A message from the President of Trail King Industries

Thank you for purchasing Trail King.

At Trail King, we are justifiably proud of the quality of our trailers. We

take very seriously our commitment in our mission statement to “meet and
exceed our customers’ expectations”; as a result, Trail King trailers do in
fact provide the best trailer value anywhere - they outlast the competition
and they repay owners at trade-in time with the highest resale value in the
industry. We are honored to serve you, and it is our sincere hope that you
will experience as much satisfaction operating your new Trail King trailer
as we have building them.

This manual has been prepared to provide you with all the information you
need to operate and maintain your new trailer safely and profitably. Please
read it thoroughly - and make sure that all others who will be involved in
operating the equipment read and understand it - before using your new
trailer. It pays to protect your investment and the personnel who use it.

Please contact us at 1-800-843-3324 with any questions or comments. Or

visit us on the web at: www.trailking.com

Don’t forget to return the Warranty Registration on your new Trail King
trailer. It must be signed and returned to Trail King Industries within 10
days of the purchase date or warranty will be VOID.

06/99 1 PAGEN0001
 Introduction
Foreword
• How to use this manual
• Symbols used in this
manual
• Special nomenclature
Please
...read this manual thoroughly!
Before you operate your new trailer, please read this manual in its entirety.
The information will help protect your investment and ensure that the trailer
performs to your satisfaction; and some of the information is important to
your safety, and must be read and understood to help prevent possible injury
to the operator or others. If anything in the manual is confusing or hard to
understand, please call your dealer or our service department, at 1-800-843-
3324 (U.S. and Canada), for clarification before operating or servicing this
equipment.

The manual is divided into clearly marked sections, arranged in the order in
which the information is most likely to be needed.: Introduction,
familiarization, operation, maintenance/service, replacement parts,
accessory/optional equipment installation. The introduction explains the
manual, gives general safety information, and gives important details about
your specific trailer.

• Symbols used in this Information of special interest

manual Information of special importance has been flagged in this manual. In
general, the following safety symbol has been used both in this manual and on
the trailer to indicate hazards that either will or may result in personal injury if
appropriate care is not taken:

Wherever this symbol appears, pay particular attention to the accompanying

instructions. Failure to do so can result in injury to the operator of the trailer
or to bystanders. Contact our service department if there is anything you do
not understand.

Decals on the trailer identify potential hazards of three levels of seriousness.

DANGER Decals with the word “DANGER” in white against a red background indicate
that if the instructions on the decal are not followed, the hazard WILL result
WARNING in severe personal injury or death. These decals are rare, but the hazard is
very real and they must never be ignored. Decals which show the word
“WARNING” in black against an orange background indicate that the hazards
CAUTION or unsafe practices noted in their pictures and text could result in severe
Decals on the trailer indicate personal injury or death. “CAUTION” in black against a yellow background
different (more to less severe) means that the hazards and unsafe practices noted could result in minor
hazard levels personal injury or in product or property damage.

06/99 2 PAGEN0001
 • Symbols used in These warning elements are standard in many industries; look for the
following variations in this manual:
this
manual SAFETY WARNING Meaning: Failure to understand and obey
(continued) this warning may result in injury to you
or to others.

ELECTRICAL Meaning: Failure to understand and

HAZARD obey this warning may result in
electrical shock.

Meaning: Failure to follow these

CAUTION instructions may result in damage to your
equipment or your trailer.

•NOTE• identifies information worthy of special attention, most often

bearing on proper operation or service of your trailer but not of a nature that
would cause damage or injury if the action is not carried out.

• Special nomenclature It is customary to use Right and Left to mean on the right or left of
someone oriented to operate the equipment. References in this manual to
the right and left sides of the trailer, then, will mean as viewed from the rear
of the trailer. In other words, Right refers to the curb side of the trailer,
Left to the road side.

06/99 3 PAGEN0001
 Table of Contents
Since this manual has been
custom assembled for your
trailer, it is not possible to
assign general page numbers.
Manual organization and
sequence is reflected in this
table of contents. For easy
navigation once you have
located the section of interest,
look at the bottom of each page
for section identification
(lower right corner) and a
page number (lower center)
that shows its position in that
section.
06/99
Introduction
How to use the manual
Explanation of symbols used in the manual
Special nomenclature used in the manual
Safety Section
General safety warnings
Equipment and controls safety
Operating safety
Service safety
Safety Decal Locations
Operation
Safety
Description of the trailer
Controls - location and use
Operating procedures
Pre-Trip Inspection
Inspection checklist
Service
Torque values for standard hardware
Maintenance
Safety
Maintenance intervals
Maintenance log
Service procedures
Axles
Axle Alignment
Troubleshooting - Brakes
Vendor Instructions
Replacement Parts
Parts illustrations and lists
Warranty
4 PAGEN0001
 Safety Section
Read the manual. Your safety is at stake!
General Safety Before anyone operates this trailer, they must read and understand the material in the
introductory and operating sections of this manual. Never allow anyone who has not
• Read the manual understood the safety warnings, the pre-trip checks, and the actual loading and operating
instructions to operate this trailer. Human safety is at stake. If additional or replacement
manuals are needed, they are available for a minimum charge at the following address:

Trail King Industries

P.O. Box 1064
Mitchell, SD 57301-7064
Phone: 1-800-843-3324 (U.S. & Canada)
Fax: 605-996-4727

SAFETY WARNING
• Safety shields & decals
• Keep the equipment and attachments in good operating condition, and keep all
safety devices in place. Replace all worn, damaged, unusable, or missing safety
shields and guards before operating the equipment.

• If safety related or instructional decals become illegible or are removed, replace

them immediately. If you replace parts that have such decals attached to them,
make sure the decals are replaced with current versions, and that the decals are on
the replacement parts before the vehicle is operated again. New decals may be
obtained from the following address:

Trail King Industries

P.O. Box 1064
Mitchell, SD 57301-7064
Phone: 1-800-843-3324 (U.S. & Canada)
Fax: 605-996-4727

• This equipment is intended to have safety decals in each of the locations shown on
Safety & Operating Decal Locations. If any of these decals are missing, order new
decals from this address and affix them to the equipment before the equipment is
operated.
• Equipment & controls • Never modify the trailer. Altering this equipment in any manner which adversely
affects its operation, performance, durability, or use will void the warranty and
may cause hazardous conditions.

• Know the location and function of all controls and how to stop this equipment
quickly in an emergency before you operate the equipment. READ AND
UNDERSTAND THE OWNER’S MANUAL.

• Keep all nuts, bolts, and screws tight to help ensure safe operation of this
equipment.

• Failure to use replacement parts that meet factory specifications, or failure to

follow recommended torque specifications, can result in equipment malfunction
and/or injury to operator or bystanders.

03/99 1 PASAF0001
 Safety Section
SAFETY WARNING
Operating To help prevent serious injury or death, always follow these safety precautions:

Safety • Make sure lights, tires, wheels, and brakes are in proper working order before
operating the trailer.
• NEVER assume that a coupling is locked or unlocked. ALWAYS check visually
before moving the tractor or truck.
• Always make sure the area is clear before moving or operating a trailer.
• Always make sure shoes and surface are clean and will provide proper traction
before climbing on or off a trailer.
• Always know the height of your load and clearance requirements before moving the
trailer.
• Always make sure you are equipped with chocks and blocks suitable for any
expected loading conditions.
• Always make sure you have proper and sufficient markers and flares to
accommodate any parking or emergency stopping situation.
• Always perform a pre-trip inspection (see “Pre-Trip Inspection” in this manual)
before each trip.

• Loading BEFORE LOADING, make sure:

• Load can be properly distributed and will not exceed trailer capacity.
• Ramp surface is clean and dry (not slippery).

WHEN LOADING vehicles onto the trailer, make sure that you:
• Avoid pinch points and keep everyone clear of moving components (tails, gates, etc.)
• Load so the center of gravity is as low as possible (high centers of gravity are a
major contributing factor to trailer tip-over accidents).
• Keep accessory attachments in the “lowered” position.
• Move the vehicle up the ramp slowly and steer or guide it carefully onto the trailer
bed.
• Secure the vehicle and all attachments to the platform with an adequate number of
chains to prevent shifting during transport.

When using a winch:

• Do not allow riders on equipment being winched onto the trailer.
• Keep people away from the area behind equipment being loaded.
• Anchor the winch cable around the drum with at least 5 wraps before using.
• Never touch a winch cable under load.
• Never use a winch cable to secure a load during transport.

03/99 2 PASAF0001
 Safety Section
Self-Contained SAFETY WARNING
Hydraulic Unit Safety To help prevent serious injury or death, always follow these safety precautions:

• Gasoline • Gasoline is extremely flammable and can be highly explosive. To minimize the
danger:
• Always use an approved container for gasoline.
• Do not allow open flames or sparks while performing maintenance or
refueling.
• Never remove the fuel tank cap or add gasoline when the engine is running or
while it is hot.
• Never fill the fuel tank indoors (fumes can collect).

• Wipe up spilled gasoline immediately and completely.

• Do not store gasoline in a room with an appliance that has a pilot light or
where electrical appliances or switches may cause sparks. Always store
gasoline outside in a safety can ( a can which has a flame arrestor and
pressure relief valve in the pour spout).

• Never store the equipment with gasoline in the tank inside a building where fumes
may reach an open flame or spark. Allow the engine to cool before storing in any
enclosure.

• Be certain to provide adequate ventilation if an engine must be run indoors -

exhaust fumes are dangerous.

• Battery & electrical • Never yank cables off battery posts - its a sure way to cause sparks, which can ignite
the surrounding battery gas.

• Do not check battery charge by placing metal objects across the posts. This will
cause sparks - and serious burns are possible.

• Charging • Make sure the charger is UNPLUGGED before you connect charger cables to the
battery or disconnect them from it. (This prevents shocks if the charger is
defective.)

• Always charge batteries in a well-ventilated area, and make sure the vents in the
caps are open. Charging causes the acid solution to give off hydrogen gas through
the vents in the caps. If the vents are clogged, pressure inside may cause the battery
to EXPLODE.

03/99 3 PASAF0001
 Safety Section
SAFETY WARNING
Service Safety To help prevent serious injury or death, always follow these safety precautions:
• Maintenance/Service
• To prevent possible eye injury, always wear SAFETY GLASSES while servicing the
equipment.

• Follow recommended lubrication schedules to help prevent equipment failure.

• Use only the recommended lubricants and fuels. Improper lubricants or fuels may
cause machine failure.

• Always read and follow safety-related precautions found on containers of

hazardous substances - like parts cleaners, primers, sealants and solvents.

• Hydraulic fluid under pressure can cause personal injury. Relieve pressure in the
hydraulic system by turning the equipment off and activating the controls before
disconnecting or reconnecting hydraulic hoses.

• Use a piece of cardboard or wood to check for hydraulic leaks, do not use your
hands - hydraulic fluid under pressure can easily penetrate skin, even through
gloves.

• If the trailer must be raised for service, use only jacks or hoists with the required
capacity. If necessary, call Trail King at 1-800-843-3324 (U.S. and Canada) for
your trailer weight (have the trailer serial number when you call). Support the
trailer with approved jackstands while working on it - jacks and hoists can fail.

• Unless otherwise noted, photos and illustrations in this manual are a reference guide
for parts identification and/or general orientation only. Since these illustrations
often do not depict actual positioning of component parts, they should not be used
as an assembly diagram - such use may result in improper assembly, which can lead
to sudden failure.

• Use genuine factory replacement parts or parts with equivalent characteristics,

including type, strength and material. Failure to do so may result in product
malfunction and possible injury to the operator and/or others.

• If you substitute equivalent products for brand-name products or tools mentioned

in this manual, they must match the brand-name products in all relevant
characteristics, such as strength, durability, and type of material. It is your
responsibility to determine if the substitution could result in product malfunction
and possible injury to the operator and/or others.

• Never reuse locknuts and locking screws - they can lose their gripping power when
loosened. Replace them with factory-authorized parts or their equivalent.

03/99 4 PASAF0001
 Safety Section
Service Safety SAFETY WARNING
(continued) • Follow torque specifications for all hardware, as shown in the general torque chart
in the service section of this manual, or as noted within the text or at the beginning
of each relevant section. If hardware is not secure, or if some of the hardware is
overtightened, equipment failure may result, posing possible safety hazards.

• Use extreme caution when conducting tests on running engines. Do not wear
jewelry or loose clothing. Keep hair, hands and clothing away from rotating
flywheels.

• Shut off engines and allow them to cool before working on them. When making
adjustments (such as idle speed) that require the engine to be running, be extremely
careful to keep fingers and hands away from moving parts.

• To avoid equipment failure, assemble parts carefully and double-check for proper
fit.

• Double-check all adjustments for accuracy.

• Test your work before you put the equipment back into service. Make sure your
repair has solved the problem and the equipment works properly and safely.

03/99 5 PASAF0001
This page left intentionally blank
 Safety and Operating Decal Locations
Safety-Related Decals
SAFETY WARNING
Carefully read and follow all safety and instructional decals. Replace
any warning decals that are damaged or missing before operating the
trailer or equipment.
(Safety decals are on both right and left sides of trailer unless otherwise
specified. Actual decal placement may vary from what is shown.)

Front of Trailer
CD Trailer
10 4 5 11 1 3 6 8 13 Thru 29 Near Controls
2 12
41 Thru 30 7

Front of Trailer
13 Thru 29 Near Controls CF Trailer

10 4 5 11 1 3 6 8 41 Thru 30 4 2 12

Front of Trailer

ACS CS-ACS-LCS Trailer

10 4 5 11 1 3 6 8 or 9 13 Thru 29 Near Controls

41 Thru 30 4 2 12

CAUTION CAUTION
THIS TRAILER IS CONSTRUCTED TRACTOR AND TRAILER PARKING
USING HIGH STRENGTH STEELS. BRAKES MUST BE SET BEFORE
DO NOT WELD WITHOUT LEAVING TRACTOR
PERMISSION. 735-155-008 735-155-262

1. WELDING WARNING 2. ABS INDICATOR 3. PARKING BRAKE CAUTION

(735-155-008) (735-155-262)

05/09 1 PASAF0006
 Safety and Operating Decal Locations
Safety-Related Decals
(continued)
CAUTION
THE USE OF ADDITIVES IN THE
AIR BRAKE SYSTEM IS NOT
RECOMMENDED AS THEY CAN BE
HARNFUL TO THE PERFORMANCE
OF THE AIR BRAKE VALVES.
FORM 8144
4. BRAKE SYSTEM ADDITIVES
WARNING
DO NOT OPERATE BOTH LIFT
AXLES SIMULTANEOUSLY.
DAMAGE TO FRONT AXLE AIR
BAGS WILL RESULT.
735-155-356
7. LIFT AXLE WARNING
(735-155-356)
05/09
WARNING
RECOMMENDED COMPRESSOR CAUTION
GOVERNOR CUT-IN PRESSURE MUST
WHEN TRAILER IS NOT IN USE,
BE 105 P.S.I. FOR TRAILERS &
GLADHAND COVERS MUST BE
CHASSIS MANUFACTURED AFTER
OCTOBER 8. 1992 TO RELEASE INSTALLED ONTO BOTH GLADHANDS
PARKING BRAKES PROPERLY. 735-155-310
FORM 8161
6. GLADHAND CAUTION
5. COMPRESSOR CUT-IN PRESSURE (735-155-310)
ANCHORING DEVICES ANCHORING DEVICES
THIS TRAILER CONTAINS ONE OR MORE OF THE FOLLOWING
ANCHORING DEVICES RATED AS SHOWN. RATINGS ARE FOR
ALUMINUM SIDE RAIL TRAILERS
THIS TRAILER CONTAINS ONE OR MORE OF THE FOLLOWING
ANCHORING DEVICES ONLY, TIE DOWN DEVICES (CHAINS, ANCHORING DEVICES RATED AS SHOWN. RATINGS ARE FOR
STRAPS, ETC.) MUST BE RATED SEPARATELY.
1" D-RING ------------------------------------------------------------- 6,600 LBS.
ANCHORING DEVICES ONLY, TIE DOWN DEVICES (CHAINS,
STRAPS, ETC.) MUST BE RATED SEPARATELY.
STAKE POCKET, STEEL --------------------------------------- 6,600 LBS.
ANGLE STYLE TIEDOWN ------------------------------------- 6,600 LBS. STAKE POCKET, ALUMINUM ------------------------------- 5,000 LBS.
KEYHOLE SLOTS -------------------------------------------------- 8,700 LBS.
PIPE SPOOL & STAKE POCKET COMBINED ------ 6,600 LBS.
PIPE SPOOL & STAKE POCKET COMBINED ------- 5,000 LBS.
DOUBLE PIPE SPOOL, COMBINED ---------------------- 6,000 LBS.
DOUBLE PIPE SPOOL, COMBINED --------------------- 6,600 LBS. STRAP WINCH OR HOOK, WELDED -------------------- 6,600 LBS.
STRAP WINCH OR HOOK, WELDED ------------------- 6,600 LBS.
TRIANGLE OR OVAL CUTOUTS, 1/4" WEB -------- 8,700 LBS.
TRIANGLE OR OVAL CUTOUTS, 1/4" WEB --------- 8,700 LBS.
CHAIN TIE DOWNS RECESSED IN FLOOR ---------- 5,000 LBS.
CHAIN TIE DOWNS RECESSED IN FLOOR --------- 5,000 LBS. UNDERBED 1" D-RING ----------------------------------------- 6,600 LBS.
SLIDING WINCH TRACK -------------------------------------- 4,000 LBS. SLIDING WINCH TRACK -------------------------------------- 4,000 LBS.
735-155-306 735-155-306
8. ANCHORING DEVICES (STEEL) 9. ANCHORING DEVICES (ALUMINUM)
(735-155-306) (735-155-307)
2 PASAF0006
 Safety and Operating Decal Locations
Operation-Related Decals

PRESSURE RETURN
735-155-080 735-155-081
ABS LIFT AXLE
735-155-203

10. PRESSURE 11. RETURN 12. ABS LIGHT DECAL 13. LIFT AXLE
(735-155-080) (735-155-081) (735-155-210) (735-155-203)

LOWERING VALVE
THIS VALVE MUST BE IN "OFF" POSITION
FOR TRANSPORTING. TURN TO "ON"
LOWERING F
POSITION TO REDUCE RAMP ANGLE.
MUST BE IN "ON" POSITION TO BOTTOM
VALVE OF
ON
OUT AIR SPRINGS WHEN LOADING OFF
735-155-112 OF DOCK. 735-155-031

14. LOWERING VALVE 15. ON/OFF 16. LOWERING VALVE OPERATION

(735-155-112) (735-155-201) (735-155-031)

AIR RIDE 3RD AXLE MECHANICAL LIFT OPERATION

OPERATING INSTRUCTIONS
WHEN VEHICLE IS IN MOTION, SWITCH MUST
BE IN "OFF" POSITION FOR NORMAL AIR RIDE
OPERATION.
TO LOWER - PLACE SWITCH IN "ON" POSITION.
THIS ALLOWS THE TRAILER TO BE USED IN A 2 & 2 CONFIGURATION
1. LOWER TRAILER AND BOOSTER USING THE RAISE AND LOWER VALVES. PUSH TO
APPLY
2. SHUT OFF AIR TO THE 3RD AXLE AIR SPRING. THE VALVE IS LOCATED ON A CROSSMEMBER
BEHIND THE LEFT REAR TIRE.
3. REMOVE THE PIN FROM THE STORAGE LOCATION ABOVE THE AXLE AND INSTALL IN THE AXLE

TO RAISE - PLACE SWITCH IN "ON" POSITION

LIFT POSITION.
4. RETURN TRAILER AND BOOSTER TO NORMAL RIDE HEIGHT BY TURNING OFF THE RAISE AND
BRAKES
AND PULL HAND VALVE LEVEL OUT. LOWER VALVES.
735-155-037 5. REMOVE THE WHEELS AND TIRES FROM THE 3RD AXLE. 735-155-163

19. “PUSH TO APPLY BRAKES”

17. AIR RIDE OPERATING 18. 3rd AXLE MECHANICAL LIFT OPERATION KNOB INSERT
INSTRUCTIONS (735-155-163) (735-155-075)
(735-155-037)

735-155-180

RAISE
TRANSPORT
AIR TANK
DUMP VALVE EXHAUST
DRAIN VALVE
20. DUMP VALVE SUSPENSION 735-155-175

(735-155-202)
21. SUSPENSION OPERATION 22. AIR TANK DRAIN VALVE
(735-155-180) (735-155-175)

AUXILIARY AIR OUTLET

735-155-231
UNLOCK LOCK 735-180-007

23. AUXILIARY AIR OUTLET 24. UNLOCK/LOCK

(735-155-231) (735-180-007)

05/09 3 PASAF0006
 Safety and Operating Decal Locations
Operation-Related Decals
(continued)

HT250U/HT250T HT250US HT230

SUSPENSION UNDERSLUNG SUSPENSION TOP MOUNT SUSPENSION
LOAD / PSI CHART LOAD / PSI CHART LOAD / PSI CHART
LOAD PER AXLE REQ'D. PSI LOAD PER AXLE REQ'D. PSI LOAD PER AXLE REQ'D. PSI
25,000 lbs. 98 25,000 lbs. 80 23,000 lbs. 98
23,000 lbs. 90 23,000 lbs. 74 21,000 lbs. 89
21,000 lbs. 82 21,000 lbs. 66 19,000 lbs. 80
19,000 lbs. 74 19,000 lbs. 60 17,000 lbs. 71
17,000 lbs. 66 17,000 lbs. 53 15,000 lbs. 62
15,000 lbs. 58 15,000 lbs. 46 13,000 lbs. 53
13,000 lbs. 50 13,000 lbs. 39 11,000 lbs. 44
11,000 lbs. 42 11,000 lbs. 32 9,000 lbs. 35
9,000 lbs. 34 9,000 lbs. 26 7,000 lbs. 26
7,000 lbs. 24 7,000 lbs. 19 5,000 lbs. 18
5,000 lbs. 17 5,000 lbs. 12 3,000 lbs. 10
735-155-205 735-155-206 735-155-211

25. HT250U SUSPENSION 26. HT250U/T SUSPENSION 27. HT230 SUSPENSION LOAD PSI SCALE
LOAD/PSI SCALE LOAD/PSI SCALE (735-155-211)
(735-155-205) (735-155-206)

SYNTHETIC
OFF 735-201-004 ON 735-201-003
GREASE ONLY 735-155-090

28. “OFF” 29. “ON” 30. SYNTHETIC GREASE ONLY

(735-201-004) (735-201-003) (735-155-090)

05/09 4 PASAF0006
 Safety and Operating Decal Locations
Vendor Supplied Decals

32. HENDRICKSON BRAKE

LINING CAUTION
31. HENDRICKSON INTRAXX 33. HENDRICKSON SUSPENSION
TORQUE SPECIFICATIONS SAFETY & INSPECTION
(735-160-020)

34. HENDRICKSON HT/HS/HK SERIES 35. HUTCH 9700 SUSPENSION 36. WALTHER HUB PILOTED DISC
SUSPENSION TORQUE TORQUE WHEEL INSTRUCTIONS

39. ERIE TORQUE SPECIFICATIONS

38. KIC HUB PILOTED WHEEL (735-155-042)
37. NEWAY TORQUE EQUIREMENTS
SYSTEM INSTALLATION
(735-155-047)

40. CON/MET PRESET HUBS 41. CON/MET DISC WHEEL INSTALLATION

(735-160-013)

05/09 5 PASAF0006
This page left intentionally blank
 Pre-Trip Inspection
SAFETY WARNING
• To avoid serious injury to yourself or others due to equipment failure or
malfunction, carefully conduct a safety inspection of the trailer and of the vehicle
used with it before operating the trailer or equipment. Perform this inspection in a
location safely away from other traffic.

• Inspection checklist
SAFETY WARNING
• A drop in tire pressure of as
little as 10 psi can reduce
carrying capacity
significantly and can result
in loss of control of the
trailer, possibly resulting in
equipment damage or severe
personal injury.
• Look for oil, water or fuel leaks.
• Inspect trailer suspension - look for
trailer lean, inspect radius arms,
verify that springs are in spring
hangers.
• Check rim clamps, wheel studs and
nuts. Look for cracks around lugs.
• On trailers equipped with oil
lubricated wheel bearings, wipe the
hub and check oil level.
• Inspect tires (including spares);
inflate to recommended pressure;
remove all objects lodged in treads
and between duals.
• Open vehicle hood and check oil and
coolant levels.
• Check all drive belts, wiring, hoses,
and tubing for damage, leaks, kinks
and wear.
• Test trailer brakes for condition and
operation. (If your trailer is equipped
with air brakes, see “If applicable”
section of this checklist on the next
page for specific inspection areas.)
• With trailer brakes on, release tractor
brakes and gently test tractor and
trailer coupling.
• Test all lights/flashers, low and high
beams.
• Test washers/wipers and condition of
windshield and windows.
• Check that mirrors on both sides of
cab are clean and aligned.
• Test heater and defroster.
• Check for damaged or missing
seatbelts.
• Check for charged fire extinguisher
and emergency equipment.
• Check oil pressure, ammeter,
tachometer and speedometer,
warning lights.
• Test all trailer controls (air, electric,
hydraulic, mechanical) to verify
proper operation.
• Clean and inspect headlights,
clearance lights, identification lights,
flashers, turn signals. Replace all
damaged reflectors, lenses and
burned out bulbs.
• Test all locking mechanisms and pins
on the trailer for proper operation.
Make sure all are in proper position.
• Inspect splash guards for proper
attachment, breaks and cracks.
• Inspect trailer frame for cracks and
structural damage.
• Inspect pintle hooks, lunette eyes and
drawbars on connector dollies for
damage.
• Make sure all safety chains are in
place, of adequate size, and properly
connected to both the trailer and the
towing vehicle.
(The items on this page cover the most
basic inspections, applicable to almost all
trailers. For most trailers, this list is not
complete. Please continue on the next
page and check off all inspection areas
applicable to your specific trailer.)

06/99 1 PASER0001
 Pre-Trip Inspection
• Inspection checklist If applicable:
(continued)

• Check hydraulic reservoir and pump for leakage; make sure reservoir oil is at proper
level.
• Check condition of air chambers, gladhands, air hoses, springs and slack adjusters.
• Drain moisture from tractor air tank.
• Check air pressure. Deplete pressure until warning buzzer sounds, then build up
pressure and check for leaks.
• Drain moisture from trailer air tanks and listen for air leaks.
• Operate the treadle valve and hand valve to determine if air is being supplied to the
brake chambers.
• Apply foot brake for one minute. Air loss should not exceed 4 psi per minute.
• Use an observer or place marks on the push rods to determine if brakes are operating;
adjust brakes at slack adjusters, if necessary.
• Visually inspect to make sure fifth wheel is locked and the mounting is secure.
• Inspect fifth wheel mountings for damage.
• Check fuel tanks are tightly secured and does not leak.
• Inspect ropes, tarps, straps, tiedowns. Make sure they are secured to prevent loosening
in the wind.
• If your truck is equipped with an anti-skid control system, check to make sure it is in
operation.

06/99 2 PASER0001
 Service
Maintenance Before performing any service procedures on this trailer or components, read thoroughly all
of the warnings in the Service Safety section of this manual.
• Safety
• Maintenance intervals SAFETY WARNING
• Maintenance log • After performing any service on this trailer, test your work to make sure the parts
serviced operate properly before putting the trailer back into service. Failure to do
so could result in malfunction during operation or transport of the trailer, possibly
causing death or serious injury.

• Torque Chart Torque Chart

For standard screw sizes and U-bolt sizes.
All values are for dry assemblies. If anti-seize compound is used, reduce torque by 45%.

Screw Shank Sizes Torque Values Torque Values

(Course Thread) (Fine Thread)
1/4 8 ± 2 lb.-ft. 8 to 13 N•m
5/16 18 lb.-ft. 20 lb.-ft.
3/8 30 lb.-ft. 35 lb.-ft.
7/16 46 ± 4 lb.-ft. 56 to 70 N•m
1/2 75 lb.-ft. 90 lb.-ft.
9/16 101 ± 9 lb.-ft. 120 to 150 N•m
5/8 160 lb.-ft. 180 lb.-ft.
3/4 230 ± 20 lb.-ft. 280 to 340 N•m
7/8 420 lb.-ft. 450 lb.-ft.
1 536 ± 50 lb.-ft. 640 to 800 N•m

U-Bolt Shank Sizes Torque Values Torque Values

(Course Thread) (Fine Thread)
7/8 500 lb.-ft. 550 lb.-ft.
1 610 lb.-ft. 660 lb.-ft.
1-1/8 800 lb.-ft. 900 lb.-ft.

• Maintenance Intervals Scheduled Maintenance

(*F) after the service entry means “whichever comes first”, interval or mileage

Interval Mileage Service

After 50-100 mi. Check spoke wheel rim clamps
After 100 mi. Check & re-torque rim nuts
250 mi. Check brake adjustments
Once a year 1,000 mi. Check oil in oil lubed hubs
Twice a year 15,000 mi. Check brake adjustments (*F)
Twice a year 30,000 mi. Lube hubs (*F)
(Spring, Fall)
Twice a year 30,000-40,000 mi. Inspect brake linings for wear
(Spring, Fall)
Every 2 years 50,000 mi. Change grease in hubs (for low-mile
operations, e.g. container, piggy-back)(*F)
06/99 3 PASER0001
 Service
• Maintenance log It is important to keep maintenance records. Before performing any
maintenance on your Trail King trailer, photocopy this maintenance log, then
use the photocopy to record maintenance as it is performed.

Maintenance
Date Mileage Service Performed

06/99 4 PASER0001
 Service
Axles Axle end component identification: Wiper
Wiper driver
• Component identification Inner wheel
nut
• Assembly
• Lubrication Spindle

Fig. 1
• End Component 1. Inspect the spindle and components for wear or damage.
Assembly 2. If necessary, install a new seal wiper on the spindle. Assemble the widest
edge of the wiper evenly over the wiper journal and use a seal driver or
installation sleeve of the correct dimension to install the wiper. The outer
edge of the wiper must be installed level with the bearing journal.
3. Replace the worn or damaged bearings. If
the hub is grease lubricated, pack the
bearings with grease.
4. Before you install the wheel bearings on the
spindle, apply a thin layer of grease to the
bearing journals to prevent corrosion.
5. Pack the bearings with a pressure packer. If
a pressure packer is not available, pack the
bearings by hand, forcing the lubricant into
the cavities between the rollers and the cage Fig. 2. Grease-lubricated hub
from the large end of the cone.
6. Install the inner and outer bearing cups and cones in the correct bores in
the hub. The bearing cups must be pressed tight against the shoulders in
the hub.
7. Use a seal driver of the correct Seal Driver
Seal Seal must
dimension to install the new bottom in
seal in the hub until it is bore cup
Inner Bearing
against the bottom of the seal
bore. Hub

Fig. 3. Seal installation

SAFETY WARNING
• Do not continue to hit on the driver after the seal has touched the
bottom of the bore. The seal may be damaged, subsequently leaking
and possibly causing a wheel to seize during operation, which could
result in injury or death.

06/99 5 PASER0001
 Service
8. If the hub is grease lubricated, pack the hub between the two bearings with
Axle Service grease, up to the smallest diameter of the bearing cups.
(continued) 9. Install the hub and drum or hub and rotor on the spindle.

SAFETY WARNING
• You must be careful not to damage the oil seal or bearings. Damage to
these components could cause a wheel to seize during operation, which
could result in injury or death.
10. Install the retaining nuts:
• Single-nut hubs On wheel ends with single nuts, use the following procedures:
a. Tighten the adjusting nut to 100 lb. ft. (135 N•m) torque while rotating the wheel
to check that all bearing surfaces are in contact.
b. Loosen the nut completely and then tighten the nut to 50 lb. ft. (68 N•m) torque.
Then loosen the nut 1/6 turn.
c. Install the cotter pin or lock ring to lock the nut in place. Bearing endplay
must be within the limits of .001” (.03mm) and .010” (.3 mm).
• Double-nut hubs On wheel ends with double nuts, use the following procedures:
a. Tighten the adjusting nut to 100 lb. ft. (135 N•m) torque while rotating the wheel
to check that all bearing surfaces are in contact.
b. Loosen the nut completely and then tighten the nut to 50 lb. ft. (68 N•m) torque.
Then loosen the nut 1/5 turn.
c. Install the nut lock ring and the jam nut. Tighten the jam nut to the correct
torque, as shown in the chart below.

Torque Chart
Nut Sizes Torque Values Torque Values
(Minimum) (Maximum)

1-1/8 and 2-5/8 200 lb.-ft. (271 N•m) 300 lb.-ft. (407 N•m)
2-5/8 and Over 250 lb.-ft. (339 N•m) 300 lb.-ft. (407 N•m)

d. Install the setscrew into the open hole in the lockwasher to prevent the loosening
of the jam nut. Bearing endplay must be within the limits of .001 (.03 mm) and
.010” (.3 mm).
11. Install the gasket, hub cap and capscrews.
Tighten the capscrews to 15-20 lb. ft.
(20-27 N•m).
• Lubrication 12. If the hubs are oil lubricated, fill the hub
with the correct type of oil to the bottom
edge of the plug hole in the hub cap.
Rotate the hub and check the oil level Lube
again.

Fig. 4. Oil-lubricated hub

06/99 6 PASER0001
 Service
Axle Service Grease Lubricated Frequency:
The frequency of lubricant changes depends on operating conditions, speeds
(continued)
and load. Change lubricant when the seals are replaced, when new brake
lining is installed, or at 30,000 miles (48,000 km). If the trailer operates less
than 30,000 miles a year, change the lubricant two times a year (Spring and
Fall).

For low-mile operations (e.g., Container or Piggy-back), change the grease

every 50,000 miles (80,500 km) or every two years. This grease must be
checked two times a year (Spring and Fall) for contamination and the
lubricant changed if required.

Oil Lubrication Frequency:

Check every 1,000 miles (1,600 km) and change when oil becomes
contaminated, seals are replaced, new brake lining is installed, or one time a
year.

06/99 7 PASER0001
 Axle Alignment

A
A = B ± .125” E
C = D ± .062”
E = ± .25”

To properly align the suspension, make sure the trailer is unloaded. Free the suspension of any “binds”
by first pushing the trailer backwards and then pulling forward. While pulling the trailer forward on a
level floor, apply the brakes and release. This will assure that an adjustable undercarriage is in its
rearmost locked position. The trailer must be level from side to side, as well as from front to rear.
Neither service nor parking brakes shall be applied during the measurement procedure.

The axle position may be determined using any established mechanical or optical (laser) measurement
equipment.

Measure distances A and B from the kingpin to the front axle. These dimensions must be equal within
1/8 of an inch. If adjustment is needed, loosen the radius rod clamp bolts and turn the adjustment
screw as required. When the front axle is positioned correctly, align any succeeding axles with the
front axle by measuring distances C and D. These dimensions must be equal to within 1/16 of an inch.

After alignment has been completed on all axles, check to make certain that the radius rod clamp bolts
and all other fasteners are tightened to the recommended torque requirement.

Check dimension E. The lateral displacement of the trailer body to the axles should not exceed 1/4 of
an inch.

Refer to TTMA RP No. 71-90 for more detail.

06/99 8 PASER0001
 Troubleshooting
• Brakes Problem Possible Cause/Solution

1. Insufficient brakes a. Brakes need adjustment

b. Brakes need lubrication
c. Brake linings worn
d. Restricted tubing or hose
e. Tractor protection valve not in “normal” position
f. Low air pressure in air brake system (below 80 psi)
g. Brake valve delivery pressure in towing vehicle below
normal
h. No tractor air supply/emergency line may be clogged
i. Wrong size actuators

2. Brakes apply too slowly a. Brakes need adjustment

b. Brakes need lubrication
c. Restricted tubing, hose or line filter
d. Low air pressure in air brake system (below 80 psi)
e. Brake valve delivery pressure in towing vehicle below
normal
f. Excessive leakage with brakes applied
g. Faulty relay emergency valve

3. Brakes release too a. Brakes need adjustment

slowly b. Brakes need lubrication
c. Brake rigging is binding
d. Restricted tubing or hose
e. Exhaust port of relay emergency valve is restricted or
plugged

4. Brakes do not apply a. Hoses between tractor and trailer not connected
b. Connecting hoses to trailer are crossed
c. Restricted tubing or hose
d. Tractor protection valve not functioning properly
e. Tractor protection valve not in “normal” position
f. No air pressure in air brake system
g. Faulty relay emergency valve

5. Brakes do not release a. Connecting hoses to trailer are crossed

b. Restricted tubing or hose
c. Brake rigging is binding
d. Tractor protection valve not functioning properly
e. Brake valve on tractor in “applied” position
f. Tractor protection valve not in “normal” position
g. Relay emergency valve in “emergency” position
h. Faulty relay emergency valve

06/99 9 PASER0001
 Troubleshooting
• Brakes Problem Possible Cause/Solution
(continued)
6. Brakes “grab” a. Grease on brake lining/re-line brakes
b. Brake rigging is binding
c. Faulty relay emergency valve
d. Restricted tubing or hose
e. Faulty brake valve on towing vehicle
f. No trailer load

7. Uneven brakes a. Brakes need adjustment

b. Brakes need lubrication
c. Brakelinings excessively worn
d. Grease on brake lining/re-line brakes
e. Brake shoe return spring is broken
f. Brake drum is out of round
g. Leaking brake chamber or actuator diaphragm
h. Restricted tubing or hose
i. Broken slack adjusters or foundation brake parts

8. Excessive leakage with a. Relay emergency valve leaking

brakes released b. Drain valve leaking
c. Leaking tubing or hose
d. Hose uncoupled
e. Leaking hose coupling

9. Excessive leakage with a. Faulty relay emergency valve

brakes fully applied b. Leaking brake chamber diaphragm
c. Leaking tubing or hose
d. Hose uncoupled
e. Leaking hose coupling

10. Excessive leakage with a. Faulty relay emergency valve

relay emergency valve
in emergency position

11. Excessive oil and water a. Reservoirs not drained often enough
present in the air brake
system

06/99 10 PASER0001
 Vendor Instruction Section
A number of vendors manufacture components and systems used on Trail
King trailers. Depending on the particular trailer model and the options and
accessories ordered with your trailer, this manual may contain installation,
maintenance, or service instructions published by these vendors. It is our
practice to sometimes bind in entire sets of instructions as they are shipped
with the components we use, and in some cases these will include instructions
for models or components not included with your particular trailer. It is our
hope that by doing this we are providing you with the most complete,
accurate, and current information available for the components and systems
on your Trail King trailer.

Among the vendors whose instructions you might find bound into this section
are the following:

• Vendor list Anchorlok - Spring brakes

Braden - Gear box/cable drum
Dana Corp., Parish Div. - Axles
Erie - Wheels, brake drums
Hendrickson Trailer Suspension Systems - Air
suspensions
Hutchens Industries, Inc. - Suspension components
Koenig Inc. - Winches
Kohler - Engines
Motor Wheel Corp. - Wheels, brake drums
Neway - Air suspensions
Prince - Directional control valves
Turner - Tandem axle air systems
Webb - Wheels

06/99 11 PASER0001
This page left intentionally blank
 Replacement Parts
Ordering To order parts and accessories for your Trail King trailer, contact Trail King
Information Industries Parts and Service:

• How to order parts and Trail King Industries, Inc.

accessories Parts and Service
P.O. Box 1064
• Parts lists/drawings Mitchell, SD 57301-7064 USA
Phone: 605-996-6482
Fax: 605-996-4727
www.trailking.com

Please refer to the drawings and parts lists in this section and have the correct
part number and description available if possible when ordering.

Please refer to the warranty page in this manual and be familiar with terms
and conditions of replacement and service before ordering parts. Contact
Trail King Parts and Service if you have any questions.

03/01 1 PARPL0001
 Replacement Parts
Ordering To order parts and accessories for your Trail King trailer, contact Trail King
Information Industries Parts and Service:

• How to order parts and Trail King Industries, Inc.

accessories Parts and Service
202 8th Street West
• Parts lists/drawings West Fargo, ND 58078-1432 USA
Phone: 701-282-3013
Fax: 701-282-3039
www.trailking.com

Please have the last 8 digits of the trailer serial number available whenever
contacting Trail King concerning replacement parts and services.

Please refer to the drawings and parts lists in this section and have the
correct part number and description available if possible when ordering.

Please refer to the warranty page in this manual and be familiar with terms
and conditions of replacement and service before ordering parts. Contact
Trail King Parts and Service if you have any questions.

01/07 1 PARPL0003
 THE COMPLETE TRAILER LINE MANUFACTURER
TRAIL KING INDUSTRIES, INC.
LIMITED WARRANTY POLICY
WARRANTY:
Trail King Industries, Inc. warrants that trailer model: ________________________, Serial number: ________________________
(herein-after referred to as “Equipment”) manufactured by Trail King Industries will be free from defects in materials and work-
manship, provided that the Equipment warranted hereunder is operated by the purchaser in accordance with the practices approved
by Trail King Industries with loads not exceeding the manufacturer’s rated capacities and with loads that are not abrasive or
corrosive in nature.
Trail King Industries’ sole obligation under this warranty shall be limited to repairing or replacing, at its option, in accordance with
the schedule below, any defective part of the warranted Equipment, which shall be returned to Trail King Industries’ factory
location or authorized service facilities and then Trail King Industries’ examination shall disclose to its satisfaction to have been
defective; provided, however, that the purchaser notifies the Warranty Department immediately upon identification of defect, and
such defective Equipment is returned by the purchaser to a Trail King Industries location authorized by the Warranty Department
of Trail King Industries with transportation and freight charges prepaid within fifteen (15) days after discovery of defective conditions.
The customer shall not be required to deliver defective Equipment to Trail King Industries if the Equipment was destroyed as a
result of defect covered in this warranty and the Trail King Industries Warranty Department is reasonably satisfied that the Equip-
ment was defective at the time of the sale.
All labor and parts warranty must be authorized by Trail King Industries Warranty Manager. Failure to do so will result in no
warranty payment of any kind.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES OF MATERIAL, WORKMANSHIP, DESIGN,
APPLICATION OR OTHERWISE WITH RESPECT TO ANY EQUIPMENT, WHETHER EXPRESS OR IMPLIED, INCLUD-
ING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, AND OF ALL OTHER
OBLIGATIONS OR LIABILITIES ON THE PART OF TRAIL KING INDUSTRIES.
Components supplied by other manufacturers shall be warranted under the following schedule:
I. Axles, Suspensions, Landing Gear, Wheels, Rims, Hubs One Year 100%
Hydraulic Valve Body
II. Air Lines, Springs, Air Bags, Leveling Valves, Bearings, Six Months 100%
Brake Valves, Paint, Oil Seals, Brake Drums, Shock
Absorbers, Electrical, Cylinders, Hydraulic Hoses &
Connections.
III. Tires, Tubes and Engines Warranty claims must be
made directly to component suppliers
IV. Wood Components 0%

Trail King Open Deck Series & Van Chassis ( i.e. Medical Chassis)
Trail King Industries shall bear that portion of the cost of repairing or replacing the main beams, (The two beams running from
front to back that both the upper coupler and the suspension are connected to) found to be defective under the following schedule:
This excludes all parts that may be bolted, welded or otherwise attached to the main beams.
Year 1 – 100% Year 2 – 75% Year 3 – 50% Year 4 – 25% Year 5 – 25%
All other Trail King manufactured components One Year 100%
Trail King Dump Series:
Bottom Dump, Side Dump and Half Round Trailers:
All Trail King manufactured components One Year 100%
(continued…)

TRAIL KING Industries, Inc. • P.O. Box 1064 • Mitchell, SD 57301-7064 USA • 800-843-3324 • Fax: 605-996-4727 • www.trailking.com

07/08 PWWAR0003
(continued from front...)

Trail King Pneumatic Bulker Series:

All Trail King manufactured components One Year 100%
Frame, Struts, Vessel Year 1 – 100% Year 2 – 75% Year 3 – 50%

Ti-Brook Series:
All Trail King manufactured components shall be warranted under the following schedule:
Steel & Aluminum - Dump Bodies, Frameless (except Ti-Lite) & Frame Type Trailers:
Year 1 – 100% Year 2 – 75% Year 3 - 50% Year 4 – 25% Year 5 – 25%
Aluminum Ti-lite frameless & Frame Type Trailers: One Year 100%
Aluminum Walking Floor & Tipper Transfer Trailers: One Year 100%
Red River Series:
The period of warranty is set forth as follows
Construction Live Bottom and 5-Star Trailers:
I. Chain, Gear box, Motor and Drive shaft.
Year 1 – 100% Year 2 – 75% Year 3 – 50% Year 4 – 25% Year 5 – 25%
II. Trail King manufactured components. Year 1 100%
This excludes all hopper sheets. Year 2 75%
Super Hi-Lite and STW Trailers:
I. Chain, Gear box, Motor and Drive shaft. Year 1 100%
II. Components Manufactured by Trail King. Year 1 100%
Year 2 75%

All other warranties, if any, extended by the makers and suppliers of component parts, accessories, or other goods included in the
manufacture of Trail King Industries’ Equipment will be assigned, if contractually permitted, to the purchaser. This warranty
excludes such parts or accessories which are not defective, but may wear out and have to replaced during the warranty period,
including, but not limited to, light bulbs, paint, brake lining, brake drums, wood pieces and equipment that has been repaired,
replaced, or altered by someone other than TRAIL KING or one of its authorized dealers. (Tire Warranties are expressly excluded
from Trail King Industries’ warranty herein.) Purchaser is expected to pay all repairs or replacement costs, in connection with this
Agreement, including sales and other taxes immediately upon completion of work performed.
LIMITATION OF LIABILITY: Trail King Industries shall not be liable to purchaser for any incidental or consequential damages
suffered by the purchaser, including, but not limited to, any commercially reasonable charges, expenses or commissions incurred in
connection with effecting cover or any other reasonable expense incident to the delay or other breach of warranty by Trail King
Industries, any loss of or damage to any cargo loaded or shipped in or on Equipment, loss of anticipated profits, transportation
expenses due to repairs, non-operation or increased expense of operation costs of purchased or replaced equipment, claim of
customers, cost of money, any loss of use of capital or revenue, or for any special damage or loss of any nature arising at any time
or from any cause whatsoever.
LIMITATION OF REMEDY: In the event of Trail Kind Industries’ failure to repair the Equipment subject to the warranty
contained herein, the purchaser’s sole and exclusive remedy against Trail King Industries shall be for the repair or replacement of
any defective part or parts of Equipment subject to work or repair within the time period and manner set forth herein. This
exclusive remedy shall not be deemed to have failed of its essential purpose so long as Trail King is willing and able to repair or
replace defective parts in the prescribed manner.

July 2008