OPERATION & MAINTENANCE MANUAL
REV 2/9/11 9:44 AM
WHEN ORDERING PARTS, PLEASE REFER TO THE
VIN NUMBER AND “TYPE OF VEHICLE” OF YOUR LEAF VACUUM.
RECORD THEM FROM THE VIN TAG ON THE
FRONT DRIVER’S SIDE OF THE TRAILER:
LEAF VAC V.I.N. NO.: ______________________________
TYPE OF VEHICLE.: _______________________________
ENGINE MODEL NO.: ______________________________
ENGINE SERIAL NO.: ______________________________
General Safety Information
1.
GENERAL SAFETY INFORMATION ................................................................................................ 5
1.1. SAFETY ALERT SYMBOLS AND SIGNAL WORDS ................................................................................... 5
1.2. MAJOR HAZARDS ............................................................................................................................. 6
1.2.1. Improper Sizing of the Trailer to the Tow Vehicle. .................................................................. 6
1.2.2. Driving Too Fast ...................................................................................................................... 6
1.2.3. Adjusting Driving Behavior to match Conditions ..................................................................... 6
1.2.4. Trailer Not Properly Coupled to the Hitch ............................................................................... 7
1.2.5. Proper Use of Safety Chains .................................................................................................. 8
1.2.6. Proper Connection of Breakaway Brake ................................................................................. 8
1.2.7. Matching Trailer and Hitch ...................................................................................................... 8
1.2.8. Worn Tires, Loose Wheels, and Lug Nuts .............................................................................. 8
1.2.9. Inoperable Brakes, Lights or Mirrors ....................................................................................... 9
1.2.10. Hazards From Modifying Your Trailer ................................................................................... 10
Safety Warning Labels on Your Trailer ............................................................................................... 10
1.2.11. Trailer Towing Guide ............................................................................................................. 13
1.2.12. Reporting Safety Defects ...................................................................................................... 13
1.3. SAFE TRAILER TOWING GUIDELINES ................................................................................................ 13
1.4. GENERAL SAFETY RELATED TO OPERATION OF VACUUM ................................................................. 14
1.5. SAFETY DISCONNECT ..................................................................................................................... 14
1.6. DECIBAL LEVELS ............................................................................................................................ 15
2. TIRE SAFETY INFORMATION ....................................................................................................... 16
2.1. STEPS FOR DETERMINING CORRECT LOAD LIMIT – TRAILER .............................................................. 16
2.2. GLOSSARY OF TIRE TERMINOLOGY ................................................................................................. 17
2.3. TIRE SAFETY - EVERYTHING RIDES ON IT ........................................................................................ 19
2.3.1. Safety First–Basic Tire Maintenance .................................................................................... 20
2.3.2. Finding Your Vehicle's Recommended Tire Pressure and Load Limits ................................ 20
2.3.3. Understanding Tire Pressure and Load Limits ...................................................................... 20
2.3.4. Checking Tire Pressure ........................................................................................................ 20
2.3.5. Steps for Maintaining Proper Tire Pressure .......................................................................... 21
2.3.6. Tire Size ................................................................................................................................ 21
2.3.7. Tire Tread ............................................................................................................................. 21
2.3.8. Tire Balance and Wheel Alignment ....................................................................................... 21
2.3.9. Tire Repair ............................................................................................................................ 22
2.3.10. Tire Fundamentals ................................................................................................................ 22
2.3.11. Tire Safety Tips ..................................................................................................................... 24
2.4. TIRE REGISTRATION ....................................................................................................................... 25
3. COUPLING TO THE TOW VEHICLE .............................................................................................. 26
3.1. USE AN ADEQUATE TOW VEHICLE AND HITCH .................................................................................. 26
3.2. CERTIFICATION / VIN TAG ............................................................................................................... 26
3.3. COUPLING AND UNCOUPLING THE TRAILER ...................................................................................... 27
3.3.1. Various Coupler Designs ...................................................................................................... 28
3.3.2. Trailer with Ball-Hitch Coupler .............................................................................................. 28
3.3.3. Rig the safety chains ............................................................................................................. 30
3.3.4. Attach and test electric breakaway brake system ................................................................. 30
4. CHECKING THE TRAILER BEFORE AND DURING EACH TOW ................................................ 33
4.1. PRE-TOW CHECKLIST ..................................................................................................................... 33
4.2. MAKE REGULAR STOPS .................................................................................................................. 33
5. BREAKING-IN A NEW TRAILER ................................................................................................... 34
5.1. RETIGHTEN LUG NUTS AT FIRST 10, 25 & 50 MILES ......................................................................... 34
5.2. ADJUST BRAKE SHOES AT FIRST 200 MILES .................................................................................... 34
5.3. SYNCHRONIZING THE BRAKE SYSTEMS ............................................................................................ 34
General Safety Information
6.
INSPECTION, SERVICE & MAINTENANCE .................................................................................. 35
6.1. INSPECTION, SERVICE & MAINTENANCE SUMMARY CHARTS .............................................................. 35
6.2. INSPECTION AND SERVICE INSTRUCTIONS ........................................................................................ 36
6.2.1. Axle Bolts, Frame, Suspension, & Structure ......................................................................... 36
6.2.2. Trailer Structure .................................................................................................................... 37
6.2.3. Trailer Brakes ........................................................................................................................ 37
6.2.4. Trailer Connection to Tow Vehicle ........................................................................................ 39
6.2.5. Trailer Jack ........................................................................................................................... 40
6.2.6. Lights and Signals ................................................................................................................. 40
6.2.7. Tires ...................................................................................................................................... 40
6.2.8. Wheel Rims ........................................................................................................................... 41
6.2.9. Wheels, Bearings and Lug Nuts ........................................................................................... 41
6.3. MAINTENANCE GUIDELINES PERTAINING TO VACUUM EQUIPMENT ................................. 44
6.3.1. CAPICITIES & SPECIFICATIONS ........................................................................................ 44
6.3.2. INITIAL SERVICING & BREAK-IN ........................................................................................ 44
6.3.3. LIST OF SUPPLEMENTAL MANUALS ................................................................................ 44
6.3.4. ENGINE SERVICE ............................................................................................................... 44
6.3.5. CLUTCH OR FLUID COUPLER SERVICE .......................................................................... 45
6.3.6. LUBRICATION ...................................................................................................................... 45
6.3.7. FAN BELT TENSION & ALIGNMENT .................................................................................. 45
6.3.8. BELT SHEAVES & ALIGNMENT .......................................................................................... 46
6.3.9. FAN ....................................................................................................................................... 47
6.3.10. BLOWER HOUSING LINER REMOVAL .............................................................................. 48
6.3.11. SUCTION HOSE ................................................................................................................... 48
6.3.12. HYDRAULIC SYSTEM (IF EQUIPPED) ............................................................................... 48
6.3.13. WETTING SYSTEM (IF EQUIPPED) ................................................................................... 48
6.4. ELECTRICAL SYSTEM ............................................................................................................... 48
6.4.1. WIRING DIAGRAMS ............................................................................................................ 48
7. GENERAL OPERATING INSTRUCTIONS ..................................................................................... 59
7.1. ENGINE RPM ............................................................................................................................... 59
7.2. HYDRAULIC BOOM OPERATION (IF EQUIPPED) ..................................................................... 59
7.3. HYDRAULIC JACK (IF EQUIPPED) ............................................................................................. 59
7.4. DISCHARGE CHUTE CYLINDER (IF EQUIPPED) ...................................................................... 60
7.5. WETTING SYSTEM (IF EQUIPPED) ........................................................................................... 60
7.6. DUAL TONGUE SYSTEM (IF EQUIPPED) .................................................................................. 60
8. SUPPLIMENTAL MANUALS .......................................................................................................... 61
8.1. MARTIN QD BUSHINGS ................................................................................................................... 61
8.2. BROWNING FAN BUSHING ............................................................................................................... 62
8.3. NACD CLUTCH .............................................................................................................................. 64
8.4. TRANS FLUID COUPLER .................................................................................................................. 88
8.5. MONARCH POWER UNIT .................................................................................................................. 95
8.6. BREAK-AWAY SYSTEM .................................................................................................................... 99
8.7. 4 POINT SAFETY HARNESS ........................................................................................................... 101
8.8. LIGHTING SYSTEMS ...................................................................................................................... 102
8.9. WETTING SYSTEM PUMP ............................................................................................................... 105
9. PART BREAKDOWNS ................................................................................................................. 110
9.1. CHASSIS ASSEMBLY ..................................................................................................................... 110
9.2. SEAT WELDMENT ASSEMBLY ........................................................................................................ 112
9.3. FUEL TANK ASSEMBLY .................................................................................................................. 114
9.4. TRAILER JACK ASSEMBLIES ........................................................................................................... 116
9.5. ENGINE BELT DRIVE FAN ASSEMBLY ............................................................................................. 118
9.6. HYDRAULIC VALVE ASSEMBLY – SOLENOID CONTROLLED LEAF VAC ............................................... 120
General Safety Information
9.7.
ELECTRIC POWER UNIT, SINGLE FUNCTION, PUSH BUTTON ............................................................ 121
9.8. ELECTRIC POWER UNIT, FUNCTION, PUSH BUTTON ........................................................................ 122
9.9. LEAF DISCHARGE ASSEMBLIES ...................................................................................................... 123
9.10. HYDRAULIC TANK ASSEMBLY ........................................................................................................ 125
9.11. MANUAL HOSE ARM ASSEMBLY ..................................................................................................... 127
9.12. HYDRAULIC HOSE ARM ASSEMBLY ................................................................................................ 129
9.13. LEAF VAC WETTING SYSTEM ......................................................................................................... 131
9.14. KUBOTA ENGINE MOUNTING ASSEMBLY .......................................................................................... 133
9.15. JOHN DEERE ENGINE MOUNTING ASSEMBLY .................................................................................... 135
9.16. ENGINE MOUNTED ACCESSORIES, KUBOTA .................................................................................... 137
10. WARRANTY .................................................................................................................................. 139
Manufactured, sold, and serviced by:
1385 Franklin Grove Road
Dixon, IL 61021
800-851-9664
www.titanleafpro.com
General Safety Information
1. GENERAL SAFETY INFORMATION
1.1. SAFETY ALERT SYMBOLS AND SIGNAL WORDS
SPECIAL NOTE: This manual contains information pertaining to both the chassis (trailer portion)
of the leaf vacuum, as well as the equipment mounted on the chassis. Throughout this manual,
the complete pull behind leaf vacuum will be referred to as a trailer, as this is how it is classified
by federal law. All rules and regulations pertaining to the operation of “regular trailers” also apply
to this ”leaf vacuum trailer”.
ANOTHER SPECIAL NOTE: An Owner’s Manual that provides general trailer information cannot
cover all of the specific details necessary for the proper combination of every trailer, tow vehicle
and hitch. Therefore, you must read, understand and follow the instructions given by the tow
vehicle and trailer hitch manufacturers, as well as the instructions in this manual.
AND ONE MORE: This trailer is 102” wide, which is within legal towing width for all US interstates
and federally designated state highways. When operating on other roadways, consult local and
state laws regarding legal towing width.
Our trailers are built with components produced by various manufacturers. Some of these items have
separate instruction manuals, and many are included in the supplemental manuals section. Where this
manual indicates that you should read another manual, but you do not have that manual, call Bonnell
Industries, Inc at 800-851-9664 for a free copy. See page 44 for a list of supplemental manuals that may
apply to this piece of equipment.
The safety information in this manual is denoted by the safety alert symbol: ^
The level of risk is indicated by the following signal words.
^ Danger
DANGER – Immediate hazards which WILL result in severe personal injury or
death if the warning is ignored.
^ WARNING
WARNING – Hazards or unsafe practices which COULD result in severe
personal injury or death if the warning is ignored.
^ Caution
CAUTION – Hazards or unsafe practices which could result in minor or
moderate injury if the warning is ignored.
^ Notice
NOTICE – Practices that could result in damage to the trailer or other property.
General Safety Information
1.2. MAJOR HAZARDS
Loss of control of the trailer or trailer/tow vehicle combination can result in death or serious injury. The
most common causes for loss of control of the trailer are:
• Improper sizing the trailer for the tow vehicle, or vice versa.
• Excessive Speed: Driving too fast for the conditions.
• Failure to adjust driving behavior when towing a trailer.
• Improper or mis-coupling of the trailer to the hitch.
• Improper braking and steering under sway conditions.
• Not maintaining proper tire pressure.
• Not keeping lug nuts tight.
1.2.1. IMPROPER SIZING OF THE TRAILER TO THE TOW VEHICLE.
Trailers that weigh too much for the towing vehicle can cause stability problems, which can lead to death
or serious injury. Furthermore, the additional strain put on the engine and drive-train may lead to serious
tow vehicle maintenance problems. For these reasons the maximum towing capacity of your towing
vehicle should not be exceeded. The towing capacity of your tow vehicle, in terms of maximum Gross
Trailer Weight (GTW) and maximum Gross Combined Weight Rating (GCWR) can be found in the tow
vehicles Owner’s Manual.
^ Danger
Use of a hitch with a load rating less than the load rating of the trailer can
result in loss of control and may lead to death or serious injury.
Use of a tow vehicle with a towing capacity less than the load rating of the
trailer can result in loss of control, and may lead to death or serious injury.
Be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight
Rating (GVWR) of your trailer.
1.2.2. DRIVING TOO FAST
With ideal road conditions, the maximum recommended speed for safely towing a trailer is 60 mph. If you
drive too fast, the trailer is more likely to sway, thus increasing the possibility for loss of control. Also your
tires may overheat, thus increasing the possibility of a blowout.
^ WARNING
Driving too fast for conditions can result in loss of control and cause death or
serious injury.
1.2.3. ADJUSTING DRIVING BEHAVIOR TO MATCH CONDITIONS
When towing a trailer, you will have decreased acceleration, increased stopping distance, and increased
turning radius (which means you must make wider turns to keep from hitting curbs, vehicles, and anything
else that is on the inside corner). Furthermore the trailer will change the handling characteristics of your
towing vehicle, making it more sensitive to steering inputs and more likely to be pushed around in windy
conditions or when being passed by large vehicles. In addition, you will need a longer distance to pass,
due to slower acceleration and increased length. With these caveats in mind:
General Safety Information
Be alert for slippery conditions. You are more likely to be affected by slippery road surfaces when driving
a tow vehicle with a trailer, than driving a tow vehicle without a trailer.
Anticipate the trailer “swaying.” Swaying can be caused by excessive steering, wind gusts, roadway
edges, or by the trailer reaction to the pressure wave created by passing trucks and busses.
When encountering trailer sway take your foot off the gas, and steer as little as possible in order to stay
on the road. Use small “trim-like” steering adjustments. Do not attempt to steer out of the sway; you’ll only
make it worse. Also do not apply the tow vehicle brakes to correct trailer swaying. On the other hand,
application of the trailer brakes alone will tend to straighten out the combination, especially when going
downhill. Check rearview mirrors frequently to observe the trailer and traffic. Use lower gear when
driving down steep or long grades. Use the engine and transmission as a brake. Do not ride the brakes,
as they can overheat and become ineffective. Be aware of your trailer height, especially when
approaching bridges, roofed areas and around trees.
1.2.4. TRAILER NOT PROPERLY COUPLED TO THE HITCH
It is critical that the trailer be securely coupled to the hitch ball, and that the safety chains and emergency
break-away brake cable are correctly attached. Uncoupling may result in death or serious injury to you
and to others.
^ WARNING
Proper selection and condition of the coupler and hitch are essential to safely
towing your trailer. A loss of coupling may result in death or serious injury.
Be sure the hitch load rating is equal to or greater than the load rating of the
coupler.
Be sure the hitch size matches the coupler size
Observe the hitch for wear, corrosion and cracks before coupling. Replace
worn, corroded or cracked hitch components before coupling the trailer to the
tow vehicle.
Be sure the hitch components are tight before coupling the trailer to the tow
vehicle.
^ WARNING
An improperly coupled trailer can result in death or serious injury.
Do not move the trailer until:
The coupler is secured and locked to hitch;
The safety chains are secured to the tow vehicle; and
The trailer jack(s) are fully retracted.
Do not tow the trailer on the road until:
Tires and wheels are checked;
The trailer brakes are checked;
The breakaway switch is connected to the tow vehicle;
The load is secured to the trailer; and
The trailer lights are connected and checked.
General Safety Information
1.2.5. PROPER USE OF SAFETY CHAINS
If your trailer comes loose from the hitch for any reason, we have provided safety chains so that control of
the trailer can still be maintained.
1.2.6. PROPER CONNECTION OF BREAKAWAY BRAKE
Your trailer is equipped with a breakaway brake system that can apply the brakes on your trailer if your
trailer comes loose from the hitch ball for any reason. See page 99 for complete instructions regarding
the break-away system. The breakaway brake system, including battery, must be in good condition and
properly rigged to be effective.
^ WARNING
An ineffective or inoperative breakaway brake system can result in a runaway trailer, leading
to death or serious injury if the coupler or hitch fails.
The breakaway cable must be connected to the tow vehicle, and NOT to any part of the hitch.
Before towing the trailer, test the function of the breakaway brake system. If the breakaway
brake system is not working, do not tow the trailer. Have it serviced or repaired.
1.2.7. MATCHING TRAILER AND HITCH
^ Danger
Use of a hitch with a load rating less than the load rating of the trailer can result in loss of
control and may lead to death or serious injury.
Use of a tow vehicle with a towing capacity less than the load rating of the trailer can result in
loss of control, and may lead to death or serious injury.
Be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating (GVWR) of
your trailer.
1.2.8. WORN TIRES, LOOSE WHEELS, AND LUG NUTS
As with any vehicle, the trailer tires and wheels are important safety items. Therefore, it is essential to
inspect the trailer tires before each tow.
If a tire has a bald spot, bulge, cut, cracks, or is showing any cords, replace the tire before towing. If a
tire has uneven tread wear, take the trailer to a dealer service center for diagnosis. Uneven tread wear
can be caused by tire imbalance, axle misalignment or incorrect inflation.
^ WARNING
Improper rigging of the safety chains can result in loss of control of the trailer
and tow vehicle, leading to death or serious injury, if the trailer uncouples
from the tow vehicle.
Fasten chains to frame of tow vehicle. Do not fasten chains to any part of the
hitch unless the hitch has holes or loops specifically for that purpose.
Cross chains underneath hitch and coupler with enough slack to permit turning
and to hold tongue up, if the trailer comes loose.
General Safety Information
Tires with too little tread will not provide adequate frictional forces on wet roadways and can result in loss
of control, leading to death or serious injury.
Improper tire pressure causes increased tire wear and may reduce trailer stability, which can result in a
tire blowout or possible loss of control. Therefore, before each tow you must also check the tire pressure.
Remember, the proper tire pressure is listed on the Certification / VIN label, normally mounted on front
left side of the trailer, and should be checked when tires are cold. Allow 3 hours cool-down after driving
as much as 1 mile at 40 mph before checking tire pressure.
^ WARNING
Improper tire pressure can result in a blowout and loss of control, which can lead to death or
serious injury.
Be sure tires are inflated to pressure indicated on sidewall before towing trailer.
The tightness of the lug nuts is very important in keeping the wheels properly seated to the hub.
Before each tow, check to make sure they are tight.
^ WARNING
Metal creep between the wheel rim and lug nuts will cause rim to loosen and could result in a
wheel coming off, leading to death or serious injury.
Tighten lug nuts before each tow.
The proper tightness (torque) for lug nuts is listed in Section 6.2.9.2 in the “Error! Reference source not
found.” chapter of this manual. Use a torque wrench to tighten the lug nuts, use the crisscross star
pattern on page 42. If you do not have a torque wrench, use a lug wrench (from your tow vehicle) and
tighten the nuts as much as you can. At the first opportunity, have a service garage or trailer dealer
tighten the lug nuts to the proper torque.
^ WARNING
Lug nuts are prone to loosen after initial installation, which can lead to death or serious injury.
Check lug nuts for tightness on a new trailer or when wheel(s) have been remounted after the
first 10, 25 and 50 miles of driving.
^ WARNING
Improper lug nut torque can cause a wheel separating from the trailer, leading to death or
serious injury. Be sure lug nuts are tight before each tow.
1.2.9. INOPERABLE BRAKES, LIGHTS OR MIRRORS
Be sure that the electric brakes and all of the lights on your trailer are functioning properly before towing
your trailer. Electric brakes and lights on a trailer are controlled via a connection to the tow vehicle,
generally a multi-pin electrical connector. Check the trailer tail lights by turning on your tow vehicle
headlights. Check the trailer brake lights by having someone step on the tow vehicle brake pedal while
you look at trailer lights. Do the same thing to check the turn signal lights.
If your trailer has electric brakes, your tow vehicle will have an electric brake controller that sends power
to the trailer brakes. Before towing the trailer on the road, you must operate the brake controller while
trying to pull the trailer in order to confirm that the electric brakes operate. While towing the trailer at less
than 5 mph, manually operate the electric brake controller in the tow vehicle cab. You should feel the
operation of the trailer brakes.
General Safety Information
^ WARNING
Improper electrical connection between the tow vehicle and the trailer will result in inoperable
lights and electric brakes, and can lead to collision.
Before each tow:
Check that the taillights, brake lights and turn signals work
Check that the electric brakes work by operating the brake controller inside the tow vehicle
1.2.10. HAZARDS FROM MODIFYING YOUR TRAILER
Essential safety items can be damaged by altering your trailer. Before making any alteration to your
trailer, contact your dealer or Bonnell Industries, Inc at 800-851-9664 and describe the alteration you are
contemplating. Alteration of the trailer structure or modification of mechanical, electrical, or other systems
on your trailer must be performed only by qualified technicians who are familiar with the system installed
on your trailer.
SAFETY WARNING LABELS ON YOUR TRAILER
Below are illustrations of the safety decals applied to your machine. Familiarize yourself with their
locations & importance. To protect you and others against death or serious injury, all of the labels shown
below must be on the trailer and must be legible. If any of these labels are missing or cannot be read,
call Bonnell Industries, Inc at 800-851-9664 for free replacement labels.
On or near trailer tongue:
General Safety Information
General Safety Information
General Safety Information
1.2.11. TRAILER TOWING GUIDE
Driving a vehicle with a trailer in tow is vastly different from driving the same vehicle without a trailer in tow.
Acceleration, maneuverability and braking are all diminished with a trailer in tow. It takes longer to get up to
speed; you need more room to turn and pass, and more distance to stop when towing a trailer. You will need
to spend time adjusting to the different feel and maneuverability of the tow vehicle with a loaded trailer.
Because of the significant differences in all aspects of maneuverability when towing a trailer, the hazards and
risks of injury are also much greater than when driving without a trailer. You are responsible for keeping your
vehicle and trailer in control, and for all the damage that is caused if you lose control of your vehicle and trailer.
As you did when learning to drive an automobile, find an open area with little or no traffic for your first practice
trailering. Of course, before you start towing the trailer, you must follow all of the instructions for inspection,
testing, loading and coupling. Also, before you start towing, adjust the mirrors so you can see the trailer as
well as the area to the rear of it.
Drive slowly at first, 5 mph or so, and turn the wheel to get the feel of how the tow vehicle and trailer
combination responds. Next, make some right and left hand turns. Watch in your side mirrors to see how the
trailer follows the tow vehicle. Turning with a trailer attached requires more room.
Stop the rig a few times from speeds no greater than 10 mph. If your trailer is equipped with brakes, try using
different combinations of trailer/electric brake and tow vehicle brake. Note the effect that the trailer brakes
have when they are the only brakes used. When properly adjusted, the trailer brakes will come on just before
the tow vehicle brakes.
It will take practice to learn how to back up a tow vehicle with a trailer attached. Take it slow. Before backing
up, get out of the tow vehicle and look behind the trailer to make sure that there are no obstacles. Some
drivers place their hands at the bottom of the steering wheel, and while the tow vehicle is in reverse, “think” of
the hands as being on the top of the wheel. When the hands move to the right (counter-clockwise, as you
would do to turn the tow vehicle to the left when moving forward), the rear of the trailer moves to the right.
Conversely, rotating the steering wheel clockwise with your hands at the bottom of the wheel will move the
rear of the trailer to the left, while backing up. If you are towing a bumper hitch rig, be careful not to allow the
trailer to turn too much, because it will hit the rear of the tow vehicle. To straighten the rig, either pull forward,
or turn the steering wheel in the opposite direction.
1.2.12. REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying
Bonnell Industries, 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 order a recall and remedy campaign. However, NHTSA cannot become involved in
individual problems between you, your dealer, or Bonnell Industries, Inc.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800424-9153), go tohttp://www.safecar.gov; or write to: Administrator, NHTSA, 1200 New Jersey Ave. SE.,
Washington, DC 20590. You can also obtain other information about motor vehicle safety from
http://www.safecar.gov.
Call 800-851-9664 to reach Bonnell Industries, Inc.
1.3. SAFE TRAILER TOWING GUIDELINES
• Before towing, check coupling, safety chain, safety brake, tires, wheels and lights.
• Check the lug nuts or bolts for tightness.
• Check coupler tightness after towing 50 miles.
• Adjust the brake controller to engage the trailer brakes before the tow vehicle brakes. Follow the
instructions given with the brake controller manufacturer’s literature.
• Use your mirrors to verify that you have room to change lanes or pull into traffic.
General Safety Information
• Use your turn signals well in advance.
• Allow plenty of stopping space for your trailer and tow vehicle.
• Do not drive so fast that the trailer begins to sway due to speed. Generally never drive faster than 60
m.p.h.
• Allow plenty of room for passing. A rule of thumb is that the passing distance with a trailer is 4 times
the passing distance without a trailer.
• Shift your automatic transmission into a lower gear for city driving.
• Use lower gears for climbing and descending grades.
• Do not ride the brakes while descending grades, they may get so hot that they stop working. Then
you will potentially have a runaway tow vehicle and trailer.
• To conserve fuel, don't use full throttle to climb a hill. Instead, build speed on the approach.
• Slow down for bumps in the road. Take your foot off the brake when crossing the bump.
• Do not brake while in a curve unless absolutely necessary. Instead, slow down before you enter the
curve.
• Do not apply the tow vehicle brakes to correct extreme trailer swaying. Instead, lightly apply the trailer
brakes with the hand controller.
• Make regular stops, about once each hour. Confirm that:
• The coupler is secure to the hitch and is locked,
• Electrical connectors are made,
• There is appropriate slack in the safety chains,
• There is appropriate slack in the breakaway switch pull pin cable,
• The tires are not visibly low on pressure
1.4. GENERAL SAFETY RELATED TO OPERATION OF VACUUM
• Review safety items with all relevant personal at regular intervals.
• Ensure all operators are familiar with this manual before operating.
• Ensure your operation is in compliance with all applicable codes and regulations.
• Before operating machine, do a safety inspection. Refer to the pre-start checklist on page 4 for
general procedures.
• Make sure all personal protective equipment is in order before leaving for the job site. Recommended
equipment includes hard hat, safety goggles or ski mask, and ear protection.
• Have a fire extinguisher on hand at all times.
• Clean leaf debris from machine and engine screen after each load to prevent build-up of flammable
material. A leaf blower works well for this. This can be done during truck change-over.
• Inspect work area before operating machine. Inspect for heavy debris, such as bricks, rocks, or glass
bottles.
• Ensure all pedestrians and operators are clear of the vacuum area.
• Keep nozzle away from loose objects that may be near the collection area, and may get caught in the
nozzle.
• Remove key and chock wheels when leaving machine unattended.
• DO NOT operate machine with guard, hose, or housing cover removed. Refer to safety disconnect
section below for lock-out procedures.
• Prior to towing, inspect pintle, safety chains, lighting, running gear & trailer brakes.
• Secure pick-up nozzle for transport.
• When rotating hose per maintenance section, inspect fan for uneven wear, cracks, or looseness. Also
check housing for large heavy debris & remove.
• With the exception of the operator’s seat, no riders are allowed on the machine. Operator’s seat is for
leaf collection operations only. Maximum speed with operator not to exceed 5 MPH.
1.5. SAFETY DISCONNECT
Your Leaf Machine is equipped with two safety disconnect devices. These disconnect devices and all
wiring are to be left operable and in place at all times, for the life of the machine. One is located on the
belt guard, and the other is located on the hose connection to the blower housing. When performing any
repair or maintenance work related to these areas, remove key from ignition, and disconnect the safety
disconnect to the area needing service.
General Safety Information
1.6. DECIBAL LEVELS
Tire Safety Information
2. TIRE SAFETY INFORMATION
This portion of the User’s Manual contains tire safety information as required by 49 CFR 575.6.
Section 2.1 contains “Steps for Determining Correct Load Limit - Trailer”.
Section 2.2 contains “Steps for Determining Correct Load Limit – Tow Vehicle”.
Section 2.3 contains a Glossary of Tire Terminology, including “cold inflation pressure”, “maximum inflation
pressure”, “recommended inflation pressure”, and other non-technical terms.
Section 2.4 contains information from the NHTSA brochure entitled “Tire Safety – Everything Rides On It”.
This brochure describes the following items;
• Tire labeling, including a description and explanation of each marking on the tires, and information
about the DOT Tire Identification Number (TIN).
• Recommended tire inflation pressure, including a description and explanation of:
A. Cold inflation pressure.
B. Vehicle Placard and location on the vehicle.
C. Adverse safety consequences of under inflation (including tire failure).
D. Measuring and adjusting air pressure for proper inflation.
• Tire Care, including maintenance and safety practices.
• Vehicle load limits, including a description and explanation of the following items:
A. Locating and understanding the load limit information, total load capacity, and cargo capacity.
B. Calculating total and cargo capacities with varying seating configurations including quantitative
examples showing / illustrating how the vehicles cargo and luggage capacity decreases as
combined number and size of occupants’ increases. This item is also discussed in Section 3.
C. Determining compatibility of tire and vehicle load capabilities.
D. Adverse safety consequences of overloading on handling and stopping on tires.
2.1. STEPS FOR DETERMINING CORRECT LOAD LIMIT – TRAILER
Trailers 10,000 Pounds GVWR or Less:
1. Locate the statement, “The weight of cargo should never exceed XXX kg or XXX lbs.,” on your vehicle’s
placard. See figure 1-1.
2. This figure equals the available amount of cargo and luggage load capacity.
3. Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not
safely exceed the available cargo and luggage load capacity.
The trailer’s placard refers to the Tire Information Placard attached adjacent to or near the trailer’s VIN
(Certification) label at the left front of the trailer.
Tire and Loading Information
Tire Information
2.2. GLOSSARY OF TIRE TERMINOLOGY
Accessory weight
The combined weight (in excess of those standard items which may be replaced) of automatic transmission,
power steering, power brakes, power windows, power seats, radio and heater, to the extent that these items
are available as factory-installed equipment (whether installed or not).
Bead: The part of the tire that is made of steel wires, wrapped or reinforced by ply cords and that is shaped to
fit the rim.
Bead separation: This is the breakdown of the bond between components in the bead.
Bias ply tire: A pneumatic tire in which the ply cords that extend to the beads are laid at alternate angles
substantially less than 90 degrees to the centerline of the tread.
Carcass: The tire structure, except tread and sidewall rubber which, when inflated, bears the load.
Chunking: The breaking away of pieces of the tread or sidewall.
Cold inflation pressure: The pressure in the tire before you drive.
Cord: The strands forming the plies in the tire.
Cord separation: The parting of cords from adjacent rubber compounds.
Cracking: Any parting within the tread, sidewall, or inner liner of the tire extending to cord material.
CT: A pneumatic tire with an inverted flange tire and rim system in which the rim is designed with rim flanges
pointed radially inward and the tire is designed to fit on the underside of the rim in a manner that encloses the
rim flanges inside the air cavity of the tire.
Curb weight: The weight of a motor vehicle with standard equipment including the maximum capacity of fuel,
oil, and coolant, and, if so equipped, air conditioning and additional weight optional engine.
Extra load tire: A tire designed to operate at higher loads and at higher inflation pressures than the
corresponding standard tire.
Groove: The space between two adjacent tread ribs.
Innerliner: The layer(s) forming the inside surface of a tubeless tire that contains the inflating medium within
the tire.
Innerliner separation: The parting of the innerliner from cord material in the carcass.
Intended outboard sidewall: The sidewall that contains a white-wall, bears white lettering or bears
manufacturer, brand, and/or model name molding that is higher or deeper than the same molding on the other
sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must
always face outward when mounted on a vehicle.
Light truck (LT) tire: A tire designated by its manufacturer as primarily intended for use on lightweight trucks
or multipurpose passenger vehicles.
Load rating: The maximum load that a tire is rated to carry for a given inflation pressure.
Maximum load rating: The load rating for a tire at the maximum permissible inflation pressure for that tire.
Maximum permissible inflation pressure: The maximum cold inflation pressure to which a tire may be
inflated.
Tire Information
Maximum loaded vehicle weight: The sum of curb weight, accessory weight, vehicle capacity weight, and
production options weight.
Measuring rim: The rim on which a tire is fitted for physical dimension requirements.
Non-pneumatic rim: A mechanical device which, when a non-pneumatic tire assembly incorporates a wheel,
supports the tire, and attaches, either integrally or separably, to the wheel center member and upon which the
tire is attached.
Non-pneumatic spare tire assembly: A non-pneumatic tire assembly intended for temporary use in place of
one of the pneumatic tires and rims that are fitted to a passenger car in compliance with the requirements of
this standard.
Non-pneumatic tire: A mechanical device which transmits, either directly or through a wheel or wheel center
member, the vertical load and tractive forces from the roadway to the vehicle, generates the tractive forces
that provide the directional control of the vehicle and does not rely on the containment of any gas or fluid for
providing those functions.
Non-pneumatic tire assembly: A non-pneumatic tire, alone or in combination with a wheel or wheel center
member, which can be mounted on a vehicle.
Normal occupant weight: This means 68 kilograms (150 lbs.) times the number of occupants specified in
the second column of Table I of 49 CFR 571.110.
Occupant distribution: The distribution of occupants in a vehicle as specified in the third column of Table I of
49 CFR 571.110.
Open splice: Any parting at any junction of tread, sidewall, or innerliner that extends to cord material.
Outer diameter: The overall diameter of an inflated new tire.
Overall width:The linear distance between the exteriors of the sidewalls of an inflated tire, including
elevations due to labeling, decorations, or protective bands or ribs.
Ply: A layer of rubber-coated parallel cords.
Ply separation: A parting of rubber compound between adjacent plies.
Pneumatic tire: A mechanical device made of rubber, chemicals, fabric and steel or other materials, that,
when mounted on an automotive wheel, provides the traction and contains the gas or fluid that sustains the
load.
Production options weight: The combined weight of those installed regular production options weighing
over 2.3 kilograms (5 lbs.) in excess of those standard items which they replace, not previously considered in
curb weight or accessory weight, including heavy duty brakes, ride levelers, roof rack, heavy duty battery, and
special trim.
Radial ply tire: A pneumatic tire in which the ply cords that extend to the beads are laid at substantially 90
degrees to the centerline of the tread.
Recommended inflation pressure: This is the inflation pressure provided by the vehicle manufacturer on the
Tire Information label and on the Certification / VIN tag.
Reinforced tire: A tire designed to operate at higher loads and at higher inflation pressures than the
corresponding standard tire.
Rim: A metal support for a tire or a tire and tube assembly upon which the tire beads are seated.
Rim diameter: This means the nominal diameter of the bead seat.
Tire Information
Rim size designation: This means the rim diameter and width.
Rim type designation: This means the industry of manufacturer’s designation for a rim by style or code.
Rim width: This means the nominal distance between rim flanges.
Section width: The linear distance between the exteriors of the sidewalls of an inflated tire, excluding
elevations due to labeling, decoration, or protective bands.
Sidewall: That portion of a tire between the tread and bead.
Sidewall separation: The parting of the rubber compound from the cord material in the sidewall.
Special Trailer (ST) tire: The "ST" is an indication the tire is for trailer use only.
Test rim: The rim on which a tire is fitted for testing, and may be any rim listed as appropriate for use with
that tire.
Tread: That portion of a tire that comes into contact with the road.
Tread rib: A tread section running circumferentially around a tire.
Tread separation: Pulling away of the tread from the tire carcass.
Treadwear indicators (TWI): The projections within the principal grooves designed to give a visual indication
of the degrees of wear of the tread.
Vehicle capacity weight: The rated cargo and luggage load plus 68 kilograms (150 lbs.) times the vehicle’s
designated seating capacity.
Vehicle maximum load on the tire: The load on an individual tire that is determined by distributing to each
axle its share of the maximum loaded vehicle weight and dividing by two.
Vehicle normal load on the tire: The load on an individual tire that is determined by distributing to each axle
its share of the curb weight, accessory weight, and normal occupant weight (distributed in accordance with
Table I of CRF 49 571.110) and dividing by 2.
Weather side: The surface area of the rim not covered by the inflated tire.
Wheel center member: In the case of a non-pneumatic tire assembly incorporating a wheel, a mechanical
device which attaches, either integrally or separably, to the non-pneumatic rim and provides the connection
between the non-pneumatic rim and the vehicle; or, in the case of a non-pneumatic tire assembly not
incorporating a wheel, a mechanical device which attaches, either integrally or separably, to the nonpneumatic tire and provides the connection between tire and the vehicle.
Wheel-holding fixture: The fixture used to hold the wheel and tire assembly securely during testing.
2.3. TIRE SAFETY - EVERYTHING RIDES ON IT
The National Traffic Safety Administration (NHTSA) has published a brochure (DOT HS 809 361) that
discusses all aspects of Tire Safety, as required by CFR 575.6. This brochure is reproduced in part below. It
can be obtained and downloaded from NHTSA, free of charge, from the following web site:
http://www.nhtsa.dot.gov/cars/rules/TireSafety/ridesonit/tires_index.html
Studies of tire safety show that maintaining proper tire pressure, observing tire and vehicle load limits (not
carrying more weight in your vehicle than your tires or vehicle can safely handle), avoiding road hazards, and
Tire Information
inspecting tires for cuts, slashes, and other irregularities are the most important things you can do to avoid tire
failure, such as tread separation or blowout and flat tires. These actions, along with other care and
maintenance activities, can also:
• Improve vehicle handling
• Help protect you and others from avoidable breakdowns and accidents
• Improve fuel economy
• Increase the life of your tires.
This booklet presents a comprehensive overview of tire safety, including information on the following topics:
• Basic tire maintenance
• Uniform Tire Quality Grading System
• Fundamental characteristics of tires
• Tire safety tips.
Use this information to make tire safety a regular part of your vehicle maintenance routine. Recognize that the
time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire
failure.
2.3.1. SAFETY FIRST–BASIC TIRE MAINTENANCE
Properly maintained tires improve the steering, stopping, traction, and load-carrying capability of your vehicle.
Underinflated tires and overloaded vehicles are a major cause of tire failure. Therefore, as mentioned above,
to avoid flat tires and other types of tire failure, you should maintain proper tire pressure, observe tire and
vehicle load limits, avoid road hazards, and regularly inspect your tires.
2.3.2. FINDING YOUR VEHICLE'S RECOMMENDED TIRE PRESSURE AND LOAD LIMITS
Tire information placards and vehicle certification labels contain information on tires and load limits. These
labels indicate the vehicle manufacturer's information including:
• Recommended tire size
• Recommended tire inflation pressure
• Vehicle capacity weight (VCW–the maximum occupant and cargo weight a vehicle is designed to carry)
• Front and rear gross axle weight ratings (GAWR– the maximum weight the axle systems are designed to
carry).
Both placards and certification labels are permanently attached to the trailer near the left front.
2.3.3. UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS
Tire inflation pressure is the level of air in the tire that provides it with load-carrying capacity and affects the
overall performance of the vehicle. The tire inflation pressure is a number that indicates the amount of air
pressure– measured in pounds per square inch (psi)–a tire requires to be properly inflated. (You will also find
this number on the vehicle information placard expressed in kilopascals (kPa), which is the metric measure
used internationally.)
Manufacturers of passenger vehicles and light trucks determine this number based on the vehicle's design
load limit, that is, the greatest amount of weight a vehicle can safely carry and the vehicle's tire size. The
proper tire pressure for your vehicle is referred to as the "recommended cold inflation pressure." (As you will
read below, it is difficult to obtain the recommended tire pressure if your tires are not cold.)
Because tires are designed to be used on more than one type of vehicle, tire manufacturers list the "maximum
permissible inflation pressure" on the tire sidewall. This number is the greatest amount of air pressure that
should ever be put in the tire under normal driving conditions.
2.3.4. CHECKING TIRE PRESSURE
It is important to check your vehicle's tire pressure at least once a month for the following reasons:
Tire Information
• Most tires may naturally lose air over time.
• Tires can lose air suddenly if you drive over a pothole or other object or if you strike the curb when
parking.
• With radial tires, it is usually not possible to determine underinflation by visual inspection.
For convenience, purchase a tire pressure gauge to keep in your vehicle. Gauges can be purchased at tire
dealerships, auto supply stores, and other retail outlets.
The recommended tire inflation pressure that vehicle manufacturers provide reflects the proper psi when a tire
is cold. The term cold does not relate to the outside temperature. Rather, a cold tire is one that has not been
driven on for at least three hours. When you drive, your tires get warmer, causing the air pressure within them
to increase. Therefore, to get an accurate tire pressure reading, you must measure tire pressure when the tires
are cold or compensate for the extra pressure in warm tires.
2.3.5. STEPS FOR MAINTAINING PROPER TIRE PRESSURE
• Step 1: Locate the recommended tire pressure on the vehicle's tire information placard, certification label,
or in the owner's manual.
• Step 2: Record the tire pressure of all tires.
• Step 3: If the tire pressure is too high in any of the tires, slowly release air by gently pressing on the tire
valve stem with the edge of your tire gauge until you get to the correct pressure.
• Step 4: If the tire pressure is too low, note the difference between the measured tire pressure and the
correct tire pressure. These "missing" pounds of pressure are what you will need to add.
• Step 5: At a service station, add the missing pounds of air pressure to each tire that is underinflated.
• Step 6: Check all the tires to make sure they have the same air pressure (except in cases in which the
front and rear tires are supposed to have different amounts of pressure).
If you have been driving your vehicle and think that a tire is underinflated, fill it to the recommended cold
inflation pressure indicated on your vehicle's tire information placard or certification label. While your tire may
still be slightly underinflated due to the extra pounds of pressure in the warm tire, it is safer to drive with air
pressure that is slightly lower than the vehicle manufacturer's recommended cold inflation pressure than to
drive with a significantly underinflated tire. Since this is a temporary fix, don't forget to recheck and adjust the
tire's pressure when you can obtain a cold reading.
2.3.6. TIRE SIZE
To maintain tire safety, purchase new tires that are the same size as the vehicle's original tires or another size
recommended by the manufacturer. Look at the tire information placard, the owner's manual, or the sidewall of
the tire you are replacing to find this information. If you have any doubt about the correct size to choose,
consult with the tire dealer.
2.3.7. TIRE TREAD
The tire tread provides the gripping action and traction that prevent your vehicle from slipping or sliding,
especially when the road is wet or icy. In general, tires are not safe and should be replaced when the tread is
worn down to 1/16 of an inch. Tires have built-in treadwear indicators that let you know when it is time to
replace your tires. These indicators are raised sections spaced intermittently in the bottom of the tread
grooves. When they appear "even" with the outside of the tread, it is time to replace your tires. Another
method for checking tread depth is to place a penny in the tread with Lincoln's head upside down and facing
you. If you can see the top of Lincoln's head, you are ready for new tires.
2.3.8. TIRE BALANCE AND WHEEL ALIGNMENT
To avoid vibration or shaking of the vehicle when a tire rotates, the tire must be properly balanced. This
balance is achieved by positioning weights on the wheel to counterbalance heavy spots on the wheel-and-tire
assembly. A wheel alignment adjusts the angles of the wheels so that they are positioned correctly relative to
the vehicle's frame. This adjustment maximizes the life of your tires. These adjustments require special
equipment and should be performed by a qualified technician.
Tire Information
2.3.9. TIRE REPAIR
The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that
surrounds the puncture hole. Punctures through the tread can be repaired if they are not too large, but
punctures to the sidewall should not be repaired. Tires must be removed from the rim to be properly inspected
before being plugged and patched.
2.3.10. TIRE FUNDAMENTALS
Federal law requires tire manufacturers to place standardized information on the sidewall of all tires. This
information identifies and describes the fundamental characteristics of the tire and also provides a tire
identification number for safety standard certification and in case of a recall.
2.3.10.1. Information on Passenger Vehicle Tires
Please refer to the diagram below.
P
The "P" indicates the tire is for passenger vehicles.
Next number
This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In
general, the larger the number, the wider the tire.
Next number
This two-digit number, known as the aspect ratio, gives the tire's ratio of height to width. Numbers of 70 or
lower indicate a short sidewall for improved steering response and better overall handling on dry pavement.
R
The "R" stands for radial. Radial ply construction of tires has been the industry standard for the past 20 years.
Next number
This two-digit number is the wheel or rim diameter in inches. If you change your wheel size, you will have to
purchase new tires to match the new wheel diameter.
Next number
This two- or three-digit number is the tire's load index. It is a measurement of how much weight each tire can
support. You may find this information in your owner's manual. If not, contact a local tire dealer. Note: You may
not find this information on all tires because it is not required by law.
Tire Information
M+S
The "M+S" or "M/S" indicates that the tire has some mud and snow capability. Most radial tires have these
markings; hence, they have some mud and snow capability.
U.S. DOT Tire Identification Number
This begins with the letters "DOT" and indicates that the tire meets all federal standards. The next two
numbers or letters are the plant code where it was manufactured, and the last four numbers represent the
week and year the tire was built. For example, the numbers 3197 means the 31st week of 1997. The other
numbers are marketing codes used at the manufacturer's discretion. This information is used to contact
consumers if a tire defect requires a recall.
Tire Ply Composition and Materials Used
The number of plies indicates the number of layers of rubber-coated fabric in the tire. In general, the greater
the number of plies, the more weight a tire can support. Tire manufacturers also must indicate the materials in
the tire, which include steel, nylon, polyester, and others.
Maximum Load Rating
This number indicates the maximum load in kilograms and pounds that can be carried by the tire.
Maximum Permissible Inflation Pressure
This number is the greatest amount of air pressure that should ever be put in the tire under normal driving
conditions.
2.3.10.2. UTQGS Information
Treadwear Number
This number indicates the tire's wear rate. The higher the treadwear number is, the longer it should take for the
tread to wear down. For example, a tire graded 400 should last twice as long as a tire graded 200.
Traction Letter
This letter indicates a tire's ability to stop on wet pavement. A higher graded tire should allow you to stop your
car on wet roads in a shorter distance than a tire with a lower grade. Traction is graded from highest to lowest
as "AA","A", "B", and "C".
Temperature Letter
This letter indicates a tire's resistance to heat. The temperature grade is for a tire that is inflated properly and
not overloaded. Excessive speed, underinflation or excessive loading, either separately or in combination, can
cause heat build-up and possible tire failure. From highest to lowest, a tire's resistance to heat is graded as
"A", "B", or "C".
2.3.10.3. Additional Information on Light Truck Tires
Please refer to the following diagram.
Tire Information
Tires for light trucks have other markings besides those found on the sidewalls of passenger tires.
LT
The "LT" indicates the tire is for light trucks or trailers.
ST
An "ST" is an indication the tire is for trailer use only.
Max. Load Dual kg (lbs) at kPa (psi) Cold
This information indicates the maximum load and tire pressure when the tire is used as a dual, that is, when
four tires are put on each rear axle (a total of six or more tires on the vehicle).
Max. Load Single kg (lbs) at kPa (psi) Cold
This information indicates the maximum load and tire pressure when the tire is used as a single.
Load Range
This information identifies the tire's load-carrying capabilities and its inflation limits.
2.3.11. TIRE SAFETY TIPS
Preventing Tire Damage
• Slow down if you have to go over a pothole or other object in the road.
• Do not run over curbs or other foreign objects in the roadway, and try not to strike the curb when parking.
Tire Safety Checklist
• Check tire pressure regularly (at least once a month), including the spare.
• Inspect tires for uneven wear patterns on the tread, cracks, foreign objects, or other signs of wear or
trauma.
• Remove bits of glass and foreign objects wedged in the tread.
• Make sure your tire valves have valve caps.
• Check tire pressure before going on a long trip.
• Do not overload your vehicle. Check the Tire Information and Loading Placard or User’s Manual for the
maximum recommended load for the vehicle.
Tire Information
2.4. TIRE REGISTRATION
TIRE REGISTRATION
In accordance with Title 49 CFR 574.1, the following tire registration
information must be filled out and returned to Bonnell Industries:
Company Name: ____________________________
Contact: ___________________________________
Address: ___________________________________
City: ______________________________________
State: __________ Zip: _______________________
Model Number: _____________________________
Serial Number: ______________________________
TIN: DOT __________________________________
SPARE TIN: ________________________________
Date of Purchase: ___________________________
The Tire Identification Number (TIN) can be found on the side wall of the tire.
The number begins with “DOT”, and ends with a four-number date code.
Please Complete Form and fax to:
815-284-8815
Coupling to the Tow Vehicle
3. COUPLING TO THE TOW VEHICLE
Follow all of the safety precautions and instructions in this manual to ensure safety of persons,
cargo, and satisfactory life of the trailer.
3.1. USE AN ADEQUATE TOW VEHICLE AND HITCH
If the vehicle or hitch is not properly selected and matched to the Gross Vehicle Weight Rating
(GVWR) of your trailer, you can cause an accident that could lead to death or serious injury. If
you already have a tow vehicle, know your vehicle tow rating, and Gross Combination Weight
Rating (GCWR) and make certain the trailer’s rated capacity is less than or equal to the tow
vehicle’s rated towing capacity. If you already have (or plan to buy) a trailer, make certain that
the tow rating of the tow vehicle is equal to or greater than the GVWR of the trailer, and that the
GCWR will be within limits.
^ Danger
Use of a hitch with a load rating less than the load rating of the trailer can
result in loss of control and may lead to death or serious injury.
Use of a tow vehicle with a towing capacity less than the load rating of the
trailer can result in loss of control, and may lead to death or serious injury.
Be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight
Rating (GVWR) of your trailer.
3.2. CERTIFICATION / VIN TAG
The VIN tag is located on the driver’s side, near the front of the trailer. The VIN Tag contains the
following critical safety information for the use of your trailer:
MANUFACTURER: Name of trailer manufacturer
DATE OF MANUFACTURE: Month and year the trailer was manufactured.
GVWR: The Gross Vehicle Weight Rating is the maximum allowable gross weight of the trailer
and its contents. The gross weight of the trailer includes the weight of the trailer and all of the
items within it (such as cargo, water, food and other supplies).
GAWR: The Gross Axle Weight Rating is the maximum gross weight that an axle can support. It
is the lowest of axle, wheel, or tire rating. Sometimes the tire or wheel rating is lower than the
axle manufacturers rating, and will then determine GAWR.
The sum total of the GAWR for all trailer axles may be less than the GVWR for the trailer,
because some of the trailer load is carried by the tow vehicle, rather than by the trailer axle(s).
The total weight of the cargo and trailer must not exceed the GVWR, and the load on an axle
must not exceed its GAWR.
TIRE SIZE: The tire size recommended for your trailer and load range.
PSIC: The “pounds per square inch- cold” is the tire pressure (Kilopascals / Pounds per Square
Inch) measured when Cold.
CERTIFICATION STATEMENT: “This trailer meets all the Federal Motor Vehicle Safety
Standards in effect on the date of manufacture shown above”.
VIN: The Vehicle Identification Number.
Coupling to the Tow Vehicle
VEHICLE TYPE: Generally the word “trailer” is used. However, after this you may put a Model #,
or additional descriptor.
3.3. COUPLING AND UNCOUPLING THE TRAILER
A secure coupling (or fastening) of the trailer to the tow vehicle is essential. A loss of coupling
may result in death or serious injury. Therefore, you must understand and follow all of the
instructions for coupling.
The following parts are involved in making a secure coupling between the trailer and tow vehicle:
Coupling: That part of the trailer connecting mechanism by which the connection is actually
made to the trailer hitch. This does not include any structural member, extension of the trailer
frame, or brake controller.
Hitch: That part of the connecting mechanism including the ball support platform and ball and
those components that extend and are attached to the towing vehicle, including bumpers
intended to serve as hitches.)
Weight Distributing Hitch (or Equalizing Hitch): A mechanical device that connects the trailer
to the towing vehicle and by means of leverage applied on both the trailer and towing vehicle
structures, when properly adjusted, distributes the imposed vertical load at the hitch and coupling
connection between structures of the towing vehicle and trailer.
Weight Carrying Hitch: A mechanical and/or structural device that connects the trailer to the
towing vehicle and that does not employ features designed to redistruibute the load imposed at
the hitch and carrying connection.
Safety chains or cables: Chains or cables permanently attached to the trailer such that if the
coupler connection comes loose, the safety chains or cables can keep the trailer attached to the
tow vehicle. With properly rigged safety chains or cables, it is possible to keep the tongue of the
trailer from digging into the road pavement, even if the coupler-to-hitch connection comes apart.
Some states do not allow safety cables, e.g. Pennsylvania; therefore it may be wise to check with
the State Police to see if your state has any restrictions on the use of safety cables, if your trailer
is so equipped.
Trailer lighting (and braking) connector: A device that connects electrical power from the tow
vehicle to the trailer. Electricity is used to turn on brake lights, running lights, and turn signals as
required. In addition, if your trailer has a separate braking system, the electrical connector will
also supply power to the trailer brakes from the tow vehicle.
Breakaway switch: If the trailer becomes de-coupled from the towing vehicle, the breakaway
switch lanyard, attached independently to the tow vehicle hitch, will pull a pin in the emergency
electrical break-away switch on the trailer. The breakaway switch is activated by a separate
battery supply in the trailer such as to energize the trailer brakes independently of the towing
vehicle. It is important to check the state of charge of the emergency break-away battery before
each trip. Simply pull the pin out of the switch by hand and then try to pull the trailer. If you feel a
significant drag force the brakes are activated. Be sure to re-insert the pin in the break-away
switch. Also be sure to allow enough slack in the break-away brake lanyard such that the switch
will only activate (pin pulls out) if the coupler connection comes loose. For additional details refer
to Section 3.3.4
Jack: A device on the trailer that is used to raise and lower the trailer tongue. On larger trailers
the jack is sometimes called the “landing gear.”
Coupling to the Tow Vehicle
^ WARNING
An improperly coupled trailer can result in death or serious injury.
Do not move the trailer until:
The coupler is secured and locked to hitch;
The safety chains are secured to the tow vehicle; and
The trailer jack(s) are fully retracted.
Do not tow the trailer on the road until:
Tires and wheels are checked;
The trailer brakes are checked;
The breakaway switch is connected to the tow vehicle;
The load is secured to the trailer; and
The trailer lights are connected and checked.
3.3.1. VARIOUS COUPLER DESIGNS
Trailers are produced with a variety of coupler devices. One of the sections below will pertain to
your trailer. If the coupler on your trailer does not resemble one of the couplers shown in the
figures, see the separate coupler instructions. If you do not have separate coupler instructions,
call Bonnell Industries, Inc at 800-851-9664 for a free copy.
3.3.2. TRAILER WITH BALL-HITCH COUPLER
A ball hitch coupler connects to a ball that is located on or under the rear bumper of tow vehicle.
This system of coupling a trailer to a tow vehicle is sometimes referred to as “bumper pull.”
THE TOW VEHICLE, HITCH AND BALL MUST HAVE A RATED TOWING CAPACITY EQUAL
TO OR GREATER THAN THE TRAILER GROSS VEHICLE WEIGHT RATING (GVWR).
IT IS ESSENTIAL THAT THE HITCH BALL BE OF THE SAME SIZE AS THE COUPLER.
The ball size and load rating (capacity) are marked on the ball; hitch capacity is marked on the
hitch.
Coupling to the Tow Vehicle
3.3.2.1. Before coupling the trailer to the tow vehicle
^ WARNING
Coupler-to-hitch mismatch can result in uncoupling, leading to death or
serious injury.
Be sure the LOAD RATING of the hitch ball is equal or greater than the load
rating of the coupler.
Be sure the SIZE of the hitch ball matches the size of the coupler.
Wipe the hitch ball clean and inspect it visually and by feel for flat spots, cracks and pits.
^ WARNING
A worn, cracked or corroded hitch ball can fail while towing, and may result in
death or serious injury.
Before coupling trailer, inspect the hitch ball for wear, corrosion and cracks.
Replace worn or damaged hitch ball.
Rock the ball to make sure it is tight to the hitch, and visually check that the hitch ball nut is solid
against the lock washer and hitch frame.
Wipe the inside and outside of the coupler clean and inspect it visually for cracks and
deformations; feel the inside of the coupler for worn spots and pits.
Be sure the coupler is tight to the tongue of the trailer. All coupler fasteners must be visibly solid
against the trailer frame.
^ WARNING
A loose hitchball nut can result in uncoupling, leading to death or serious
injury.
Be sure the hitch ball is tight to the hitch before coupling the trailer.
Raise the bottom surface of the coupler to be above the top of the hitch ball. Use the jack if one
is provided; otherwise, use wood or concrete blocks to support the trailer tongue.
Prepare the coupler and hitch
Lubricate the hitch ball and the inside of the coupler with a thin layer of automotive bearing
grease. If your trailer is equipped with a jack, raise the coupler above the ball height.
Open the coupler locking mechanism. Ball couplers have a locking mechanism with an internal
moving piece (ball clamp) and an outside handle, wheel, or latch.
In the open position, the coupler is able to drop fully onto the hitch ball.
See the coupler instructions for details of placing the coupler in the “open” position.
Slowly back up the tow vehicle so that the hitch ball is near or aligned under the coupler, if the
trailer jack has raised the coupler.
Couple the trailer to the tow vehicle
If your trailer does not have a jack, you will have to lift the coupler and place it over the ball.
Coupling to the Tow Vehicle
If you have a jack, lower the trailer tongue until the coupler fully engages the hitch ball. If the
coupler does not line up with the hitch ball, adjust the position of the tow vehicle.
Engage the coupler locking mechanism. In the engaged position, the locking mechanism
securely holds the coupler to the hitch ball.
Insert a pin or lock through the hole in the locking mechanism.
Be sure the coupler is all the way on the hitch ball and the locking mechanism is engaged. A
properly engaged locking mechanism will allow the coupler to raise the rear of the tow vehicle.
Using the trailer jack, test to see that you can raise the rear of the tow vehicle by 1 inch, after the
coupler is locked to the hitch.
If the coupler cannot be secured to the hitch ball, do not tow the trailer. Call Bonnell
Industries, Inc at 800-851-9664 or your dealer for assistance.
Lower the trailer so that its entire tongue weight is held by the hitch, and continue retracting the
jack to its fully retraced position.
3.3.3. RIG THE SAFETY CHAINS
Visually inspect the safety chains and hooks for wear or damage. Replace worn or damaged
safety chains and hooks before towing.
Rig the safety chains so that they:
• Criss-cross underneath the coupler so if the trailer uncouples, the safety chains can hold
the tongue up above the road.
• Loop around a frame member of the tow vehicle or to holes provided in the hitch system
(but, do not attach them to an interchangeable part of the hitch assembly)
• Attach hooks up from underneath the hole (do not just drop into hole); and
• Provide enough slack to permit tight turns, but not be close to the road surface to drag.
3.3.4. ATTACH AND TEST ELECTRIC BREAKAWAY BRAKE SYSTEM
If the coupler or hitch fails, a properly connected and working breakaway brake system will apply
electric brakes on the trailer. The safety chains will keep the tow vehicle attached and as the
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