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TrailMax TD-40-T, Manual

The TrailMax TD-40-T manual is available for free download on manualshive.com, providing comprehensive instructions for operating and maintaining this exceptional product. This user-friendly manual ensures smooth navigating experiences, maximizing your satisfaction with the TD-40-T. Discover all the details and download it now to elevate your trail adventures.

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TD-40-T

®

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 ............................................................ 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
Securing Loads With Chains ............................................ 15

Section 2. Maintenance .............................................................................. 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
Axle Alignment .................................................................. 23
Axle End Component Disassembly ................................... 23
Hub Inspection .................................................................. 23
Broken or Damaged Studs ............................................... 23
Brake Drum Inspection ..................................................... 24
Brake Drum Troubleshooting Chart ................................... 25
Brake Drum Troubleshooting Chart (continued) ................. 26
Axle End Component Cleaning and Inspection .................. 27
Axle End Component Assembly ........................................ 27
Wheel Bearing Adjustment ................................................ 27

Table of Contents

Rev. F 06/01/05

Summary of Contents for TD-40-T

Page 1: ...tion 2 Maintenance 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 ...

Page 2: ... Function Test 35 Brake Lubrication 35 Section 3 Parts 36 3 1 Structural Components 36 Sub frame 36 Deck Assemblies 37 3 2 Major Sub Assemblies 38 Drawbar Eye 38 Binkley 2 Speed Jack 39 Cushion Cylinder 40 Upper Lower Latch Assemblies 42 Deck HingeAssembly 44 3 3 Rear Impact Guard RIG Assembly 45 3 4 Running Gear 46 Suspension 46 Axle End Components 48 Brakes 50 Bearings and Hubs 51 3 5 Wheels and...

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 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 given ...

Page 4: ... 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 are...

Page 5: ...ailer 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 could re...

Page 6: ...iliar 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 The b...

Page 7: ... 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 without th...

Page 8: ... 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 tools can...

Page 9: ...page 9 TD 40 T 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: ...d 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 400...

Page 11: ...er 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 recommen...

Page 12: ...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 working order For trailers with air brakes connect the Glad Hands on...

Page 13: ...en 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 LOAD FO...

Page 14: ...rior 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 the...

Page 15: ... 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 TD 40 T THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 17: ...y 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 dut...

Page 18: ...on 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 Eye C...

Page 19: ... 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 of t...

Page 20: ...he 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 straighte...

Page 21: ...f 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 Visu...

Page 22: ... 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 Ite...

Page 23: ...er 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 sho...

Page 24: ... 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 in ...

Page 25: ...E 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 SPO...

Page 26: ... 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 OF R...

Page 27: ...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 cra...

Page 28: ...ith 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 to ...

Page 29: ...e 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 not b...

Page 30: ...er 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: ...age 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 problem...

Page 32: ...eathing 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 under ...

Page 33: ... 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 brak...

Page 34: ... 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 the s...

Page 35: ...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 with ...

Page 36: ... No 1 1 Sub frameAssembly SA 02107 2 2 Safety Chain and HookAssembly 3 8 ASSY 3 2 Front Hanger 7701 01 4 2 Rocker Hanger 16319 01 5 2 Rear Hanger 7703 01 6 2 Lower Latch Side Plate C 04019 7 1 Tool Box LidAssembly SA 01144 These items are included in Sub frameAssembly SA 02107 2 Parts 5 4 3 6 1 7 ...

Page 37: ... Lumber 2 1 8 X 8 24 4 9 Deck Lumber 2 1 8 X 10 10 5 1 Deck Lumber 2 1 8 X 10 24 6 5 Deck Lumber 2 1 8 X 12 10 7 2 TrailMax Mudflap B30PCB 8 2 Mudflap Bracket MFW 2375 9 256 Torx Deck Screws 1 4 20 x 3 32523 10 1 Upper LatchAssembly SA 12551 This item is included in Deck Assembly SA 12198 1 2 Parts P A R T S 7 8 3 5 6 4 9 10 ...

Page 38: ... T Parts 3 2 Major Sub Assemblies Drawbar Eye Ref Quantity Description Part No 1 1 Premier 300 Drawbar Eye 300 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 NF 36466 1 4 2 3 ...

Page 39: ...page 39 TD 40 T Parts P A R T S Binkley 2 Speed Jack Ref Quantity Description Part No 1 1 Binkley 2 Speed Jack LG4701 72 2 1 Universal Crank LG0083 01 3 1 Jack Handle Extension SA 04291 1 2 3 ...

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

Page 41: ...page 41 TD 40 T Parts P A R T S THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 42: ...1 2 Adjusting Bolt 15359 2 1 Latch Hook C 04109 3 2 Glide Latch Bearing GFI 1618 08 4 1 Latch Pin C 06050 5 2 E clip SE 982 D 10385 00128 Lower Latch Assembly 1 1 LatchArm Assembly SA 12552 2 1 Latch Handle C 12604 3 4 Glide Latch Bearing GFI 1618 08 4 2 Latch Pin C 06050 5 4 E clip SE 982 D 10385 00128 ...

Page 43: ...page 43 TD 40 T 1 5 Upper Latch Assembly 4 3 2 2 5 1 3 Lower Latch Assembly 4 ...

Page 44: ...ge Assembly Ref Quantity Description Part No 1 1 Deck Hinge Assembly SA 04027 2 2 Hinge BracketAssembly SA 07099 3 2 Hinge Pin C 06179 4 2 3 8 24 Top Lock Nut Gr C Zinc 37304 5 2 3 8 24 x 3 1 2 Cap Screw Gr 8 Zinc 18846 6 2 Grease Fitting 60105 ...

Page 45: ...1 Torsion BlockAssembly 8020141 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 bold type while component names are regular ...

Page 46: ...9 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 Spring Brake Chamber Type 2424 B213276X24 Note Kit names are bold type while component name...

Page 47: ...page 47 TD 40 T Parts P A R T S 1 2 5 8 9 10 11 12 3 4 13 14 15 16 6 7 ...

Page 48: ...ner Washer 1229 J 868 5 2 Retaining Ring 1229 X 1116 6 2 Bracket Assembly A 3105 V 282 7 2 Slack Adjuster R803205 8 2 Outer Bushing 1225 A 833 2 Inner Bushing 1225 B 834 9 2 Retaining Ring 1229 D 3124 Note Kit names are bold type while component names are regular type kit components are indexed under the kit name Kit component quantities are per kit other parts and kit quanti ties are per trailer ...

Page 49: ...page 49 TD 40 T 1 2 9 3 8 6 7 4 5 Parts ...

Page 50: ...Ring 1229 T 3166 5 2 Anchor Pin 1259 N 274 6 2 Anchor Pin Bushing 1225 B 496 7 2 Return Spring Pin 1218 G 85 8 1 Return Spring 2258 B 704 Note Kit names are bold type while component names are regular type kit components are indexed under the kit name Kit component quantities are per kit other parts and kit quanti ties are per trailer Note Quantities shown are per brake 1 2 3 7 4 5 6 8 Parts ...

Page 51: ...E 5997 5 1 Wheel Hub Non ABS Hayes 450002 1 Wheel Hub ABS Webb 20271CW3T 80 6 1 Brake Drum Webb 63680 7 1 Outer Bearing Cup HM212011 8 1 Outer Bearing Cone HM212049 9 1 Axle Jam Nut E 540 10 1 Inner Jam Nut Washer E 573 11 1 Outer Jam Nut E 572 12 1 Oil Cap Seal Stemco 330 3009 13 1 Oil Cap Stemco 340 4009 Note Quantities shown are per wheel 2 1 3 4 5 6 7 8 11 9 10 12 13 Parts ...

Page 52: ... 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 4 8 22mm x 1 5 Wheel Nut R005991 Note Tires are not available through Gem State Manufacturing contact your local equip ment tire retailer for replacement parts Parts 1 2 4 3 ...

Page 53: ...page 53 TD 40 T Parts P A R T S THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 54: ...4 9 5 Red clearance lamp sealed 10205R 10 4 Oval stop turn tail light sealed 60202R 11 4 Oval mounting grommet 60700 12 1 License plate lamp 26331 13 1 Harness ABS 52200 0084 14 1 Amber ABS lamp sealed 30257Y 15 1 ABS lamp mounting grommet 30700 16 1 Sensor Extension Cable OW4497130080 17 1 ABS Power Cable OW4493260050 Note Kit names are bold type while component names are regular type kit compo n...

Page 55: ...page 55 TD 40 T P A R T S Parts 2 1 3 4 5 6 7 8 9 8 10 11 12 13 17 16 15 14 ...

Page 56: ...ctrical Plug Ref Quantity Description Part No 1 1 Seven Way Plug and Spring PL 15 730 Brown Tail and Marker Blue ECU Power Electric Brakes Black Accessories Yellow Left Turn White Ground Green Right Turn Red Stop Parts 1 ...

Page 57: ...page 57 TD 40 T Parts THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 58: ...n Tubing Black NT PF6BIN0E 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 PB2200P 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 OW4005001020 18 1 Pipe Nipple F1 60060E 19 1 Male Branch Tee 3 8 x 1 4 PB...

Page 59: ...page 59 TD 40 T Parts Detail shown on follow ing pages P A R T S 4 7 5 6 2 1 3 3 ...

Page 60: ...page 60 TD 40 T 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 61: ...page 61 TD 40 T Parts Hidden between ECU and tank P A R T S 13 5 20 22 18 17 4 21 13 6 19 15 ...

Page 62: ... 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 War...

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