TrailMax TD-24-T(5+20), Manual

Page 1: ...ub 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 1...

Page 2: ...43 Measuring Amperage 45 Manual Brake Adjustment 46 Electric Brake System Troubleshooting Chart 47 2 9 Pre Storage Maintenance 48 2 10 Pre Season Maintenance 49 Section 3 Parts 50 3 1 Structural Compo...

Page 3: ...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 a...

Page 4: ...ot 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 limi...

Page 5: ...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...

Page 6: ...miliar 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...

Page 7: ...ry 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 n...

Page 8: ...ng brake cans before the trailer is put into service The brake system WILL NOT FUNCTION with the keys installed and the trailer will roll freely until they are removed To remove the keys use the follo...

Page 9: ...page 9 TD 24 T 5 20 Operation Spring Brake Chamber Rubber Seal Caging Key...

Page 10: ...tion 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...

Page 11: ...rder 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...

Page 12: ...g 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 properl...

Page 13: ...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 place ment of the load Load the trailer so tha...

Page 14: ...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 to...

Page 15: ...for correct operation Quarterly or 3000 miles Check wheel nut torques see page 30 Check brakes for adjustment air brakes see page 34 electric brakes see page 46 Semi Annually or 6000 miles Lubricate...

Page 16: ...sion If the trailer has been overloaded or in an accident inspect the 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...

Page 17: ...e 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 designe...

Page 18: ...rmity 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 defor...

Page 19: ...pension system seat in as much as 25 of the original clamp load on the bolted joints can be lost After the parts of the suspension have worked together for a very short period of time re torquing the...

Page 20: ...5 8 diameter U bolts 110 130 lb ft 4 3 4 diameter U bolts 130 170 lb ft Item 4 Torque U bolts in the sequence shown TORQUE REQUIREMENTS Follow all torque requirements Do not use any component with vi...

Page 21: ...trailer W1 W2 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 X1 is 1 8 less than X2 Next check the W and Z di...

Page 22: ...being careful not to allow the outer bearing cone to fall out The inner bearing cone should be retained by the oil seal Hub Inspection Clean the hub with a commercial solvent for inspection Check for...

Page 23: ...at 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...

Page 24: ...HIGH TEMPERATURES IN 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 DIS...

Page 25: ...EL 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 WIT...

Page 26: ...rk surface with the cup to be removed on the bottom side 2 Using a brass drift punch carefully tap around the small diameter end of the cup to drive it out 3 After cleaning the hub bore area tap in th...

Page 27: ...lean the hub surfaces If the bearing is removed for any reason be 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...

Page 28: ...ls which can lead to loose wheels resulting in a crash 3 Fit Use only the correct matched parts when mounting disc wheels Incorrect components can result in separation of the rim components 4 Bolt Cir...

Page 29: ...t install a tube to correct a leak through the rim If the rim is cracked the air pressure in the tube may cause the pieces of the rim to explode with great force and can cause serious injury or death...

Page 30: ...age the stud threads Make sure the disc wheel is flat against the mounting surface and there is clearance between the disc wheel taper and the brake drum Position the outer disc wheel against the inne...

Page 31: ...on and significantly reduced service life Use tire mounting procedures as outlined by the Rubber Manufacturers Association or the tire manufacturer Inflation Pressure Correct tire inflation pressure f...

Page 32: ...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 bal...

Page 33: ...tage 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 junct...

Page 34: ...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 suppo...

Page 35: ...uler measure the distance from the face of the air chamber to the center of the large pin in the clevis Make an 85 psi brake application and allow the chamber pushrod to travel to its maximum stroke A...

Page 36: ...cracked brake drums or improper lining to drum contact If the free stroke is less than 3 8 then a dragging brake can occur Readjust the slack adjuster manually as described below If the applied strok...

Page 37: ...extension did not rotate clockwise or it took less than 15 lbs ft of torque to rotate the hex extension then the slack adjuster must be replaced If an imme diate replacement part is not available the...

Page 38: ...ectromagnets 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 dru...

Page 39: ...ide 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 controller pr...

Page 40: ...skid Note Minimum vehicle stopping distances are achieved when wheels approach lockup however actual brake lockup should be avoided as it results in poor vehicle stability and control Depending on lo...

Page 41: ...ets Your electric brakes are equipped with high quality electromagnets that are de signed to provide the proper input force and friction characteristics Your magnets should be inspected and replaced i...

Page 42: ...nce 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 li...

Page 43: ...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 actuated sh...

Page 44: ...TD 24 T 5 20 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 AMMETER Maint...

Page 45: ...ual 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 ends Make su...

Page 46: ...t maximum gain should be 3 0 amps for each magnet in the circuit Manual Brake Adjustment Your brakes are designed with automatic adjusters The following procedure can be used for manual adjustment aft...

Page 47: ...OKEN BRAKE COMPONENTS OVERLOADED TRAILER ADJUST CLEAN OR REPLACE INCORRECT BRAKE COMPONENTS UNDERADJUSTMENT CORRECT MACHINE OR REPLACE GREASE OR OIL ON LININGS OR MAGNET IMPROPER SYNCHRONIZATION TEST...

Page 48: ...blocks under the suspension tie plates so that 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 protec...

Page 49: ...check at approxi mately 3 ohms If shorted or excessively worn replace the magnets 6 Lubricate all brake moving parts using a high temperature brake lubricant Lubriplate or equivalent BRAKE LINING CONT...

Page 50: ...24 T 5 20 Section 3 Parts 3 1 Structural Components Sub frame Ref Quantity Description Part No 1 1 Sub frame Assembly A 10139 2 2 Safety Chain and Hook Assembly 3 8 ASSY 3 2 Deck Lumber 2 X 12 X 20 1...

Page 51: ...tity Description Part No 1 1 Deck Assembly A 10019 2 2 Step Assembly SA 04069 3 2 Deck Lumber 2 X 8 x 20 4 Deck Lumber 2 X 10 x 20 2 Deck Lumber 2 X 10 X 24 1 Deck Lumber 2 X 12 X 24 4 2 TrailMax Mudf...

Page 52: ...5 20 Parts 3 2 Major Sub Assemblies Drawbar Eye Ref Quantity Description Part No 1 1 Drawbar Eye BDB 1250 15D 2 4 3 4 x 2 1 2 Bolt Grade 8 NF 18992 3 4 3 4 Lock Washer 33632 4 4 3 4 Hex Nut Grade 8 N...

Page 53: ...page 53 TD 24 T 5 20 P A R T S Parts Binkley Jack Ref Quantity Description Part No 1 1 Binkley Jack 48000 2 1 Universal Crank LG0083 01 3 1 Jack Handle Extension SA 04291 1 2 3...

Page 54: ...page 54 TD 24 T 5 20 Parts Cushion Cylinder Ref Quantity Description Part No 1 1 Cushion Cylinder 4 x 16 SA 03027 1...

Page 55: ...k Latch Assembly Ref Quantity Description Part No 1 1 Latch Assembly SA 03114 2 1 Roll Pin 3 8 x 2 64315 3 8 Flanged Bushing GFI 1618 08 4 6 E clip SE 982 D 10385 00128 5 3 Groove Pin C 06050 6 1 Safe...

Page 56: ...sembly SA 07099 3 2 Hinge Pin C 12665 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...

Page 57: ...1 Torsion Block Pivot Pin C 12229 7 2 Linkage Pin Short C 12239 8 1 Linkage Pin Long C 12249 9 1 Pushrod Bolt 9 16 x 3 shackle bolt B 3 10 1 Pushrod Nut for shackle bolt N 3 11 2 Crush Block Assembly...

Page 58: ...59 160 00 1 Multi Axle Conversion Kit HAP 203 03 4 2 Spring Eye Bolt 007 169 00 5 2 Keeper Bolt 007 095 00 6 2 Lock Nut 006 112 00 7 2 Lock Nut 006 046 00 8 2 Center Hanger 029 037 04 9 1 L H Equalize...

Page 59: ...page 59 TD 24 T 5 20 2 6 7 11 8 3 9 10 5 4 12 13 14 16 15 1 Parts P A R T S...

Page 60: ...ting Screw 7 103 5 1 Brake Drum 9 28 1 6 1 Hub with Cups and Studs RH 8 214 8 7 1 Locating Pin 56 8 8 8 Wheel Mounting Stud RH 7 115 9 1 Outer Bearing Cup 28622 10 1 Outer Bearing Cone 28682 11 1 Tang...

Page 61: ...page 61 TD 24 T 5 20 4 5 6 8 7 16 15 14 13 11 9 12 10 Parts P A R T S 3 2 1...

Page 62: ...for 1 brake 71 98 9 2 Roller 14 57 2 Roller Pin 56 10 2 Roller Pin Retainer 69 18 10 2 Anchor Pin 56 11 4 Anchor Pin Washer 5 73 4 Anchor Pin Retainer 69 19 11 1 Anchor Pin Clamping Screw 7 137 12 2 R...

Page 63: ...page 63 TD 24 T 5 20 9 12 10 13 5 7 6 3 4 3 1 6 8 7 17 2 11 16 15 14 Parts P A R T S...

Page 64: ...7 71 1 1 Actuating Arm Assembly RH 47 72 1 6 3 Cable Tie 27 15 7 1 Arm Shoe Retainer LH 71 16 1 Arm Shoe Retainer RH 71 16 1 8 1 Flange Nut 6 62 1 Magnet Kit 71 108 9 1 Magnet Retainer Clip 46 55 10 1...

Page 65: ...page 65 TD 24 T 5 20 1 2 3 4 5 6 7 8 9 10 11 12 1 13 14 15 18 17 23 16 19 20 21 22 Parts P A R T S...

Page 66: ...on Part No 1 2 Tire 245 75R 16 2 2 Wheel 17 5 x 6 75 17 279 14 SP 3 2 Valve Stem 501 4 1 Clamp Ring 33 52 1 5 8 Wheel Nut 6 109 Note Tires are not available through Gem State Manufacturing contact you...

Page 67: ...page 67 TD 24 T 5 20 Parts P A R T S THIS PAGE LEFT BLANK INTENTIONALLY...

Page 68: ...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...

Page 69: ...page 69 TD 24 T 5 20 Parts P A R T S 5 6 6 7 8 9 10 12 11 4 3 1 2...

Page 70: ...rt No 1 E 9 Electrical Kit K01185C 1 1 Harness ABS 52200 0240 2 1 Amber ABS lamp sealed 30257Y 3 1 Mounting Grommet 30700 4 1 Boot Kit 2 conductor 77850 1 Boot Kit 4 5 conductor 77851 5 2 Sensor Exten...

Page 71: ...page 71 TD 24 T 5 20 Junction Box shown for reference only Parts P A R T S 4 1 3 2 6 5...

Page 72: ...page 72 TD 24 T 5 20 Ref Quantity Description Part No 1 E 6 Electrical Kit 51306 1 1 Harness Electric Brake 512332 2 1 3 8 Connector Kit 77850 2 1 Parts...

Page 73: ...page 73 TD 24 T 5 20 Electric Breakaway System Ref Quantity Description Part No 1 1 Electric Breakaway Kit 110898 1 Parts P A R T S...

Page 74: ...1 Air Tank 9508 1488 AT9534 11 2 Hose Assembly 3 8 x 3 8 x 32 TA32002 032 12 1 Hose Assembly 3 8 x 3 8 x 28 TA32002 028 13 2 Hose Assembly 3 8 x 3 8 x 56 TA32002 056 14 2 Hose Assembly 3 8 x 3 8 x 62...

Page 75: ...page 75 TD 24 T 5 20 Parts Detail shown on follow ing pages P A R T S 4 7 5 6 2 1 3 3...

Page 76: ...page 76 TD 24 T 5 20 Parts Hose end fitting included with 3 8 hose assemblies Hidden under tank 15 11 16 17 14 15 9 8 13 10 12 13 11...

Page 77: ...page 77 TD 24 T 5 20 Parts Hidden between ECU and tank P A R T S 15 5 15 20 19 18 4 21 15 6...

Page 78: ...ve 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 4 Give a detailed description a...