NHTSA ID Number: 10235262
Manufacturer Communication Number: 23-001
TSB/Document Date: 2023-05-01
Summary
Technical Service Bulletin related to retro-fitting Rayco TR100L Trailers to allow axles to carry newer model RG74T-R and RG165T-R machines.
WORK INSTRUCTIONS
MODEL: TR100L
TR100L AXLE RETROFIT
TSB #23-001
RAYCO MANUFACTURING LLC © 2022
4255 E LINCOLN
WAY
WOOSTER, OHIO 44606 U.S.A.
800-392-2686
ALL RIGHTS RESERVED
PRINTED IN USA
PART NUMBER: 45562-INSTRY
TR100L AXLE RETROFIT
Overview
Rayco Manufacturing has determined that certain TR100L trailers may require an
axle retrofit, dependent on the year and model of machine issued to the trailer. The
trailer’s as built are capable of the rated capacity, however the machines listed below
may exceed the trailer capacity. A serial number picture of the trailer and machine
being transported with it will be required as part of the warranty claim process. Email
the pictures to [email protected]. If it has been determined that due to the
machine being transported the trailer requires the retrofit, the following instructions
will show you what is necessary to properly complete this job. Customers will be
compensated 8 hours to complete this job. If you have any questions contact Rayco
Manufacturing or your local dealer.
Machines Effected:
RG74T-R
RG165T-R
Phone Number: 800-392-2686
Email: [email protected]
NOTICE
•
•
2
Maintenace and Repairs should
ONLY be performed by a trained
specialist or qualified person.
Please contact Rayco Mfg. for a
listing of approved maintenance
facilities in your area
TR100L AXLE RETROFIT
45562RY TR100L Axle Retrofit Kit
•
(1) Serial Tag
Part #: 37398RY
•
(28) 5/8” SAE Flat Washers
Part #: 763436RY
•
(4) 3/8” x 1.5” Bolts
Part #: 722605RY
•
(2) Formed Spacer Anlge
Part #: 45556RY
•
(4) 3/8” Nuts
Part #:724300RY
•
(2) 4000 lb Axles Rework
Part #: 45630RY
•
(4) 3/8” Lock Washers
Part #: 726302RY
•
(1) Retrofit Subframe
Part #: 45560RY
•
(8) 3/8” SAE Flat Washers
Part #: 726300RY
•
(1) Adjustable 2” Coupler
Part #: 808676RY
•
(14) 5/8” x 1.75” Bolts
Part #: 763669RY
•
(10) Body Clips
Part #: 730018RY
•
(14) 5/8” Nuts
Part #: 724702RY
•
(8”) Heat Shrink Tubing
Part #: 750777RY
•
(14) 5/8” Lock Washers
Part #: 726702RY
•
(1) Yellow Spray Paint
Part #: 734020RY
•
(8) Torx Screws
Part #: 807502RY
800.392.2686
3
TR100L AXLE RETROFIT
Hinge Installation
The trailer will need to be on jackstands
or other appropriately rated support
device to perform this job.
Step #1:
Disconnect the trailer from any vehicle
that it may be attached to and lower the
jackstand on the front.
Step #2:
Jack up the trailer in the rear and place
jackstands on the frame. Do not place
them on the axles because the axles will
be removed. Remove the wheels when
the trailer is in the air.
WARNING
Failure to use proper support devices
and/or supporting the trailer in incorrect
locations could lead to serious injury or
death.
Figure 1
Support Points
4
TR100L AXLE RETROFIT
Axle Removal
Step #3:
Remove the outside boards from the top
of the trailer (Items 1, Figure 2).
Step #4:
Remove the axles from the frame. They
are held on by six bolts, three on each
side, see Figure 3.
• After the axles are dropped, cut the
white wires coming out of the right
drums, see Figure 4.
• The axles can be slid out from under
the trailer now.
Figure 2
Outside Boards Removed
Figure 4
Cut White Wires
800.392.2686
5
TR100L AXLE RETROFIT
Cutting the Frame
Step #5:
The frame will need to be cut to accomodate the new subframe.
• The middle hangers (Items 1 and 2,
Figure 5) need cut off.
•
Figure 6 shows the hangers cut off.
1
2
Figure 5
Hangers to Cut
Figure 6
Hangers Cut Off
6
TR100L AXLE RETROFIT
Cutting the Frame
Step #6:
After the hangers have been cut off the
frame needs notched in six places.
• Measure 2-1/2” in from the outside
as shown in Figure 7.
• The frame should look like Figure 8
when all cuts have been made.
•
•
Test fit the subframe to make sure
that enough material has been cut
before moving forward.
Paint any bare metal with the spray
paint provided.
Figure 7
Crossmembers to Cut
Figure 8
Crossmembers Notched
800.392.2686
7
TR100L AXLE RETROFIT
Drilling the Mounting Holes
Step #7:
Holes will need to be drilled into the
frame so that the new subframe can be
attached to the trailer.
•
•
Use the 45560RY subframe as a
stencil to mark the holes.
Be sure to have the subframe oriented in the correct direction with the
front spacers installed as shown in
Figure 9. Lift the subframe using a
floor jack as shown in Figure 10.
FRONT
Figure 9
Subframe Orientation
Figure 10
Subframe Lifted into Place
Figure 11
Subframe Clamped into Place
8
TR100L AXLE RETROFIT
Drilling the Mounting Holes
Step #8:
Use a center punch to determine where
the frame needs to drilled. Drill a small
pilot hole from underneath the trailer and
then the remaining step up in drill sizes
can be done from the top of the trailer.
Step #9:
Mount the subframe using the 5/8” x
1-3/4” bolts provided using flat washers
and lock washers. A full print showing
hardware is given at the end of these
instructions.
Figure 12
Holes Drilled in Frame
800.392.2686
9
TR100L AXLE RETROFIT
Mounting the Subframe
Step #10:
The outside boards that were removed
will need to be either countersunk or
drilled through so that the bolt heads
do not interfere with the fitment of the
boards. See Figure 13.
Step #11:
The boards can be reinstalled using the
new screws provided (PN: 800980RY).
Figure 13
Board Countersunk
10
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TSB/Document ID: 23-001
Replacement Service Bulletin Number:
MFR Communication Date: 2023-04-03
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
MFR Component Subsystem:
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