...

Page 15: ...r pressure measured in pounds per square inch psi a tire requires to be properly inflated You will also find this number on the vehicle information placard expressed in kilopascals kPa which is the me...

Page 16: ...of all tires Step 3 If the tire pressure is too high in any of the tires slowly release air by gently pressing on the tire valve stem with the edge of your tire gauge until you get to the correct pre...

Page 17: ...coln s head upside down and facing you If you can see the top of Lincoln s head you are ready for new tires A 9 Tire Balance and Wheel Alignment To avoid vibration or shaking of the vehicle when a tir...

Page 18: ...as the aspect ratio gives the tire s ratio of height to width Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement R The R stand...

Page 19: ...mph tire manufacturers some times use the letters ZR For those with a maximum speed capability over 186 mph tire manufacturers always use the letters ZR U S DOT Tire Identification Number This begins...

Page 20: ...a tire graded 400 should last twice as long as a tire graded 200 Traction Letter This letter indicates a tire s ability to stop on wet pavement A higher graded tire should allow you to stop your car...

Page 21: ...tion the tire is for trailer use only Max Load Dual kg lbs at kPa psi Cold This information indicates the maximum load and tire pressure when the tire is used as a dual that is when four tires are put...

Page 22: ...Check tire pressure regularly at least once a month including the spare Inspect tires for uneven wear patterns on the tread cracks foreign objects or other signs of wear or trauma Remove bits of glass...

Page 23: ...hly Check for loose or missing suspension fasteners Check brake adjustment see page 25 Quarterly Lube Dico surge actuator rollers see Surge Actuator Maintenance on page 27 Annually Pack wheel bearings...

Page 24: ...ither rubber compound or wood For wood decks 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 weath...

Page 25: ...lug and drain out the old fluid Add 10W hydraulic fluid until the cylinder is full and all the air has been expelled Deck Latch If the latch becomes difficult to operate apply some penetrating lubrica...

Page 26: ...cess wear elongation of bolt holes and loosening of fasteners Whenever loose or replaced the fasteners in your suspension system should be torqued as detailed below 1 U bolt 45 to 60 lbs ft 2 Shoulder...

Page 27: ...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 NOTE Bea...

Page 28: ...e Bearing Lubrication If your axles are equipped with the E Z Lube feature the bearing can be lubricated without removing the hubs from the axle The feature consists of axle spindles that have been sp...

Page 29: ...sure to reinstall it before pressing in the new seal Apply a Permatex sealant to the outside of the new seal metal seal shells only 3 Tap the seal into place using a clean wood block Hub Reinstallati...

Page 30: ...s 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 m...

Page 31: ...e clean dry and in good condition for applying installation torque Tighten the lug nuts in the following pattern in three steps first to 20 25 lbs ft next to 50 60 lbs ft and then to the final torque...

Page 32: ...Rubber Manufacturers Association or the tire manufacturer Inflation Pressure Correct tire inflation pressure LT245 75R 16 E 80 psi ST225 75R 15 D 65 psi is the most important factor in tire life Infl...

Page 33: ...rticular load 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 Adju...

Page 34: ...or volt meter to verify that the electrical system is functioning properly If it is then replace the lamp if not then troubleshoot the electrical system Junction Block The junction block requires no r...

Page 35: ...und especially if you are going to be working under the trailer Brake Adjustment Brakes should be adjusted 1 after the first 200 miles of operation when the brake shoes and drums have seated 2 at 3000...

Page 36: ...ning is worn to 1 16 thickness or less contaminated with grease or brake fluid or abnormally scored or gouged Hardware Check all hardware Check shoe return spring hold down springs and adjuster spring...

Page 37: ...which then causes the trailer brakes to be applied Surge Actuator Maintenance Before towing check that the brake fluid reservoir is full If not refill to 3 8 inch below the top of the reservoir with...

Page 38: ...pect the hoses for age checking cracking of the outer rubber sheath damage blisters or other signs of impending failure and replace as neces sary Hydraulic Brakes The hydraulic brakes on your trailer...

Page 39: ...wheel cylinder left rear if tandem axle You should always begin the bleeding operation on the wheel cylinder that is farthest from the master cylinder Have the loose end of the hose submerged in a gla...

Page 40: ...OR WHEEL CYLINDER PISTONS REPLACE EXCESSIVE DRUM WEAR BLEED SYSTEM TRAPPED AIR IN LINES CORRECT OVERLOADED TRAILER TROUBLESHOOT SYSTEM MALFUNCTIONING ACTUATION SYSTEM ADJUST BRAKES OVERLOADED TRAILER...

Page 41: ...electromagnets in the brakes The high capacity electromagnets are energized and are attracted to the rotating armature surface of the drums which moves the actuating levers in the direction that the d...

Page 42: ...lers provide a modulation function that varies the current to the electric brakes with the pressure on the brake pedal or amount of deceleration of the tow vehicle It is important that your brake cont...

Page 43: ...els and tires not all trailer brakes are capable of wheel lockup If the controller is applying the trailer brakes before the tow vehicle brakes then the controller level adjustment should be adjusted...

Page 44: ...agnets that are de signed to provide the proper input force and friction characteristics Your magnets should be inspected and replaced if worn unevenly or abnormally As indicated below a straight edge...

Page 45: ...of the tow vehicle should be running when checking the voltage so that a low battery will not affect the readings Voltage in the system should begin at zero volts and as the controller bar is slowly a...

Page 46: ...e 36 S 5 UT Maintenance From Trailer Harness From Trailer Harness To measure VOLTAGE measure across both brake magnet wires To measure AMPERAGE measure between one open brake magnet wire VOLTMETER AMM...

Page 47: ...g Individual brake amperage draw can be measured by inserting the ammeter in the line at the magnet you want to check Disconnect one of the magnet lead wires and attach the ammeter between the two end...

Page 48: ...ss or malfunction are traceable to improperly adjusted or non functioning controllers See your controller manufacturers data for proper ad justment and testing procedures If the voltage and amperage i...

Page 49: ...LAZED LININGS CORRECT CORRECT BROKEN BRAKE COMPONENTS OVERLOADED TRAILER ADJUST CLEAN OR REPLACE INCORRECT BRAKE COMPONENTS UNDERADJUSTMENT CORRECT MACHINE OR REPLACE GREASE OR OIL ON LININGS OR MAGNE...

Page 50: ...the weight will be off the tires The best way to jack the trailer for this is to place the jack under the trailer frame rail using a wood block to protect the finish Raise the jack until the suspensio...

Page 51: ...brake magnets with an ohmmeter The magnets should check at 3 2 ohms If shorted or excessively worn replace the magnets 6 Lubricate all brake moving parts BRAKE LINING CONTAMINATION Do not get grease o...

Page 52: ...n Part No 1 2 Safety Chain and Hook Assembly 1 4 ASSY 2 1 Tongue Assembly SA 06249 3 6 D ring B 40 4 2 Hinge Pin Assembly SA 06159 5 2 Fender Assembly SA 02168 6 1 Left Hand Tail Light Bracket SA 0604...

Page 53: ...page 43 S 5 UT Parts P A R T S 1 2 6 5 8 3 4 7...

Page 54: ...1 2 32519 9 Rubber Compound Decking 9106 16 200 Torx Deck Screws 1 4 20 x 2 1 2 32519 Note Rubber compound decking requires additional crossmember support and cannot be retrofitted to trailers built...

Page 55: ...cription Part No 1 Hammerblow Top Wind Snap Ring Jack 151401 1 1 Outer Tube Assembly 018911 2 1 Inner Tube Assembly 018920 3 1 Crank Assembly 018916 4 1 Plunger Assembly 018400 5 1 Swivel Bracket 0159...

Page 56: ...page 46 S 5 UT Couplers Ref Quantity Description Part No 1 1 2 Ball Coupler 05823 X 2 4 5 8 11 UNC x 1 5 8 Hex Head Bolt Grade 5 04051 3 4 5 8 11 UNC Stover Lock Nut 03730 Parts 1 2 3...

Page 57: ...ity Description Part No 1 1 Pintle Eye B16137 2 2 5 8 11 UNC x 4 1 2 Hex Head Bolt Grade 5 02434 3 2 5 8 11 UNC Nylon Insert Lock Nut 02587 Note Pintle Eye and associated hardware is an available opti...

Page 58: ...page 48 S 5 UT Parts Cushion Cylinder Ref Quantity Description Part No 1 1 Cushion Cylinder 3 x 4 30X04 1...

Page 59: ...4 3 Grooved Pin C 12644 5 6 E clip SE 982 D 10385 00118 6 6 Flanged Bushing GFI 1214 06 7 1 Latch Handle C 12535 Note Kit names are bold type while component names are regular type kit com ponents if...

Page 60: ...Hanger 721585 5 8 Shackle Bolt 9 16 x 3 1 2 91635B 6 8 Hex Locknut 9 16 916DLN 7 2 5 K Slipper Spring E 5226 2 Shackle Bolt Kit 4201 5 2 Shackle Bolt 9 16 x 3 1 2 91635B 6 2 Hex Locknut 9 16 916DLN 2...

Page 61: ...page 51 S 5 UT Parts P A R T S 1 3 4 5 7 6 8 9 11 10 2...

Page 62: ...57 6 1 Push Rod 9783 7 1 Adjusting Screw Assembly 23323 8 1 Spring Adjusting Screw 9784 9 1 Shoe Lever 46223 10 1 Travel Link 17917 11 2 Locknut 17406 12 1 Hex Cap Screw 7949 13 1 Pin Front Shoe 12560...

Page 63: ...page 53 S 5 UT 15 24 17 25 7 8 21 23 3 1 18 22 5 4 6 9 11 10 2 12 14 20 19 16 13 11 Parts P A R T S...

Page 64: ...40 045 00 7 2 Shoe Hold Down Pin 049 011 00 8 2 Shoe Hold Down Spring 048 077 00 9 1 Adjuster Assembly 043 004 00 10 1 Adjusting Screw Spring 046 018 00 1 Magnet Kit K71 105 00 11 1 Magnet white wire...

Page 65: ...page 55 S 5 UT 9 10 8 6 12 11 13 18 17 1 7 14 15 3 2 5 16 4 Parts P A R T S...

Page 66: ...030 02 3 1 Inner Bearing Cup 031 030 01 4 6 1 2 Wheel Stud 007 122 00 5 1 Brake Drum 6 stud on 5 5 circle 008 201 09 6 1 Outer Bearing Cup 031 029 01 7 1 Outer Bearing Cone 031 029 02 8 1 Spindle Wash...

Page 67: ...es Ref Quantity Description Part No 1 1 Tire LT245 75R 16 E 2 1 Wheel 17 153 14 SP 3 6 Wheel Nut 1 2 20 60 006 080 00 Note Tires are not available through Gem State Manufacturing contact your local eq...

Page 68: ...p sealed 10205Y 4 2 Oval Stop Turn Tail Light sealed 60202R 5 2 Oval Mounting Grommet 60700 6 1 License Plate Lamp 26331 7 1 Main Harness 51440 8 2 Marker Clearance Harness 50321 0120 Note Kit names a...

Page 69: ...page 59 S 5 UT 5 4 2 3 2 1 6 7 8 Parts P A R T S...

Page 70: ...y Plug S603 Note Six Way Plug is an available option Brown Tail and Marker Red or Blue Electric Brakes Black Accessories Yellow Left Turn White Ground Green Right Turn Open Not Used Black Accessories...

Page 71: ...Harness 51362 0096 3 4 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 Kit component quantities are...

Page 72: ...Hose Bracket 25 x 15 4 5 Hose Clip 1457 5 1 Adapter Tee 7900 6 1 Brake Line 82 T 16082 C 7 2 Brake Line 64 1 2 T 16064 50 C 8 1 Brake Line 50 T 16050 C Note Kit names are bold type while component nam...

Page 73: ...page 63 S 5 UT Parts P A R T S 7 1 4 3 6 8 2 5...

Page 74: ...961 17 4 1 4 20 UNC x 3 4 Hex Head Bolt Grade 5 01076 18 2 1 4 Internal Tooth Lock Washer 05695 19 1 Emergency Lever 05951 20 1 Master Cylinder Cap w diaphragm and O ring 03876 Replacement O ring 0584...

Page 75: ...page 65 S 5 UT Parts P A R T S 1 22 21 24 29 23 26 30 31 11 6 4 5 3 2 14 7 10 9 12 13 19 27 15 25 16 8 28 18 17 20 8...

Page 76: ...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...