TrailMax 8012DT Manual Download

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8012DT

Power Unit Control Valve

Parts

Summary of Contents for 8012DT

Page 1: ...ts 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 Gear 16 Suspension 16 Hubs and Drums 16 Brake Drum In...

Page 2: ...ing Chart 38 2 9 Pre Storage Maintenance 40 2 10 Pre Season Maintenance 41 Section 3 Parts 42 3 1 Structural Components 42 3 2 Major Sub Assemblies 45 Binkley Jack 45 Couplers 46 3 3 Running Gear 48 H...

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: ...eir 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...

Page 11: ...ng capacity or other unstable trailer characteristics which could result in an accident causing property damage bodily injury or death It is the operators responsibility to take whatever steps necessa...

Page 12: ...ading 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 i...

Page 13: ...ly Check for loose or missing suspension fasteners Check brake adjustment see page 25 Quarterly Lube Demco surge actuator rollers see SurgeActuator Maintenance on page 27 Annually Pack wheel bearings...

Page 14: ...ther 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 weathe...

Page 15: ...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 If...

Page 16: ...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 17: ...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 18: ...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 19: ...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 Reinstallatio...

Page 20: ...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 21: ...lean 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 of...

Page 22: ...bber Manufacturers Association or the tire manufacturer Inflation Pressure Correct inflation pressure for the ST235 80R16 tire is 65 psi and is the most impor tant factor in tire life Inflation pressu...

Page 23: ...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 24: ...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 25: ...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 26: ...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 27: ...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 28: ...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 29: ...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 30: ...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 31: ...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 32: ...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 33: ...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 34: ...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 35: ...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 36: ...e 36 8012DT 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 37: ...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 38: ...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 39: ...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 40: ...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 41: ...ing 5 Check 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...

Page 42: ...hain and HookAssembly 1 4 ASSY 6 4 D ring B38W 1 Tandem Hanger Kit H202 AP216 PKG2 10429 7 2 Front Hanger 28 1 8 2 Equalizer 13 44 9 2 Equalizer Bolt 7 8 x 4 5 8 7 1 1 10 2 7 8 Hex Locknut for 7 1 1 b...

Page 43: ...page 43 8012DT 1 2 3 4 6 5 8 7 9 10 11 12 13 14 15 16...

Page 44: ...page 44 8012DT THIS PAGE LEFT BLANK INTENTIONALLY...

Page 45: ...ef Quantity Description Part No 1 Dump Trailer Jack Assembly SA 14093 1 1 Binkley Jack Drop Leg 12K 4800 2 1 Jack Drop Foot Extension C 14059 3 1 Jack Plunger Extension C 14058 4 1 Jack Handle Extensi...

Page 46: ...page 46 8012DT Couplers Ref Quantity Description Part No 1 1 2 5 16 Lever Lock Coupler 07678 97 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 47: ...Quantity Description Part No 1 1 Pintle Eye 09557 97 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 availab...

Page 48: ...per springs and u bolt kits 2 4 24 3 5K Slipper Spring 1203T3 4 U Bolt Kit 3 round axle APUBR 8 3 2 U bolt 1 2 1755892LN 4 1 Tie Plate 117521 5 4 Hex Nut 1 2 12N 6 4 Lock Washer 1 2 12LW Note Kit name...

Page 49: ...page 49 8012DT Parts P A R T S 1 2 3 4 5 6...

Page 50: ...1 Adjusting ScrewAssembly SB42159 8 1 Spring Adjusting Screw SB24765 9 1 Shoe Lever SB18502 95 10 1 Travel Link SB17917 95 11 1 Locknut 05962 12 2 5 16 Star Washer 05424 13 1 Pin Front Shoe 05824 14...

Page 51: ...page 51 8012DT Parts P A R T S 15 24 17 25 7 8 21 1 18 22 5 4 6 9 11 10 2 12 14 20 19 16 13 11 12 3 23...

Page 52: ...Shoe and Lining 040 045 00 7 2 Shoe Hold Down Pin 049 011 00 8 2 Shoe Hold Down Spring 048 077 00 9 1 AdjusterAssembly 043 004 00 10 1 Adjusting Screw Spring 046 018 00 1 Magnet Kit K71 105 00 11 1 Ma...

Page 53: ...page 53 8012DT Parts P A R T S 9 10 8 6 12 11 13 17 1 7 14 15 3 2 5 16 4...

Page 54: ...earing Cup 031 030 01 4 6 1 2 Wheel Stud 007 262 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 Washer 005 023 00 9 1...

Page 55: ...y Description Part No 1 1 Tire ST235 80R16 2 1 Wheel 17 153 14 SP 3 8 Wheel Nut 1 2 20 60 006 080 00 Note Tires are not available through Gem State Manufacturing contact your local equipment tire reta...

Page 56: ...urn Tail Light sealed 60202R 5 2 Oval Mounting Grommet 60700 6 1 License Plate Lamp 26331 7 1 Main Harness 51437 8 2 Marker Clearance Harness 50321 0216 9 1 Tail Light Harness 51305 10 1 Electric Brak...

Page 57: ...page 57 8012DT Parts P A R T S 9 10 2 3 2 1 6 8 7 5 4...

Page 58: ...ck Accessories White Ground Yellow Left Turn Stop Brown Tail and Marker Green Right Turn Stop Red or Blue ECU Power Electric Brakes Brown Tail and Marker Red or Blue Electric Brakes Black Accessories...

Page 59: ...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 per kit other parts and kit qu...

Page 60: ...1 Brake Line 113 AG 16113 C 6 2 Brake Line 62 T 16062 C 7 1 Brake Line 71 T 16071 C 8 8 1 4 Loom Clamp A0250 Finish Surge Line Kit 0716 08 9 1 Brake Hose 13 18013 MF 10 4 Hose Clip 1457 Note Kit names...

Page 61: ...page 61 8012DT Parts P A R T S 1 3 2 7 8 5 6 4 10 9...

Page 62: ...8 Hex Head Bolt Grade 5 05961 13 2 5 16 External Tooth Lock Washer 05424 14 4 1 4 20 UNC x 2 Hex Head Bolt Grade 5 00618 15 4 1 4 Lock Washer 00057 16 1 Emergency Lever 05951 17 1 Push RodAssembly 03...

Page 63: ...page 63 8012DT Parts 9 7 5 3 1 20 25 24 17 15 14 21 23 13 12 16 10 8 2 6 11 18 4 22...

Page 64: ...page 64 8012DT Parts Power Unit Motor...

Page 65: ...page 65 8012DT P A R T S Parts THIS PAGE LEFT BLANK INTENTIONALLY...

Page 66: ...page 66 8012DT Power Unit Control Valve Parts...

Page 67: ...page 67 8012DT Parts P A R T S Power Unit Control Valve Schematic...

Page 68: ...page 68 8012DT Gear Pump and Manifold Assembly Parts List Parts...

Page 69: ...page 69 8012DT Parts P A R T S Gear Pump and Manifold Assembly Parts Illustration...

Page 70: ...page 70 8012DT 3 7 Tool Box Ref Quantity Description Part No 1 1 Tool Box TM321 421...

Page 71: ...page 71 8012DT P A R T S THIS PAGE LEFT BLANK INTENTIONALLY...

Page 72: ...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 WarrantyAdministrator for as sistance 1 800 447 0213...

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