Great Dane 42101401 User Manual
MAINTENANCE
®
MANUAL
Part No. 42101401
Please route to the individual
responsible for trailer maintenance
MAINTENANCE
MANUAL
VANS
CONTENTS
Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . 2
Reporting Other Claims. . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Tips . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Appearance Maintenance . . . . . . . . . . . . . . . . . . . . 5
Freezing Weather Maintenance . . . . . . . . . . . . . . . 5
Suggested Preventive Maintenance . . . . . . . . . . . . 5
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake Care and Adjustment . . . . . . . . . . . . . . . . . . 8
Brake Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil Seals and Hub Caps . . . . . . . . . . . . . . . . . . . . 11
Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Running Gear Assembly . . . . . . . . . . . . . . . . . . . . 14
Servicing Rims and Wheels . . . . . . . . . . . . . . . . . 14
Single-Piece Rim Wheels . . . . . . . . . . . . . . . . . . . 15
Rim and Wheel Inspection and Maintenance . . . . 15
Rim and Wheel Problems . . . . . . . . . . . . . . . . . . . 16
Tire Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Axle Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Upper Coupler and Kingpin . . . . . . . . . . . . . . . . . . 20
Pintle Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Support Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rear Impact Guard . . . . . . . . . . . . . . . . . . . . . . . . 21
Side and Roof Panels - Vans . . . . . . . . . . . . . . . . 22
Rear Frame, Doors and Hardware . . . . . . . . . . . . 22
Entry and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Floor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Insulated Trailer Maintenance . . . . . . . . . . . . . . . . 23
Maintaining Insulation Efficiency . . . . . . . . . . . . . . 24
Safety Measures - Urethane Foam . . . . . . . . . . . . 24
Converter Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Alterations to the Trailer . . . . . . . . . . . . . . . . . . . . 26
PLATFORMS
CONTENTS
Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . 2
Reporting Other Claims. . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Tips . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Appearance Maintenance . . . . . . . . . . . . . . . . . . . . 5
Freezing Weather Maintenance . . . . . . . . . . . . . . . 5
Suggested Preventive Maintenance . . . . . . . . . . . . 5
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake Care and Adjustment . . . . . . . . . . . . . . . . . . 8
Brake Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil Seals and Hub Caps . . . . . . . . . . . . . . . . . . . . 11
Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Suspensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Running Gear Assembly . . . . . . . . . . . . . . . . . . . . 14
Servicing Rims and Wheels . . . . . . . . . . . . . . . . . 14
Single-Piece Rim Wheels . . . . . . . . . . . . . . . . . . . 15
Rim and Wheel Inspection and Maintenance . . . . 15
Rim and Wheel Problems . . . . . . . . . . . . . . . . . . . 16
Tire Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Axle Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Upper Coupler and Kingpin . . . . . . . . . . . . . . . . . . 20
Pintle Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Support Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rear Impact Guard . . . . . . . . . . . . . . . . . . . . . . . . 21
Floor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main Beams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Crossmembers . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Extendable Platforms . . . . . . . . . . . . . . . . . . . . . . 25
Converter Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Running Gear Assembly . . . . . . . . . . . . . . . . . . . . 26
Alterations to the Trailer . . . . . . . . . . . . . . . . . . . . 26
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
This safety alert symbol is used throughout this manual to indicate potential personal
safety hazards. Failure to heed the warnings associated with the safety alert symbol
can result in property damage, serious injury or death.
REPORTING SAFETY DEFECTS AND OTHER CLAIMS
Customer Service Phone Number: 877-369-3493
This vehicle was designed and quality inspected to
conform with all applicable National Highway Traffic
Safety Administration (NHTSA) safety standards. Great
Dane Limited Partnership warrants this vehicle to be
free from defects in materials and workmanship in
accordance with its standard printed warranty (see
Appendix). If you detect a defect that could cause an
accident, injury or death; or if you wish to report any
such accident, injury or death, or any property damage
claim or other complaint not addressed to the Customer
Service Department, then you should in writing advise:
Director, Quality Assurance
Great Dane Limited Partnership
P.O. Box 67
Savannah, GA 31402-0067
2
If you believe that your vehicle has a defect which
could cause a crash or could cause injury or death,
you should immediately inform NHTSA in addition to
notifying Great Dane Limited Partnership.
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 order a recall and remedy
campaign. However, NHTSA cannot become involved
in individual problems between you, your dealer, or
Great Dane Limited Partnership.
To contact NHTSA, you may call the Vehicle Safety
Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-
9153); go to http://www.safercar.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.safercar.gov.
INTRODUCTION
his manual has been prepared to assist you in retain-
T
ing the safety, dependability, and performance that are
built into Great Dane trailers. It is essential that this
trailer receives periodic inspections, maintenance, and
service parts replacement.
It is to your advantage to be able to show that regularly
scheduled TPM inspection checks have been made on
every piece of equipment operated. A regular TPM
rogram will assure that you get the most from your
p
Great Dane trailer.
Maintenance should be performed by Great Dane
branches and dealers, or other qualified service outlets
that regularly provide such service. The Great Dane
Operator’s Manual covers pre-trip inspections, safety
and maintenance checks, and other helpful information
regarding Great Dane trailers. If you have questions
about this manual or its instructions, contact Great
Dane Trailers Customer Service Department for
answers.
It is important that every trailer owner and/or operator
have an organized Trailer Preventive Maintenance
(TPM) program. The United States Department of
Transportation requires that the maintenance records
be kept on every commercial highway vehicle.
SAFETY PRECAUTIONS:
Before performing any maintenance or repair work
which requires raising the vehicle, ensure vehicle is
properly supported with lift stands of sufficient rating
capacity. Do not rely on jacks alone for support of the
vehicle.
Safety glasses and hard hats should be worn when
repairing and maintaining this vehicle.
You can get help in setting up your trailer preventive
maintenance program by sending for a “Trailer
Maintenance Manual.” Contact the Truck Trailer
Manufacturers Association, 1020 Princess Street,
Alexandria, Virginia 22314, Telephone: (703) 549-3010.
A serious or fatal injury can occur...
A. If you lack proper training.
B. If you fail to follow proper safe procedures.
C. If you do not use proper tools and
safety equipment.
D. If you fail to use compatible replacement
components.
NOTICE:
It is recommended that all necessary replacement components be from the original equipment manufacturers
to insure proper fit and to maintain the structural capability built into your vehicle.
The Great Dane Operator’s Manual, included with every new trailer, will give specific information about the
following subjects:
Gross Axle Weight Rating (GAWR)
Gross Vehicle Weight Rating (GVWR)
Cargo Capacity
Proper Loading & Weight Distribution
Information shown in this Maintenance Manual is general information for maintenance and preventive
maintenance of your Great Dane trailer. It is strongly recommended that you obtain specific maintenance
manuals provided by the manufacturers of the components specified on this trailer. Refer to the bibliography
in the back of this manual.
3
MAINTENANCE TIPS
REAKING-IN A NEW TRAILER
B
The most critical time in a new trailer’s life is its initial
n-service check and first month’s “shakedown.”
i
Preventive maintenance mechanics should be alert for
under-inflated tires and threaded fasteners that may
have loosened from factory-torque settings. Fastener
torque should be all-inclusive and include refrigeration
nits, tanks, steps, carriers etc.
u
Following are several areas that deserve particularly
close attention during the first 30 days of a van or
platform trailer’s service life. Of course, your
operation’s maintenance records should reflect all
areas which need to be closely checked.
TIRES
While a new trailer’s tires were correctly inflated when
they were mounted at the factory, tire pressure is
related to ambient temperature at inflation time. If a
new trailer had tires mounted in a 70˚ F. ambient
environment, but was put in service in 20˚ F. weather,
the tires may have lost as much as 10 psi for every
drop of 20˚ F. in ambient temperatures below 50˚ F.
Therefore, all tire pressures should be verified with an
air gauge, and rechecked each time the tractor refuels.
WHEELS
Smaller fleets commonly overlook the need to retighten
new-trailer-wheel lug nuts after the first 50 to 100 mi.
of service on the initial “in-service.” Retightening
compensates for “normal” clamp force lost due to
“seating in” of new materials. Tests have shown
new-trailer-wheel lug nuts lose 250 lb-ft, or about half
of their original torque value, during a short period of
initial service. Unless those nuts are retightened to
spec, additional clamping force will be lost, and
damage to components will occur. Re-tightening during
the initial in-service prevents wheel and stud damage.
Thereafter, lug nuts should be checked every 25,000 mi.
LEAF-SPRING SUSPENSIONS
All tandem axles are aligned when new trailers leave
the factory. However, suspension fasteners may
sometimes loosen, causing alignment settings to
change, and that can translate into possible erratic
ride, or accelerated tire wear. Therefore, at the first
TPM interval, all suspension-system fasteners should
be rechecked for correct torque value.
When tightening suspension-system fasteners,
mechanics must tighten the “nut side” of torque-arm
bolts. Tightening bolt heads does not produce the
correct clamping force on the fastener.
It is also important to keep U-bolts, as well as torque-arm
bolts, tight. Loose U-bolts allow trailer axles to shift, and
even minor shifting during braking can cause control problems, excessive tire wear, or even broken spring leaves.
When U-bolts are torqued to proper specs, leaf-spring
main leaves remain in proper contact with wear pads, with
no “twists.” Spring wear-pad contact will then be even, too.
Also, at the first TPM, a trailer mechanic should take
the time to verify that there are no obstructions to
movement of the suspension equalizers.
When the mechanic has made sure all fasteners are
tight, he should use the 50-ft.-tape method, with axle
xtenders, to verify that the trailer tandem is, indeed,
e
properly aligned. Remember: the longer the trailer,
the more critical tandem alignment is to long tire life.
AIR-SPRING SUSPENSIONS
Loose U-bolts in an air-spring suspension can cause a
new trailer to roll and sway. Usually, a driver is quick to
report this condition. The mechanic should make doubly
sure that trailer-suspension fasteners, including U-bolts,
are properly tightened.
Excessive play in an air-spring suspension’s front-pivot
connection is another cause of premature tire wear and
erratic handing. Again, connection bolts, which may
have loosened during the first weeks of service, may
produce such handling problems. If not retightened,
these loose bolts cause rubber bushing wear.
SLIDING-TANDEM OPERATION
A driver learning to handle a new trailer equipped with
a sliding tandem should be sure he knows exactly how
to use the stop-selector bar. He should also make sure
that all four slider lock pins are set in place before
operating the trailer, otherwise the tandem may not be
“locked,” and a sudden brake application could force
the slider rearward, causing damage to the tandem
and trailer.
AIR SYSTEM AND BRAKE OPERATION
During the first month’s operation, a certain amount
of “burnishing in” of brake lining occurs. This is normal
and may result in some adjustment loss. Because
out-of-adjustment trailer brakes mean increased stopping distance, plus an increased potential for jackknifing under certain conditions, trailer brake adjustment
should be checked at the first TPM inspection.
During routine maintenance the dust cover cap on air
chambers must be inspected to assure that is in place
and sealing properly.
ANNUAL FHWA INSPECTION
It is the carriers’ responsibility to make sure that the
vehicles operated by them are inspected and maintained under this Federal requirement. During this
inspection, make sure the upper slide rail to crossmember welds, pintle hook assemblies, safety equipment, etc. are inspected and corrected as required.
DOORS
Almost invariably, a new trailer’s hinged-type doors are
difficult to latch. Drivers should expect to use extra
muscle to secure doors until seals seat, but drivers
should not use bars or some other device to force doors
shut. It is equally important not to make adjustments to
a new trailer’s door latches or hinges to “correct” door
closing. This will result in a poor sealing later on.
4
APPEARANCE MAINTENANCE
ppearance maintenance includes cleaning, polishing,
A
corrosion prevention and removal, and protective
coating. You must have a working knowledge of each
for the complete and proper appearance maintenance
of a Great Dane trailer.
ASHING AND CHEMICALS
W
Improper use of chemical cleaners has caused many
a newly delivered trailer finish to streak and fade,
particularly yellow, red and black models. Ironically,
fade is often caused by a desire to keep the units
clean – and using too strong a chemical solution.
When instructions call for a 150:1 water/chemical ratio,
do not use a 50:1 ratio. Sometimes fading caused by
an overly concentrated caustic agent may be remedied
with warm water rinsing and application of a glazing wax.
APPEARANCE MAINTENANCE MATERIALS
Many chemical companies compound materials for
appearance maintenance, and some will even provide
instruction. Protective films, such as paints and clear
coats, are necessary for the prevention of corrosion
and the preservation of metal and wood surfaces.
They add color, beauty, and distinction.
NOTICE: Aluminum brighteners should not be used.
Enclosed air systems for brakes and air-operated
equipment should be drained regularly of accumulated
moisture. The air tanks should be drained daily. The
trailer air system should be treated through tractor
quipment only. Use of additives can cause damage to
e
the brake system. This could result in metal corrosion
or swelling of brake valve seals. Make sure electrical
and brake lines are adequately supported.
Ice and mud accumulations on brake lines and actuators
should be removed regularly. Any air leaks that may exist
are difficult to find when they are encased in ice and mud.
WARNING Do not use heat on any part of the
air system. The use of heat can cause a rupture
and can be very dangerous.
WINTER CORROSION MAINTENANCE
Magnesium and calcium chlorides used to control snow
and ice over our national highways, if not property
cleaned from your tractor and trailer equipment after
each trip, will result in rust and corrosion damage in as
little as one winter of operation.
Information concerning corrosion maintenance can be
found in the publication’s bibliography and on Great
Dane’s website, www.greatdanetrailers.com.
These references outline:
Trailer undercoat materials can lose effectiveness if steam
cleaned or if they come in contact with most solvents.
The underside, including beams, has been undercoated
with a special, soft, rust preventive coating. To prolong
the life of this coating, avoid the use of high-pressure
washers, strong cleaning solutions and brighteners.
Due to the normal weathering and abrasion caused
by road conditions this coating must be inspected and
recoated as necessary (approximately every 24 months).
Dry-freight laminated wood floors should be cleaned
by sweeping and should not be washed out.
BENEFITS OF APPEARANCE MAINTENANCE
Complete and proper appearance maintenance of
Great Dane trailers not only adds to their physical
condition and ultimate trade-in value but also favorably
affects the operator’s feelings about himself and his
company. It also favorably affects the public image
of the company.
FREEZING WEATHER MAINTENANCE
Winter cold weather and its slush, sleet, and snow
present special problems to the truck trailer operator
and to maintenance men. Low temperatures can mean
frozen and sluggish or inoperative brakes, sagging light
and brake lines, broken connections, increased corrosion,
and can require the installation of winter equipment.
1. What states use these chemicals
2. How these chemicals affect equipment operated
over road surfaces treated with it.
3. What you should do to protect and maintain your
equipment when it’s exposed to these highly
corrosive chemicals.
SUGGESTED PREVENTIVE MAINTENANCE
EVERY 1,000 MILES:
❏ Check oil level in wheel hub and inspect wheel
hub for leaks
15,000 MILES OR MINIMUM OF TWICE A YEAR:
❏ Check brake adjustment
❏ Check and repack wheel bearings as required once
per year or every 100,000 miles as recommended
by the T.M.C.
25,000 to 30,000 MILES:
❏ Check lining wear and estimate reline time
❏ Inspect camshaft, camshaft spider bushing
and camshaft support bracket bushing for
any signs of wear
❏ Lubricate brake actuating components
100,000 MILES, ONCE A YEAR, OR AT BRAKE RELINE:
❏ Replace wheel bearing lubricating oil (if applicable)
❏ Check brake air actuators and adjusters
❏ Inspect brake rollers, roller shafts, anchor pins and
bushings and replace if necessary
5
ELECTRICAL SYSTEM
GREEN
BROWN
WHITE
YELLOW
BROWN
WHITE
WHITE
WHITE-GREEN
BROWN
BROWN
GREEN
BROWN
WHITE
RED
BROWN
WHITE
BROWN
RED
BROWN
WHITE
YELLOW
BROWN
WHITE
7 COND MAIN HARNESS
4 COND ABS HARNESS
— TOP VIEW OF TRAILER —FRONT REAR
BLUE
WHITE
WHITE-GREEN
RED
CAUTION
CONNECTOR WIRING CHANGE
NOTICE TO ALL
TRACTOR-TRAILER OWNERS AND USERS
Federal Motor Vehicle Safety Standard No. 121,
Air Brake Systems, was amended by the National
Highway Traffic Safety Administration of DOT to
require that truck tractors manufactured on or after
March 1, 1997, provide constant power for a trailer’s antilock brake system (ABS). Some manufacturers provided this feature before the effective
date. These tractors using a single 7-way
electrical connector will have constant power
for ABS on the center pin when the key switch
is on. Tractor-trailer owners and users who
presently use the center pin for auxiliary power to
equipment other than trailer ABS (for example,
dome lights, backing lights, bottom dumps, sliding
undercarriages, air ride dump valves, etc.) will be
affected by this change. In certain uses of this
constantly powered center pin connector,
unexpected or unintended activation of this
equipment may be hazardous or result in
personal injury. Before connecting your tailer to a
tractor, MAKE SURE that the constantly powered
center pin WILL NOT UNINTENTIONALLY TURN
ON TRAILER EQUIPMENT. If you have any
questions about your present wiring, or how to
rewire your vehicles, you should contact the tractor
manufacturer, auxiliary equipment manufacturer,
and/or Great Dane Trailers Customer Service
Department.
The electrical system on every Great Dane trailer
meets or exceeds all federal and state requirements in
effect at the time of manufacture. Wherever required
by law, lamps and reflectors are marked by the
anufacturer to indicate the appropriate specification
m
with which each complies.
For optimum performance and long life from the trailer’s
lamps and wiring, follow this inspection procedure.
Clean all reflective tape or devices and lamps. See that
all lamps burn properly. Replace all burned-out lamps
and broken or missing reflective devices. Factoryapproved replacement parts should be used, and
replacement bulbs of equal candlepower should be
used for safety.
WARNING
TRAILER IS EQUIPPED WITH ANTILOCK BRAKE SYSTEM (ABS). NO. 7
(BLUE) CIRCUIT IS RESERVED FOR CONTINUOUS POWER SUPPLY TO
ABS. FOR MOST EFFECTIVE ABS OPERATION,TOWING VEHICLE MUST
SUPPLY MINIMUM OF 10 AMPS AT 12.5 VOLT S TO NO. 4 (RED) &
NO. 7 ( BLU E) CIRCUITS.
J560
SOCKET
FAILURE TO HEEDTHIS WARNING CAN RESULT IN PROPERTY
DAMAGE, SERIOUS INJURY OR DEATH.
NOTE: Electrical circuits may be protected by circuit
breakers located inside the front nose box.
COLOR CIRCUIT
PIN
1 WHITE GROUND RETURN TOTOWING VEHICLE
2 BLACK CLEARANCE, SIDE MARKER & ID LAMPS
3 YELLOW LEFT TURN SIGNAL & HAZARD LAMPS
4 RED STOP LAMPS & ABS POWER
5 GREEN RIGHT TURN SIGNAL & HAZARD LAMPS
6 BROWN TAIL, LICENSE, CLEARANCE &
7 BLUE ABS CONTINUOUS SHARED POWER
SIDE MARKER LAMPS
WIRING DIAGRAM
6
A warning decal, as shown on the previous page, is
located on the front of each trailer. You may trace
individual electrical circuits by the wire colors indicated.
Refer to the schematic drawing and the decal for
onductor numbers and wire colors.
c
WARNING Do not exceed 21 candlepower
for dome lamps. Stronger bulbs may generate
xcessive heat and start a cargo fire. Cargo
e
must be kept away from dome lamps. Dome
lamps must be turned off for over-the-road
operation.
Use only a 12-volt DC battery for checking lamps or
antilock brake systems. Never use battery chargers or
transformers.
Inspect all wiring to see that it is not damaged, and
that it is properly supported and protected, with all
connections tight. Frayed or damaged wiring should be
replaced with stranded cable of equal size or larger,
and should never be replaced with a smaller cable, or
with a solid conductor. All holes where wiring passes
through must contain rubber grommets.
MAINTENANCE DURING MAJOR OVERHAUL
OF BRAKES
During a major overhaul, check the following parts and
replace them with original equipment parts or equal, as
required:
. Spiders – for looseness or sheared fasteners.
1
2. Anchor pins – for wear or misalignment.
3. Brake shoes – for wear at anchor pin holes.
4. Cam shafts and cam shaft bearings or bushings –
for wear.
5. Shoe-return springs – replace during overhaul and
when you replace lining. Do not reuse springs.
6. Brake linings – for oil or grease saturation, wear,
loose rivets or bolts.
7. Drums – for cracks, scoring, other damage.
Install all new lock rings where they are used.
During a major overhaul, before reassembling parts
that have been inspected, lightly coat cam shaft bushings and cam roller follower shafts and journals with
brake lubricant.
NOTICE: Most trailers are equipped with a
sealed wiring harness. Check the circuits at the
plugs only – do not cut or probe test for shorts.
Every time the harness is unplugged, repack
connector with Grafo 112X grease or equivalent.
Never replace fuses or breakers with metal foil or other
devices.
BRAKE MAINTENANCE
SCHEDULED MAINTENANCE
Establish a preventive maintenance schedule for
the periodic adjustment, cleaning, inspection, and
lubrication of brake equipment on the basis of past
experience and expected severity of operations. Take
into account that linings and drums are particularly
subject to wear and should not be allowed to wear
to the point where rivets or bolts may contact brake
drums. To compensate for this, schedule brake
inspections as frequently as required to maintain
satisfactory operation and maximum safety (not to
exceed 25,000 miles). Accepted maintenance practices
require that bearings should be adjusted properly
before making brake adjustments; that adjustments
provide uniform lining clearance, correct travel of
levers, and proper equalization; and that brakes should
be cleaned, inspected, lubricated, and adjusted each
time the hubs are removed.
WARNING Brake liners contaminated with
lubricant cannot be salvaged or cleaned.
They must be replaced.
For all fittings on cam shafts, meter-type fittings that
have a maximum of 40 psi pressure relief or shutoff
are recommended.
BRAKE LUBRICANTS
A high-temperature waterproof grease in a number 1
NLGI grade to lubricate the brake actuating system is
recommended. It should be smooth textured, corrosion
resistant, and free of fillers and abrasives. It should
maintain a satisfactory softness under normal parking
and storage temperatures so the brakes can be applied
and released.
The following greases meet these recommendations:
Texaco Thermotex EP #1 Shell Darina #1
Marathon 528 HD Sunaplex #1 EP
Amdex #1 EP Philube B #1
Trailers operating in extremely cold weather (below -40˚ F)
may require a grease conforming to MIL-G-25013C.
7
BRAKE CARE AND ADJUSTMENT
he trailer brake system will perform safely and
T
efficiently only as long as it is properly maintained
and not abused. Trailer brakes should be inspected
frequently in connection with a Trailer Preventive
Maintenance (TPM) Program. Out-of-adjustment
rakes can cause increased stopping distance, shorter
b
brake component life, and a greater tendency for the
trailer to jackknife.
WARNING Prior to performing maintenance
on any air brake system component, chock the
wheels. The system air pressure should be
exhausted by opening the reservoir drain cocks.
In a system employing spring brake control valves, the
spring brakes should function and apply the brakes.
In a system that does not employ spring brake control
valves, the relay emergency valve should function and
pply the brakes.
a
WARNING Serious air leaks in the trailer’s
raking system are hazardous conditions that
b
require the trailer to be placed out of service
until they are properly corrected
A schedule for periodic cleaning, inspection, adjustment
and lubrication of brake equipment should be established by the operator, based on past experience and
severity of operation.
AIR SYSTEM AND BRAKE OPERATION
Proper operation of the brake systems requires a
firm seal between the air brake couplers. Inspect the
couplers for seal damage and cracked housings. Some
couplers are equipped with filters. These filters must
be cleaned at regular intervals to prevent malfunction
of the brake systems. Inspect the air hoses for cracking
and for frayed connections. Be sure air hoses are not
rubbing on any metal surface or each other. Replace
or repair damaged components.
Keep the air system clean. All air tanks should be
drained daily to remove moisture and other contaminants. See Freezing Weather Maintenance.
Some air valve manufacturers discourage the use of
air line antifreeze. Use may result in deterioration of
seals in these valves.
If you use Teflon tape or other thread sealers to seal
threaded connections in your air lines, be careful not
to allow pieces of the sealer to enter the air system.
It can clog passages into the valves and cause them
to malfunction.
Keep the air system tight. The air system cannot be
charged properly if there are leaks in reservoirs, lines,
hoses, or valves. Always check the tractor pressure
gauge for unusual drops or extended buildup times.
Run the tractor engine until the air brake system
pressure gauge shows at least 105 psi. Listen for air
leaks. With the engine off, check the gauge reading
with no brakes applied. The gauge reading loss
should not exceed three psi in one minute.
BRAKE SHOES
Brake shoe designs vary, depending on the type of
brake and brake manufacturer. Some brakes require
special tools. If you have problems removing brake
shoes, refer to the brake manufacturer’s manual.
BRAKE SHOE SPRINGS
Replace weak or unmated brake shoe springs whenever
they cause pulling or dragging brakes. The springs are
constantly expanding and contracting in the confined
hot area of the brake drums. Excessive heat during
expansion will cause them to weaken.
BRAKE LINERS
The certified Gross Axle Weight Rating (GAWR) in
many cases is determined by the friction level of the
brake liners. The friction level is determined by the
axle and vehicle manufacturer to provide the required
brake torque as prescribed by governmental regulations.
NOTICE: When replacing liners, be sure to use
liners with the same friction level as those
removed from the trailer so that the GAWR is
not reduced.
REFACING DRUMS
It is not a good practice to reface brake drums.
Refacing can weaken the drums, making them unable
to dissipate all the heat generated by brake applications,
and making them susceptible to distortion and heat
cracks.
With the engine still off, apply the brakes fully for two
minutes. The gauge reading drop should not exceed
four psi in one minute.
With engine still off, slowly open drain cocks in the trailer’s air tanks and allow the pressure to drop gradually.
8
If brake drums must be refaced on cam-type brakes,
when oversized linings are used, precautions regarding
cam travel should be checked to prevent sticking cams
or cam rollover. This problem often exists when the
linings become worn. It may be necessary to install
oversized rollers to prevent this problem.
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