TrailMax TD-40-T Bedienungsanleitung
page 1
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
page 2
TD-40-T
®
Table of Contents
Wheel Bearing Lubrication ............................................... 27
2.5 Wheels and Tires ................................................................ 27
Wheels ............................................................................. 27
Wheel Torquing Procedures .............................................. 28
Tires ................................................................................. 29
Inflation Pressure .............................................................. 29
Tire Wear Diagnostic Chart .............................................. 30
2.6 Electrical ............................................................................ 31
Harnesses and Lights ....................................................... 31
Junction Block .................................................................. 31
Seven-Way Plug ............................................................... 31
2.7 Brake System ..................................................................... 32
Preventive Maintenance ................................................... 32
Manual Brake (Free Stroke) Adjustment ............................ 34
Slack Adjuster 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 Hinge Assembly ...................................................... 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 Tires ................................................................ 52
3.6 Electrical ............................................................................ 54
Harnesses and Lights ....................................................... 54
Electrical Plug .................................................................. 56
3.6 Air Brake System ............................................................... 58
Section 4. Warranty Claim Procedure ....................................................... 62
Section 2. Maintenance ................................................................ Continued
page 3
TD-40-T
®Operation
O
P
E
R
A
T
I
O
N
Section 1. Operation
1.0 Introduction
This section describes how trailers can have different operational characteristics
based on design, load configuration, gross weights, suspension characteristics, articu-
lation and extreme differences between loaded and unloaded weights.
Trailers have safe operating limits just as automobiles, airplanes, and other ve-
hicles. The interaction of the vehicle characteristics, maintenance, load, roadway,
weather, the skill of the driver and vehicle speed affect these limits. Knowledge of how
these factors affect the vehicle’s operating limits and utilization of defensive driving
techniques should result in safer driving.
1.1 Purpose
The purpose of this section is to describe how the vehicle characteristics, mainte-
nance, road conditions, and weather can affect trailer control and 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 the opportunity to read this manual.
1.2 Rating
Gross Axle Weight Rating (GAWR) is the rated load-carrying capacity of an indi-
vidual axle and wheel assembly. It represents the load that may be steadily sustained
by the components in the system; i.e., tires, wheels, hubs, bearings, axles, brakes,
suspension, sub-frame, etc. with the GAWR limited by the component with the lowest
working rating. Consideration of environmental and operational factors may require the
manufacturer to reduce the nominal rating.
Gross Vehicle Weight Rating (GVWR) is the maximum rated combined weight of a
trailer and its payload (uniformly distributed) based on its structural capabilities.
page 4
TD-40-T
®
Operation
1.3 Design and Safety Factors
The safety factor is a ratio between the design stress imposed by the load sitting
static on the trailer and the minimum yield stress of the steel used in construction of
that trailer structure. For example, if the structure is built using 50,000 psi minimum
yield strength steel and the load sitting on it causes a stress level of 25,000 psi then a
2:1 safety factor would exist. THIS SAFETY FACTOR DOES NOT MEAN THAT THE
STRUCTURE CAN THEN BE USED TO CARRY TWICE THE RATED LOAD. Under
dynamic conditions, or as the trailer moves and encounters shocks, vibrations, twists
and other conditions that exist during transport, stress levels are elevated far beyond
those in the static situation.
Distributed Load is when a load is distributed evenly over the length of the trailer
deck. This would be considered as the ideal load scenario when fully loaded to rated
capacity.
Concentrated Load is one that is localized over a shorter than normal distance and
imposes greater stress in the concentrated load areas. Under these conditions, it is not
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 designed to provide maximum directional
control and roll stability within the constraints of highway size and weight limits. Any
combination can be rolled over by driving too fast around a curve, making too abrupt a
maneuver, or by leaving the roadway. Locking up the wheels on an axle can result in a
jackknife or trailer swing out.
One of the major contributing factors to vehicle rollover is high center of gravity on
tall loads. Extreme caution should be used in maneuvering a vehicle and trailer combi-
nation, or any unit that has a tall load. Positioning the load in a central side to side
location will enhance directional control, roll stability and braking.
You should be aware that trailers with a shorter wheel base are more prone to roll
during an abrupt lane change or quick reactions at the wheel. This tendency can be
made dramatically worse with a tall, high center of gravity load.
page 5
TD-40-T
®Operation
O
P
E
R
A
T
I
O
N
Overloading a vehicle should never be permitted. Overloading results in tire blow-
outs, spring breakage, frame damage, diminished braking capacity, and will severely
alter the vehicle’s normal handling characteristics. All vehicles are designed with a
maximum load capability. To best utilize these vehicles in the safest manner the loads
as shown on the certificate label should not be exceeded.
Adequate tongue weight is required for trailers to tow correctly. Inadequate tongue
weight can cause a “whipping action” particularly in shorter wheel base trailers. Too
much tongue weight can overload tow vehicle hitch resulting in reduced steering load
and loss of steering control. Selecting the correct tow vehicle is crucial for the applica-
tion.
Always maintain enough braking and stopping distance. Erratic or unequal brake
action from side to side on either tow vehicle or trailer can cause handling problems in
braking situations. A balance between tow vehicle and trailer on brake application and
release timing and synchronized pressure will reduce push/pull characteristics which
when excessive, may result in jackknife. The use of properly matched brake lining is
recommended to enhance safer braking.
Proper alignment of both tow vehicle and 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 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 result in an accident if proper precautions and driving
techniques are not followed. Even a vehicle that meets all maintenance and load re-
quirements can become hazardous when excessive speeds and certain roadway char-
acteristics are combined.
While on a downgrade, the force of gravity works against the driver in maintaining
control of the vehicle, particularly if the road surface is wet or slick from snow and ice
or loose material. On upgrades, the problem is spinning out due to insufficient traction
at the drive wheels, particularly on snow and ice.
Great care must be taken to avoid excessive use of brakes on long downgrades.
Overheated brakes are dangerously inefficient. It is very dangerous to brake on a
downgrade using only the trailer brakes. If this is done, the trailer brakes heat up and
fade and the tow vehicle brakes alone will not be able to stop the combination by
themselves. Drivers should reduce speed, downshift and use engine compression as
the principal means of controlling speed on long grades and using all brakes so brake
temperatures can be held to a safe level.
page 6
TD-40-T
®
Operation
Weather conditions can be a major factor in the cause of accidents. Rain, ice, snow,
high winds and visibility combined with excessive speed, sudden lane changes, or
other factors that put lateral forces into a tow vehicle trailer combination contribute
significantly to an accident.
Slippery roads can increase stopping distances and reduce the ability to control the
vehicle. When the road is wet, the available tire/road friction may be half that of a dry
road, and icy roads can reduce friction many times over wet roads. If hard braking or
rapid acceleration occurs, there may be little or no friction available to prevent tire
lateral movement and skidding results.
The driver has a responsibility to compensate for the characteristics and conditions
of his vehicle, the road conditions and weather. Reducing speeds and increasing atten-
tiveness may compensate for most of these conditions. The more familiar 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 best driving practice is to
decelerate to a safe conservative speed before entering a corner or approaching con-
gested traffic and then apply only moderate power until an essentially straight path has
been established.
It is imperative that a safe speed always be maintained. The safe speed is that
speed at which control can be maintained over the vehicle at all times. This speed will
allow an emergency change of lane maneuver, travel off an exit ramp with a tightening
radius and recovery from pavement drop-off or wet pavement. This speed will vary from
one combination of vehicle to another and takes into consideration such factors as
road conditions, weather, traffic, visibility, type of load and experience of the driver.
page 7
TD-40-T
®Operation
O
P
E
R
A
T
I
O
N
1.5 Alert Symbols
It is important that you know the meaning of the following symbols that are used
throughout this document.
SAFETY ALERT!
This is the safety alert symbol. It is used to alert you to potential per-
sonal injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury 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 the safety alert symbol indicates a potentially
hazardous situation which, if not avoided, may result in property dam-
age.
!
DANGER
!
WARNING
!
CAUTION
!
CAUTION
page 8
TD-40-T
®
Operation
1.6 Uncaging Air Brakes
Air brakes are designed with a safety feature called a spring brake, so that if no air
pressure is present in the system springs will apply force to the brake system linkages
and apply the brakes. To allow the trailer to be moved during shipping a release tool
assembly is installed in each of the spring brake cans to prevent the brakes from being
applied. These release tools MUST be removed before the trailer can be put into ser-
vice.
INOPERATIVE BRAKE SYSTEM!
The spring brake release tool assemblies must be removed from the
spring brake cans before the trailer is put into service. The brake system
WILL NOT FUNCTION with the release tools installed, and the trailer will
roll 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 be removed without applying air pressure to the brake system,
although the removal process is easier if air is applied.
3. Slowly loosen the nut on the release tool until the spring pressure has been
released.
4. Rotate the release tool approximately 1/4turn to align the tee with the slots and
pull out.
5. Install the release tool assembly in the storage position on the bottom of the can
for future use.
5. Cover the release tool assembly port with the attached rubber seal.
6. Repeat this procedure for all spring brake cans.
WARNING
!
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
TD-40-T
A. Reporting Safety Defects
If you believe that your vehicle has a defect that could cause a crash, injury, or death,
you should immediately inform the National Highway Traffic Safety Administration (NHTSA)
in addition to notifying Gem State Mfg., Inc.
If NHTSA receives similar complaints it may open an investigation, 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, NHTSA cannot 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 Seventh Street SW., Washington, DC 20590. You can also obtain other
information about motor vehicle safety from http://www.safecar.gov.
Inhaltsverzeichnis
Andere TrailMax Nutzfahrzeug Handbücher
TrailMax
TrailMax 8012DT Bedienungsanleitung
TrailMax
TrailMax TD-42-T Bedienungsanleitung
TrailMax
TrailMax TRD-54-T Bedienungsanleitung
TrailMax
TrailMax S-5-UT Bedienungsanleitung
TrailMax
TrailMax FWTD-50-T Bedienungsanleitung
TrailMax
TrailMax TD-24-T(5+20) Bedienungsanleitung
TrailMax
TrailMax TRD-54-FBR Bedienungsanleitung
TrailMax
TrailMax T-10-UR Bedienungsanleitung
TrailMax
TrailMax T-12-UT Bedienungsanleitung
TrailMax
TrailMax T-16-UT (4+16) Bedienungsanleitung
