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8012DT

Maintenance

Hydraulic Brake System Troubleshooting Chart

REMEDY CAUSES SYMPTOM CAUSES REMEDY

ADJUST BRAKES

UNDERADJUSTMENT

LUBRICATE

NOISY BRAKES

LACK OF LUBRICATION

REPLACE COMPONENTS

BROKEN BRAKE

COMPONENTS

CORRECT

INCORRECT BRAKE

COMPONENTS

REPAIR OR REPLACE

ADJUST BRAKES

BROKEN OR KINKED

BRAKE LINE

TROUBLESHOOT SYSTEM

SEVERE

UNDERADJUSTMENT

NO BRAKES

MALFUNCTIONING

ACTUATION SYSTEM

PULLS TO ONE SIDE

SURGING BRAKES

BLOCKED MASTER

CYLINDER

PARKING BRAKE

CABLE FROZEN

IMPROPER LINING THICK-

NESS OR LOCATION

FREE CABLE

AND LUBRICATE

INSTALL NEW

SHOES AND LININGS

ADJUST BRAKES

INCORRECT BRAKE

ADJUSTMENT

REPLACE SHOES

AND LININGS

EXCESSIVELY WORN

BRAKE LININGS

INCORRECT LININGS

REPLACE GREASE SEAL OR CYLINDER.

INSTALL NEW SHOE AND LINING

GREASE OR FLUID

SOAKED LININGS

REBURNISH OR REPLACE

WEAK BRAKES

FROZEN MASTER CYLINDER

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

REPLACE SHOES

AND LININGS

ADJUST BRAKES

GREASE OR FLUID

ON LINING

INCORRECT BRAKE

ADJUSTMENT

HARSH BRAKES

MACHINE OR REPLACE

CLEAN OR REPLACE

OUT OF ROUND

OR CRACKED DRUMS

GREASE OR OIL

ON LINING

DRAGGING BRAKES

REPLACE COMPONENTS

ADJUST

LOOSE, BENT OR BROKEN

BRAKE COMPONENTS

MACHINE OR REPLACE

LOCKING BRAKES

INSTALL CORRECT

SHOE AND LININGS

UNMATCHED TIRES

ON SAME AXLE

RESTRICTED BRAKE

LINES OR HOSES

MALFUNCTIONING

CYLINDER ASSEMBLY

DEFECTIVE OR DAMAGED

SHOE OR LINING

ONE SIDE OUT

OF ADJUSTMENT

IMPROPER FLUID

OUT OF ROUND DRUMS

UNDERADJUSTMENT

INCORRECT TIRE

PRESSURE

MATCH TIRES ON AXLE

REPAIR OR REPLACE

CHECK FOR STUCK OR

SLUGGISH PISTONS

INSTALL CORRECT SHOE AND

LINING- COMPLETE AXLE

INFLATE EVENLY TO PROPER

PRESSURE ON BOTH SIDES

OPEN WITH COMPRESSED

AIR OR REPLACE CYLINDER

ADJUST

REPLACE RUBBER PARTS-

SERVICE WITH DOT 3 FLUID

Содержание 8012DT

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

Страница 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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