XL Hydraulic Folding Gooseneck Manual
Contents
1. spECIALIZED TRAILERS OPERATIONS MANUAL XL HFG XL Hydraulic Folding Gooseneck TABLE OF CONTENTS 1 SAFETY PRECAUTIONS Page 1 2 GERERAL TRAILER INFORMATION PARTS Page 2 3 OPERATING INSTRUCTIONS Page 3 4 4 USERS MANUAL Page 5 14 5 ACCESSORIES Page 15 33 HYDRAULIC 5 OUTRIGGERS LANDING GEAR MANUAL DUMP VALVE RAISE AND LOWER VALVE LIQUID FILLED AIR GAUGE HONDA POWER UNIT WINCHES DIGITAL SCALE po 6 AXLES Page 34 39 7 ABS ANTI LOCK BRAKING SYSTEM Page 40 45 a 2S 1M 4S 2M c SEALCO AIR SYSTEMS 8 AIRCONTROL KITS Page 46 47 9 SUSPENSION Page 48 55 a HENDRICKSON b RIDEWELL 10 BIBLIOGRAPHY Page 56 1 SAFETY PRECAUTIONS OPERATOR S RESPONSIBILITY MOST ACCIDENTS OCCUR BECAUSE OF NEGLECT OR CARELESSNESS AVOID NEEDLESS ACCIDENTS BY FOLLOWING ALL OF THE SAFETY PRECAUTIONS LISTED BELOW THE USER IS RESPONSIBLE FOR INSPECTING HIS TRAILER AND FOR HAVING PARTS REPAIRED OR REPLACED WHEN CONTINUED USE OF THE PRODUCT WOULD CAUSE DAMAGE OR EXCESSIVE WEAR TO OTHER PARTS IT IS THE USER S RESPONSIBILITY TO DELIVER HIS TRAILER TO A X L DEALER FOR SERVICE OR REPLACEMENT OF DEFECTIVE PARTS WHICH ARE COVERED BY THE STANDARD WARRANTY IT IS THE RESPONSIBILTY OF THE USER TO READ THE OPERATOR S MANUAL AND UNDERSTAND THE SAFE AND CORRECT OPERATING PROCEDURES AS PERTAINS TO THE OPERATION OF THE PRODUCT AND TO LUBRICATE AND MAINTAIN THE PRODUCT ACCORDING TO TH2. D Prior to installing the new ring the spindle should be clean and free from chips burrs etc XL Specialized Trailers 36 XL Specialized Trailers A thin coating of the No 2 Sealer is first applied to the spindle axle ring collar Using the proper tool the ring is installed on the spindle See special manufacturer s recommendations for the proper position of the ring Apply No 2 Sealer to the outer seat diameter Using the proper tool press the seal into the hub until it is properly seated Proper seating specifications are available from the specific seal manufacturer Inspect the installation to assure that the seal components have bottomed evenly and are in the recommended position 37 SERVICE AND MAINTENANCE BEARING ADJUSTMENT The bearings must be correctly adjusted and properly lubricated to achieve maximum bearing life and to prevent damage to wheels axles and possibly the trailer The bearings should be lubricated at regular intervals depending on vehicle speeds loads and general operating conditions Changes of wheel bearing lubricants are recommended every 20 000 to 25 000 miles or twice a year spring and fall 1 XL Specialized Trailers Remove wheel assembly and bearing cones Clean all old grease from hub of wheel bearings and hub cap with a good grade commercial cleaner and a stiff brush NOT STEEL DO NOT use gasoline and DO NOT use air hose in cleaning operation Avoid spinning cone while c
3. ECCENTRIC BOLT 11376948000 90030928000 11406048108 11507098105 11671408100 Z P d NUMBER UNDERSLUNG LOWER BEAM ASS Y SEE CHART FOR NUMBER HANGER ASSY BUSHING BEAM ASSY BUSHING 326773ac100 200 _ sezoo e zo 6040029 puro is ee szerraac100 200 se70100 10 _ ____ 0 1ooaseezozx as seaman 3267744C108 208 5970027 28 6040029 60 DURO 1000001 3260110711 5970027728 6040029 60 DURO 1000003 3260056757 5970075776 6040029 60 DURO 1003589101C 3267744C108 208 5970080779 6040029 60 DURO 1000001 3267744C112 212 5970091792 6040029 60 DURO 1003529101C 3267744C105 205 59777448100 200 6040029 GO DURO 1003529334C 3267744C106 206 5977744 100 200 6040029 60 DURO 3267744C107 207 5977744 100 200 6040029 60 DURO 1003529010Cc 3267744C108 208 59777448100 200 6040029 60 DURO 1003589082 3267744C110 210 5977744 100 200 6040029 60 DURO 1003589082C 3267744C112 212 5977744 100 200 6040029 60 DURO 1003529101C 3267744C107 7207 5977744 100 200 6040029 60 DURO 1003589010 AD CTM Aver XL Specialized Trailers 55 21 22 23 24 25 BIBLIOGRAPHY Tank Trailer Stability by Malikarjunarao and P S Fancher The Highway Safety Research Institute of the University of Michigan prepared for the Freuhauf
4. 001 6 5 008 7 5 001 7 5 005 9 001 9 002 9 003 12 001 14 001 5 20127 2 9 006 5 20413 2 6 5 011 5 20414 2 9 010 B9 010 5 20716 2 6 5 002 12 AIR SPRING BOLT KIT 5 20033 2 2 ALL 13 FRAME BRACKET CHANNEL 1631 19 6 5 001 86 5 001 6 5 002 6 5 008 6 5 011 7 5 001 7 5 005 9 001 9 002 9 006 9 010 B9 010 12 001 14 001 14 TRI FUNCTIONAL II BUSHING KIT 140 Welded Alignment A 6914 2 6 5 001 6 5 002 6 5 008 6 5 011 7 5 001 7 5 005 9 001 9 002 9 003 9 006 9 010 12 001 14 001 14b QUIK ALIGN 5 21166 2 86 5 001 B9 010 15 ALIGNMENT COLLARS 15a Welded Alignment 5 2770 4 6 5 001 6 5 002 6 5 008 6 5 011 7 5 001 7 5 005 9 001 9 002 9 003 9 006 9 010 12 001 14 001 15b Eccentric QUIK ALIGN 5 20925 2 86 5 001 89 010 15c Concentric QUIK ALIGN 5 20924 2 86 5 001 B9 010 16 LOWER SHOCK CLEVIS 5 2592 2 ALL 2 The Tri Functional Bushing Kit includes Item 7 Pivot Bolt and Item 6 Bushing Wear Pad Bushing Tool 5 21307 is required to correctly re bush the suspension Lower Shock Clevis is included when ordering Item 1 Beam Assembly XL Specialized Trailers 51 HT250U BEAM PARTS LIST p H XL Specialized Trailers WELDED PIVOT CONNECTION 158 C 52 H HT250U Y BEAM PARTS LIST ITEM DESCRIPTION PART NO QTY MODEL NO DESCRIPTION 1 BEAM ASSEMBLY 1 Standard Roadside QUIK ALIGN 22350 1 1 Standard Curbside QUIK ALIG
5. 20321 1 1 6 5 001 6 5 008 6 5 011 7 5 005 0 20322 1 1 7 5 001 9 001 9 002 9 003 9 006 9 010 0 20324 1 1 14 001 0 20323 1 1 12 001 0 20717 1 6 5 002 Wingless Welded Alignment Supplied by slider manufacturer on Model HT250U 9 003 suspension XL Specialized Trailers Curbside Weld on D 20321 2 1 6 5 001 6 5 008 6 5 011 7 5 005 D 20322 2 7 5 001 9 001 9 002 9 003 9 006 9 010 D 20324 2 1 14 001 D 20323 2 12 001 D 20717 2 _ 1 6 5 002 2 Wingless QUIK ALIGN Roadside Weld on 0 21926 1 1 B9 010 0 21927 1 1 86 5 001 Wingless QUIK ALIGN Curbside Weld on D 21926 2 1 B9 010 D 21927 2 1 B6 5 00 3 AIR SPRING SPACER ASSEMBLY 21210 4 2 14 001 21210 3 2 9 002 12 001 AIR SPRING PLATE B 21209 2 6 5 001 86 5 001 6 5 002 6 5 008 6 5 011 7 5 001 7 5 005 9 001 9 006 9 010 B9 010 5 UPPER SHOCK CLEVIS C 20113 2 6 5 001 86 5 001 6 5 002 6 5 008 6 5 011 7 5 005 5 2592 2 7 5 001 9 001 9 002 9 003 9 006 9 010 89 010 12 001 14 001 6 BUSHING WEAR PAD 5 11613 4 ALL 7 PIVOT BOLT KIT 74 Welded Alignment 5 3646 2 6 5 001 6 5 002 6 5 008 6 5 011 7 5 001 7 5 005 9 001 9 002 9 003 9 006 9 010 12 001 14 001 7b QUIK ALIGN 5 21052 2 86 5 001 B9 010 8 SHOCK ABSORBER 5 20002 2 ALL 9 SHOCK ABSORBER BOLT KIT 5 2157 2 2 ALL 10 U BOLT KIT 5 3650 4 4 ALL 50 ITEM DESCRIPTION PART NO QTY MODEL NO HT250U or N HT250U 7 11 AIR SPRING 5 20124 2 6 5 001 86 5
6. Corporation November 1979 1979 Roadside Vehicle Inspections by Bureau of Motor Carrier Safety United States Department of Transportation Influence of Front Axle Loading and Fifth Wheel Placement on Tractor Trailer Handling and Ride Characteristics prepared for the International Brotherhood of Teamsters Office of Safety and Health by Roberts et al Massachusetts Institute of Technology September 1975 as reference in the letter of December 15 1976 from Richard Hinchcliff American Trucking Associations to Donnell Morrison Bureau of Motor Carrier Safety Tire Properties and Truck Handling Some Surprising New Findings by R Ervin Highway Safety Research Institute of the University of Michigan HSRI RESEARCH Load Securement Specialized Loads Item No 516 video Specialized Carriers 8 Rigging Association Steel Hauling No 517 slides Specialized Carriers amp Rigging Association Steel Hauling Booklet Item No 518 Specialized Carriers amp Rigging Association The Effect of Truck Size and Weight on Accident Experience and Traffic Operations Volume III Accident Experience of Large Trucks Vallette H McGee J H Sanders and D J Enger Bio Technology Inc 1981 Heavy Traffic Safety The Need to Know by Farrell Krall International Harverster Co and Gary Rossow Motor Vehicle Manufacturers Association Truck and Bus Driver s Manual by the Ontario Ministry of Tr
7. OPTIONAL FEATURES OPERATION OPTION 5 OPERATION 4 MANUAL KICKOUT AIR HYO KICKOUT r 80 400 4 1 4 DRYM DRUM ENGAGED 2 59 2 59 XL Specialized Trailers 28 MODEL 10J WIRE ROPE LINE WIRE ROPE LINE DIA YER pur LB DIA IN EB 3 8 Model 10 Performance based on 18 2300 MODEL 12J DIA IN LINE WIRE ROPE LINE pull LNE SPEED FPM SPEED FPM NEN 1 12000 4 ____ 9920 49 ____ _____ 585 ___ 57 ____ Model 12 Performance based on 20 2200 PSI NOTE The rated line pulls are for the winch only Consult the wire rope manufacturer for wire rope ratings 41 49 8450 58 67 Flows listed ore Moximum for each specific mator 7360 pL TYPICAL HYDRAULIC SYSTEM 5 POSTION 4 WAY CONTROL 4 VALVE WITH MOTOR SPOOL AND PRESSURE RELIEF DRUM CAPACITIES E Loustomer SUPPLIED INCLUDING HOSES WINCH FITTINGS TO WINCH NOTE Drum capacities are in aecardance wth SAE 1706 Actual capacities are usually up to 10 greater than these shown Lost loyer capocity does not meet SAE J7OB XL Specialized Trailers 29 _ Models 12AJ 15AJ 20AJ 12 000 20 000 ib DRUM ROTATION Rady ee 9 53 TYP 116 MOUNTING HOLES WO KICKOUT MODEL 2AJ APPROX WEIGHT 245 LBS MODEL 1
8. Valve s Air Tank Front of Vehicle P NC n Manual a s Switch Air Spring Electric Solenoid valve 1 ot Va n Air Spring Type CR lt gt HCV Shown a gt OM NO To T Air Spring Air Spring Exhaust 1 1 XL Specialized Trailers 46 HALDEX AIR CONTROL KITS AC 78 M Series Function Lowering Exhausting Systems from Ride Height Application Truck or Trailer with One Height Control Valve Pressure Protection Valve Air Tank Front of Vehicle Ne NL L NS 3e Masona Air Spring Ay Switch B Electric 4 M Hand Valve Solenoid St Y Valve SS S AA d 3 T Pilot Valve _ PY Air Spring amp ia 447 CH Air Spring lt ZZ Air Gauge KE 5 4 N lt N N O N C gt HCV Shown To Air Spring Air Spring Exhaust Ph Yee KE b D MI Supply XL Specialized Trailers 47 9 SUSUPENSIONS H HENDRIGKSON HENDRICKSON TURNER SUSPENSION XL Specialized Trailers 48 MODEL HT250U UNDERSLUNG STYLE PARTS LIST 49 XL Specialized Trailers ITEM DESCRIPTION PART NO QTY MODEL NO HT250U or N HT250U 1 BEAM ASSEMBLY Roadside 20335 1 1 ALL Curbside C 20335 2 1 ALL 2 FRAME BRACKET 20 Wingless Welded Alignment Roadside Weld on 0
9. 000 to 40 000 miles or whenever the wheels must be removed for any reason the seals should be inspected for knicks etc which could result in a leak B REPLACEMENT 1 Felt Type Retainer A With a wheel puller remove the entire retainer assembly B Separate the inner and outer ring of the assembly usually hand pressure is sufficient Remove the old felt D Inspect the inner and outer rings for excessive damage bent knicked etc and replace as required E Install new felt F Assemble inner ring felt washer and outer ring G Install assembly on spindle by tapping the assembly until it is seated against the rear shoulder of the spindle grease retainer collar 2 Ring amp Seal A Remove the seal from the hub by tapping on the face of the bearing cone Care should be taken to avoid bending the cone cage or knicking the cone rollers Ifthe axle ring 5 found to be defective it can be removed by carefully and lightly tapping the ring all around with a blunt cold chisel Extreme caution must be exercised to avoid cutting through the ring and damaging the spindle collar After properly tapping the seal it should expand so as to be removed by hand Do not to force the ring by hitting it from the axle bar side There is no collar or lip on this side of the ring sufficient to prevent spindle damage C To install the new ring and seal it is mandatory that the seal manufacture s recommended tool be used
10. 2 For QUIK ALIGN amp Welded Alignments 6 5Y 006 7 5Y 006 9Y 006 9 031 Rotated Stud 5 20414 2 For QUIK ALIGN amp Welded Alignments 9Y 010 High Pressure Standard 5 20124 2 For QUIK ALIGN amp Welded Alignments 6 5Y 001 7 5Y 001 9Y 001 9Y 021 High Pressure Rotated Stud 5 20413 2 12 AIR SPRING BOLT KIT 5 20033 2 2 13 UPPER SHOCK CLEVIS Standard 5 2592 2 For Use with Shock Straps C 20113 2 14 SHOCK ABSORBER S andard QUIK ALIGN or welded 5 20002 2 Ext Service High Damping QUIK ALIGN B 21553 2 15 SHOCK ABSORBER BOLT KIT 5 2157 2 2 16 LOWER SHOCK CLEVIS 20145 1 17 SHOCK STRAP KIT not shown 14587 8 Includes strap amp nylon tie 158 3 XL Specialized Trailers 53 XL Specialized Trailers RIDEWELL SUSPENSIONS RIDEWELL SUSPENSION 240 manufactured after 10 1 95 BUSHING REPLACEMENT KIT SEE CHART FOR ORDER 1 KIT PER AXLE gt 125 3054 9 FOR 2400014 NO SHOCK FOR 2400054 SHOCK FOR 24006084 12450005 FOR 24077440407 PART NUMBER 24003 N 2400708 2400712 2404105 2404106 2404107 2404108 2404110 24077440507 Underslung 25 000 cap SPACER 4 IF REQ D UNDERSLUNG ANTI TURN WASHER HANGER ASSY SEE CHART FOR _ NUMBER AIR SPRING PLATE AIR SPRING SEE CHART FOR NUMBER BUSHING ASSY SEE CHART FOR DURO 7 11676808000
11. 5AJ APPR X WEIGHT 251 LBS MODEL ZOAJ APPROX WEIGHT 257 LBS DPTIONAL FEATURES IOR OFRON gr FLOW MOTOR OFTON 1 HIGH FLOW 9 40 onsen 12AJ 8 97 CASE DRA 1 4 OUTLET PORT INLET PORT BAF 420 4 1 1 4 SAE 20 OPERATION OPTION FS OPERATION OPTION 4 MANUAL LEVER AR HYDRAULIC KIGKOUT 6 85 50 400 PSI 174 DRU DISENGAGED DRUM ENGAGED 6 59 PI 2 2 59 XL Specialized Trailers 30 MODEL 15 2 2 WIRE LAYER LINE RAD DIA IN HIGH LOW FLOW FLOW 39 1 2 Model 154 Performance based 20 2450 PSI low flow and 45 amp 2650 PSI high flow MODEL 20AJ DFED FP LINE SPEED FPM WIRE ROPE LAYER LINE SPEED M LINE SPEED FPM DIA IN in HIGH LOW HICH LOW FLOW FLOW FLOW FLOW 20000 EUN 9 16 _ 5 204 Performance based 20 2550 PSI low flaw ond 60 GPM 2800 PSI high flow NOTE The rated line pulls are for the winch only Consult the wire rope manufacturer for wire rope ratings Flows listed are Maximum far each specific mator CAPACITIES FT DRUM CAPACITIES Fi TYPICAL HYDRAULIC SYSTEM oe e Sg aue p 2 4 5 57 8 12 102 95 amp 19 e o is a _ NOTE Drum capacities are in accordance wth SAE 706 Actual cap
12. CH STARTER GRIP OIL FILLER CAP HIGH MOUNT MUFFLER B type dw a 16 Ni 5 SPARKPLUG MI gt id CA gt OIL LEVEL DIPSTICK wr OIL DRAIN BOLT ELECTRIC STARTER XL Specialized Trailers 26 SERVICING YOUR HONDA ENGINE MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD 3 First Every Every Refer ear to Perform at every indicated 3 month or operating hour interval pag whichever comes first Engine oil check 200 Hrs 8 filter Check Replace Spark plug Clean Adjust Replace Spark arrester Clean optional part _ Idle speed _ Check Adjust Valve clearance Check Readjust Combustion Clean After every 500 Hrs 2 chamber Fuel filter LL Lol Ju Fueltank _ Every year 2 e Fuel tube Check Every 2 years Replace if necessa e Emission related items Replace the paper air filter element only 1 Service more frequently when used in dusty areas 2 These items should be serviced by your servicing dealer unless you have the proper tools and are mechanically proficient Refer to Honda shop manual for service procedures 3 For commercial use log hours of operation to determine proper maintenance intervals XL Specialized Trailers 27 WINCHES UD Models 10J 12J WINCH 10 000 12 000 Ib NO NICKOUT 65 MOUNTING HOLE 12 PLACES APPROK WEIGHT 190 js 1 75
13. COMMENDATIONS 1 0 INTRODUCTION 1 1 Tractor and low bed or heavy duty platform trailer combinations may have different operational characteristics than typical tractor trailer combinations due to gross weights large differences between loaded and unloaded weights suspension characteristics and articulation 1 2 Tractor and truck trailer combinations have safe operating limits just as automobiles trains and airplanes have operating limits These limits are affected by the interaction of the vehicle characteristics maintenance load roadway weather the skill of the driver and vehicle speed Knowledge of how these factors affect the vehicle s operating limits and defensive driving techniques should result in safer driving 2 0 PURPOSE 2 1 The purpose of this section is to describe how tractor and truck trailer control and stability limits are affected by the vehicle characteristics maintenance roadway weather and driver operation and how to compensate for these factors Knowledge of these factors will assist operators in productive use of this equipment 22 Theinformation in this bulletin has been gathered from a number of research reports and accident summaries These sources of information are referenced in the Bibliography at the end of this manual 2 3 First and foremost DO NOT operate the trailer until you have read and you fully understand the instruction and operating manual supplied to you by the manufacturer of the trail
14. E MAINTENANCE SCHEDULE IN THE OPERATOR S MANUAL 1 When performing adjustments or maintenance on a trailer first lower it to the ground or block it securely at a workable height Detach a trailer in a safe area Flags or other warning devices should be used when parked with over width loads Loose fitting clothing should not be worn to avoid catching on various parts Equipment should only be operated by those who are authorized to do so Make certain everyone is in the clear before starting raising or lowering the trailer if the unit is designed to do so Reduce speed on hillsides or curves so there is less danger of tipping Avoid driving too close to the edge of ditches or creeks 9 Stop the engine lock the brakes and remove the ignition key before dismounting from the tractor 10 A first aid kit should be provided for immediate treatment of all scratches cuts etc 11 Never stand between tractor and trailer while tractor is being backed up to trailer hitch 12 Do not transport wide loads on public roads without proper reflectors Wide load and slow moving vehicle emblems must be used in daylight and have approved warning light at night and other periods of poor visibility 13 Observe all laws and regulations while transporting on public roads Check the local highway regulations 14 Carefully maintain control of equipment at all times when traveling on the highway 15 Due to the width and height of some equipment
15. I RESEARCH REVIEW March April 1980 Volume 10 Number 5 Articulated Vehicle Roll Stability Methods of Assessment and Effects of Vehicle Characteristics by R N Kemp B P Chinn and G Brock Transport and Road Research Laboratory United Kingdom Report 788 1973 http www bulldogproducts net 04CAT_Jacks pdf Bulldog Heavy duty square jacks parts list 2005 HT250U Parts List Hendrickson International January 17 2005 http www hendrickson intl com pdfs trailer_PDFs HT250U_from_catalog pdf HT250U Beam Parts List Hendrickson International January 17 2005 http www hendrickson intl com pdfs trailer_PDFs L58 pdf Mark V Maintenance The Holland Group Inc January 17 2005 http www thehollandgroupinc com NR rdonlyres A418EA09 582E 4F26 85C2 4ABEB66FE056 0 XLLG22501 pdf Mark V Operating amp maintenance Procedures The Holland Group Inc January 17 2005 http www thehollandgroupinc com NR rdonlyres OFF49B83 6390 4B9D A309 2DCC91 16447F 0 XLLG305_HiRes pdf XL Specialized Trailers 56
16. N C 22350 2 1 For Use with Shock Straps not shown Roadside QUIK ALIGN 23365 1 1 For Use with Shock Straps Curbside QUIK ALIGN C 23365 2 1 10 Standard Roadside Welded Alignment 20131 1 6 5Y 001 6 5Y 006 9 001 9Y 006 9Y 010 9 027 9Y 037 21076 1 1 9 021 9 031 Standard Curbside Welded Alignment C 20131 2 1 6 5Y 001 6 5Y 006 9Y 001 9Y 006 9Y 010 9Y 027 9Y 037 C 21076 2 1 9Y 021 9 031 2 BUSHING ASSEMBLY 2d Bushing Assembly QUIK ALIGN B 23349 2b Bushing Assembly Welded Alignment B 7343 2 3 TUBE SLEEVE A 7342 2 4 ALIGNMENT COLLAR 4 Eccentric Washer QUIK ALIGN 5 20925 2 Pivot hole is offset from center collar 4b Concentric Washer QUIK ALIGN 5 20924 2 Pivot bolt hole is in center of collar 4c Welded Alignment B 7349 4 5 BUSHING TUBE SPACER 5 11613 4 6 PIVOT BOLT KIT 6d QUIK ALIGN 5 25948 2 Includes shear type bolt hex nut amp hardened steel washers 6b Welded Alignment 5 7345 2 Includes bolt cap screw hex nut amp liner 7 U BOLT KIT 5 3650 4 4 8 TRI FUNCTIONAL II BUSHING 8d QUIK ALIGN 5 26000 2 Includes bushing beam tube bushing tube spacers shear type bolt amp nut 8b Welded Alignment 13136 2 Includes alignment collars bushing beam tube bushing tube spacers bolt nut amp liner 9 BUSHING TUBE SPACER KIT not shown 5 26371 Includes shear type 12 in bolt nut hardened washers amp 3 bushing tube spacers 10 AIR SPRING PLATE B 21209 2 11 AIR SPRING Standard 5 20127
17. accelerate when coming off a ramp or curve If this is done on slippery pavement skidding may occur On icy roads it is important to avoid deceleration which can lock up the drive wheels Avoid backing off the throttle suddenly down shifting or use of any engine retarder brake Sudden deceleration may result in the trailer pushing the tractor around 12 14 Properly inflated tires get the best traction on icy roads Don t attempt to let air out of the tires to gain traction On ice proper selection of drive wheel tires can make a XL Specialized Trailers 12 20 percent improvement traction Single reinforced chains can increase that traction by 500 percent The interaxle lock should be used to avoid wheel spin 14 Cross winds at bridges and near large structures such as grain elevators and passing trucks and buses may cause vehicle sway and sideways movement sufficient to push the combination off a slippery road 5 5 2 HYDROPLANING As a result of recent studies 15 16 the National Transportation Safety Board has concluded drivers of heavy trucks need to be made aware of the dangers of hydroplaning in wet weather Hydroplaning occurs when water onthe road builds up underthe tires and literally lifts them clear of the pavement Major contributing factors are 1 excessive speed 2 inadequate tread depth which reduces the dispersion of water between the tire and roadway and 3 under inflation which results in deformation of the tre
18. acities are usually up to 10 greater than those shown PINGS TO WINCH Last layer capacity does not meet SAE J 06 XL Specialized Trailers 31 DIGITAL SCALES The Air Weigh Trailer Scale Kit consists of the scale the air suspension pressure sensor assembly sensor and power cables and mounting fasteners One kit is installed on each trailer suspension The pressure sensor is installed in the suspension air line Air Weigh s patented technology accurately indicates the weight by precisely calibrating then measuring the suspension air pressure Air Weigh TRAILER SCALE XL Specialized Trailers 32 How to Check Weigh with your own on board truck and trailer scales With the Air Weigh scale installed on your truck and trailer s suspension your entire vehicle becomes the scale When you want to weigh remember that you need to operate the vehicle the same way every time you weigh It is most important that the air suspension be inflated to its factory specified ride height without any binding or torque on the suspension So park on a level surface Coast to a stop if possible or use the brakes gently Make sure you release the brakes when you weigh because the brakes will bind the air springs and make the scale display a heavier weight than you actually have Chock the wheels if you leave the cab or weigh the tractor and the trailer separately if necessary If your suspension is equipped with a dump valve brie
19. actice When tying down steel coils refer to the Specialized Carriers and Rigging Association s information on steel securement and Federal Motor Carrier Safety Regulation requirement as specified in 49 CFR 393 100 5 6 7 Also refer to 94 for more information 5 3 AXLELOADS Check axle loads against the GVWR and the GAWR of the power vehicle and the trailer to insure that loading is within the limits of the vehicles being used REMEMER IMPROPER LOAD PLACEMENT CAN HAVE A DETRIMENTAL EFFECT ON BRAKING EVASIVE MANEUVERS AND HANDLING CHARACTERISTICS OF A VEHICLE COMBINATION TRUCK TRAILER OR COMBINATION TRACTOR TRAILER 5 4 ROAD SURFACE Uneven terrain steep grades and crowned roads especially rural roadways freeways exit ramps curves bumps and depressions introduce forces into a tractor trailer XL Specialized Trailers 10 combination that could result an accident if proper precautions and driving techniques are not followed Even a vehicle that meets all maintenance and load requirements can become hazardous when excessive speeds and certain roadway characteristics are combined 5 4 1 5 4 2 5 4 3 XL Specialized Trailers GRADES Trucks are more likely to have accidents on grades than on level terrain Rural non freeways have the worst grade accident experience particularly downgrades Further the steeper downgrades have the greatest accident frequency 8 On a downgrade the force of gravi
20. ad permitting water buildup 17 The Board recommends tires be replaced at a tread depth of 4 32 inch for high speed operation on wet pavement Above all drivers should be made aware hydroplaning can affect large trucks and combinations and the surest means of prevention is reduced speed on wet pavement 17 X ATTENTION THESE ITEMS MENTIONED ARE VERY BASIC TO VEHICLE SAFETY AND ARE ITEMS INSPECTED BY STATE AGENCIES FOR THE PURPOSE OF THIS DOCUMENT ATTENTION IS CALLED TO THEM RELATIVE TO A VEHICLE S STABILITY AND ITS ABILITY TO PERFORM CERTAIN EVASIVE MANEUVERS SAFELY THE USE OF THESE WILL BY NO MEANS REPLACE A PROPER MAINTENANCE AND PREVENTIVE MAINTENANCE PROGRAM 6 0 OPERATIONAL CRITERIA 6 1 JACKKNIFE When the tractor s rear wheels are locked up a jackknife results in the tractor rotating through about 120 degrees in one to two seconds until the cab strikes the trailer 9 In severe cornering maneuvers such as exiting a ramp at high speed a directional instability may occur without tractor rear wheel lockup This also results in a jackknife motion although the rotational rate is lower than that of a drive axle lockup jackknife 4 A jackknife can be prevented by avoiding rapid acceleration and deceleration by reducing speed on curves and by controlled braking to avoid wheel lockup Rolling wheels are necessary to keep control When brakes are on they slow the vehicle When the brakes are off steering control is maint
21. ained Anti lock devices automatically fan the brakes 14 However most vehicles built before 1975 and after 1979 have not been equipped with anti lock and therefore fanning the brakes is the best method of avoiding wheel lockup Brakes should not be fanned except on XL Specialized Trailers 13 slippery pavement where this type of braking gives better control reduces danger of skidding and gives a shorter stop Fanning reduces air pressure and serves no useful purpose on dry pavement 10 Tests have shown that a driver cannot recover from a jackknife when the angle between tractor and trailer is greater than 15 degrees unless the tractor is equipped with front wheel drive 14 18 Vertical hinged steering and the load divider dolly rear steering trailer combinations are subject to some decrease in roll stability while turning This is because the rear most axles are swung inboard during a turn decreasing their contribution to roll resistance The tighter the turn the less roll resistance This decrease in roll stability is normally very slight and without consequence However accidents can occur due to an accumulation of minor negative factors which singly are of no great consequence Other factors which may contribute to loss of roll stability are A High center of gravity B High speed turns Side slopes or super elevations turns D Emergency braking while turning sharply or during high speed turns The prudent operator sh
22. ansportation and Communication 1981 Analysis of Cargo Tank Integrity in Rollovers by S Davis P Masser C Culley and J Edwards Dynamic Science Inc October 1977 Trucking Industry Safety Program Jackknifing Fourth Quarter 1977 by the Safety and Security Department of American Trucking Association Inc Criterion Levels for Minimum Braking and Handling Performance by L M Forbes Ford Motor Company Sixth International Technical Conference on Experimental Safety Vehicles soonsored by the United States Department of Transportation Washington D C October 12 15 1976 Winter Truck Driving Safety by the National Safety Council 1978 Truck Tire Hydroplaning Empirical Confirmation of Horne s Thesis by lvey Texas Transportation Institute Pneumatic Tire Hydroplaning and Some Effects on Vehicle Performance by Horne and Joyner Langley Research Center National Aeronautics and Space Administration Tractor Semitrailer Intercity Bus Head On Collision Interstate 10 Beaumont Texas May 4 1987 by the National Transportation Safety Board NTSB HAR 88 01 A Study of the Factors Governing the Stability and Controllability of Articulated Vehicles by the Committee on Winter Driving Hazard National Safety Council 1952 Unintended Responses of Heavy Trucks to Braking or Steering Inputs by Robert Ervin Highway Safety Research Institute of the University of Michigan THE HSR
23. cking the brake adjustment 3 2 TIRES AND WHEELS Many operators use a tire billy to check air in tires but the purchase of a good tire gauge would eliminate the guessing Before moving the trailer check the air pressure in the tires as a drop of 10 PSI in the tire pressure can reduce the carrying capacity of the tire by as much as 2096 on certain tires This reduced capacity could cause tire failure and loss of control of the trailer Low tire pressure also is the main cause of poor tire life which can be very costly At the same time tires are checked inspect wheels for cracks around the lugs These can be observed in most cases by rust lines These wheels should be replaced immediately There is no reason for any set of duals to be wobbling on any vehicle or tractor trailer combination Installing duals with proper shop techniques will result in wheels running true The result is increased tire mileage smoother ride and less stress on structural components all providing a safer vehicle XL Specialized Trailers 6 3 3 TOWING DEVICES AND SUSPENSION Fifth wheels Be sure the fifth wheel is locked to the king pin before pulling away Visual inspection of the locking device is better than relying solely on applying air to the trailer brakes and jerking against the king pin Inspect fifth wheel mountings for any tell tale sign of failure or damage to load bearing components Inspect the pintle hooks lunette eyes and drawbars on conne
24. code lamp displays numerical fault code sequence for each existing fault one at a time If the ECU stores more than one existing fault in memory you must repair the first fault before Normal Mode diagnostics will display the second existing fault In the Normal Mode the lamp only identifies the component that needs repair for exam THREE FLASHES SENSOR BUT1 identify and display intermittent faults use Expert Mode diagnostics See Appendix The ECU stores existing faults into memory in the order in which they occur but the blink code lamp displays the most recent fault first To identify and display intermittent stored faults such as a loose cable or wire from ECU memory you must use Expert Mode diagnostics To activate Normal M ode diagnostics 1 The vehicle must be stationary Power the ECU with 12 volts 9 5 14 is an acceptable range The warning lamp on the trailer will come ON 2 Locate the diagnostic tool Plug the diagnostic tool into the diagnostic cable socket located usually on the right side of the trailer sub frame 3 Press the blink code switch once for one second and release the switch 4 if there are no existing faults in the system When activated the blink code lamp will Come ON GoOFF Remain OFF 5 When there is an existing fault The blink code lamp will ash between three and fifteen ti mes to identify the existing fault Refer to Table Normal Mode Fa
25. ctor dollies by visually observing them for any unusual appearances such as bent members cracks in welds or chipped paint where structural members have received high load Inspect the suspensions by observing if the vehicle is leaning to one side which may indicate a broken spring or faulty air valve on air suspensions Visually inspect radius arms to be sure they are in place and look at the spring hangers to see if springs are in the hangers and that the hangers are not bent or otherwise damaged 3 4 FRAME Before beginning any trip make a thorough inspection of the trailer for cracks in the structure Typical locations of cracks are at welds at changes in beam depths above suspension components and at the upper coupler Experience may also indicate other areas that need to be checked 3 5 SAFETY CHAINS Check all safety chains and their attachment to both the towed and the towing vehicle Make certain the chains are of adequate size and are in good condition Also make certain that all attachment devices are properly installed and all nuts are tight 3 6 STATELAWS Before any trip to an area where you are not accustomed to traveling check the state laws with regard to bridge requirements especially if the trailer being towed has liftable axles 4 0 VEHICLE 4 1 Tractor and truck trailer combinations are designed to provide maximum directional control and roll stability within the constraints of highway size and weight limits and ut
26. d corrective action Emergency brake ON Wheels properly chocked 2 Provide 12 volts DC power 9 5 to 14 volts is acceptable range to the ECU Valve Assembly 3 Checkthe ABS warning lamp on the trailer If The warning lamp comes ON briefly then goes OFF There is no faultin system Figure 5 1 The warning lamp comes ON and stays ON There is an existing fault Go to Step 4 4 Checkthe blink code lamp on the ECU See Figure 5 1 If blink code lamp is OFF there is system fault 1 Blink Code Lamp Table D ECU Part Number 472 500 011 0 Blink Codes Blink Code Problem Area eton ooo Sensor YE1 curbside sensor Check sensor installation and connections verify proper sensor resistance and air gap Make necessary repairs Sensor YE2 roadside sensor Check sensor installation and connections Verify proper sensor resistance and air gap Make necessary repairs a ECUNa ve Assembly verify proper installation Make sure all connections are If code continues contact Meritor WABCO for assistance Power verify proper electrical installation and connections Check power supply Make necessary corrections ECU Failure Verify proper installation If code continues contact Meritor WABCO for assistance XL Specialized Trailers 40 Section 5 Diagnostics How to Test for Existing Faults Using the Normal Mode When you use Normal Mode di stics the blink
27. er It is also important that each and every person who operates the trailer and or is responsible for the loading and operating of the trailer be given the opportunity to read the manuals 3 0 PRE TRIP INSPECTION There are some items on every vehicle combination that can be and should be inspected prior to every trip that require no special knowledge training or sophisticated equipment XL Specialized Trailers 5 BRAKES Function test Operate the brake pedal and hand control valve to determine if air is being supplied to the brake chambers Use an observer or place marks on push rods to determine if the brakes are operating Visually inspect the brake chambers and slack adjusters for problems caused by road hazards Keeping brakes in proper adjustment is imperative to stable straight line braking and maintaining minimum stopping distances Visually inspect the air brake hoses and glad hands to determine if air loss is occurring Air leaks can reduce braking capability Anti lock devices if provided should be maintained and inspected routinely Their use can prevent wheel lock up improve stopping capability and reduce the probability of jackknife 3 1 1 Automatic Slack Adjusters As automatic slack adjusters become more widely used it is important to point out that they do require periodic maintenance Primarily they should be greased at specific intervals When they are being serviced they should be checked for proper operation by che
28. er Manufacturers Association and the Motor Vehicle Manufacturers Association XL Specialized Trailers 8 5 1 3 STEERING AND SUSPENSION Proper alignment of both tractor and trailer wheels will add significantly to the handling characteristics of the combination and allow the professional driver to utilize all the design responses ofthe vehicle to make evasive maneuvers in the safest manner Replacement of worn parts weak springs shock absorbers and bushings will help maintain a vehicle s stability and limit road surface induced sway in both tractor and trailer Proper cleaning and greasing of fifth wheels will insure smooth steering between tractor or dolly and trailer 5 1 4 LIGHTS Insurance companies have often stated that the cause of many accidents was not seeing the other vehicle With this in mind the lights on the trailer should be checked whenever the trailer is moved and problems should be corrected immediately Also all lights and reflectors should be wiped clean before every move so that they will produce the maximum amount of light and reflectivity 5 1 5 STRUCTURAL COMPONENTS Proper maintenance will not only give the trailer a longer life but it will be a safer trailer to operate Follow the service manual faithfully and at least once a year thoroughly check every weld and beam for cracks or stress marks If a crack or a broken structure is found have it repaired by an authorized dealer or technician If you are in doubt a
29. er to avoid rollover In order to round a curve without skidding there must be friction keeping the tire from skidding sideways However the tire road interface can generate only so much friction Part of the friction is used up when the tire is accelerating or braking Thus accelerating or braking on a curve can reduce the tire side friction and result in a skid If the trailer tires skid trailer swing occurs If the rear tractor tires skid tractor swing and jackknifing occur 5 5 WEATHER A major factor in the causes of accidents is weather Rain ice snow and high winds can each contribute significantly to an accident when combined with excessive speed sudden lane changes or other factors that put lateral forces into a tractor trailer combination Slippery roads can increase stopping distances and reduce the ability of a vehicle to perform maneuvers 12 However a study has shown that drivers often do not reduce their soeed when the pavement is slippery and thus exceed the stopping and maneuvering limits of their vehicle 13 A tire s friction must be shared between friction required for braking or accelerating and that required to keep from skidding sideways When the road is wet the available tire road friction may be half that of a dry road If hard braking or rapid acceleration occurs there may be little or no friction available to prevent tire lateral movement and skidding results Many tractors have the capability to rapidly
30. fly exhaust the air pressure 5 to 10 seconds and then let it re inflate again When the scale weights stop changing the suspension is fully inflated and the weight displayed will be accurate to within 300 pounds of a DOT scale It may take a few loads to learn how to weigh accurately but with a little practice you ll be able to get within 100 Ibs ona regular basis When operated properly Air Weigh will be accurate to within 300 Ibs of a DOT scale XL Specialized Trailers 33 6 AXLES gt MERITOR XL Specialized Trailers 34 Description Description Description 2 Bushing anchor pin De Pin anchor Slack adjuster washer Beam axle Slaok adjuster looknut Gasket Camshaft left Automatik slack adjuster Wheel bearin Slack adjuster washer Slack adjuster snap rinc Brake shos retaining spring i oin Wheel bearing seal Camshaft bushing assembly 1 __ E NE OM LN 15 16 4 EN ing jam nut wu 9 6A Soteorow ___7 Wheel bearing adjustingnut 21 _ J cup L3 24 OM our 20 2 cone 26 XL Specialized Trailers 35 SERVICE AND MAINTENANCE GREASE RETAINERS OIL SEALS A MAINTENANCE 1 Felt Type Retainer Grease A Felt should be replaced every 30 000 to 40 000 miles 2 Ring and Seal Type oil A Every 30
31. hind the centerline of the tandem on the tractor in an attempt to improve the ride The result will be reduced steering load and loss of steering control 3 4 Steering control is affected also if the fifth wheel is placed too far forward since this position places too much weight on the front axle There are proper ways and positions for utilizing adjustable fifth wheels and their misuse can have adverse effects as has been outlined The most common operating range is O to 24 inches ahead of center of tandem or axle on single axle tractor Note that the 24 inch setting is quite common on west coast tractors above 230 inch wheelbase Proper position of a load relative to the trailer wheelbase will greatly enhance handling characteristics For instance positioning the load to distribute the weight proportionately over the axles of the combination in a fore and aft location as well as balancing the load in a side to side position will enhance directional control roll stability and braking When tying down the load on the trailer always be sure that you have adequate strength chains This is to prevent a failure of the chains under severe stress due to sudden stops or quick changes in direction Many accidents are caused by shifting loads Always be sure that the equipment is securely tied down on the trailer Because rubber tied equipment is sometimes difficult to secure to the trailer chock blocks ahead of and behind the tires is a good safety pr
32. ility Any combination can be rolled over by driving too fast around a curve making too abrupt a maneuver or by leaving the roadway Locking up the wheels on an axle of a combination can result in a jackknife or trailer swing out 4 2 Some truck trailer combinations are less resistant to roll during an abrupt lane change due to a whipping action The opposite is the case for the tractor semi trailer combination which is relatively more roll resistant in abrupt lane changes the long wheelbase tends to stabilize the combination compared to a steady turning maneuver 1 36 3 Long wheel base multi axle trailers with spread steering axles present new operational concerns The rear steering found on these rigs dramatically affects XL Specialized Trailers 7 performance and must be taken into account Also consult the trailer manufacturer s operating manual 5 0 ACCIDENT PREVENTION 5 1 MAINTENANCE Maintenance is the single most important item that when neglected will seriously limit the handling and response characteristics of any vehicle or tractor trailer combination Statistics taken by the Office of Motor Carriers of the Federal Highway Administration support the fact that over 10 of interstate truck accidents are related to mechanical defects These defects have been isolated to include wheels tires brakes and steering 2 5 1 1 TIRES Insure proper inflation Low tire pressure can cause sway uncertain steering decrea
33. leaning Allow the cleaned parts to dry and wipe them with a clean absorbent cloth or paper Clean and dry hands and all tools used in the service operation Grease will not adhere to a surface which is wet with solvent and the solvent may dilute the lubricant CLEANLINESS IS MOST IMPORTANT Inspect seals and seal spring surfaces bearing cups and bearing cones for indications of wear or damage Handle all parts carefully during inspection and packing so the cage will not be bent or the rollers and cone damaged Place bearing cones in cups and check for proper fit and proper number The bearings must mate as follows CUPS CONES 553X 560 653 663 HM212011 HM212049 HM218210 HM218248 A Grease lubricated bearings pack the bearings with a pressure packer if possible using an approved lubricant of medium consistency ASTM penetration 265 295 See bulletin 5492 Rev 1 Timken Roller Bearings If a pressure packer is not available pack bearings by hand by forcing the grease into the cavities between the rollers and cage from the large end of the cone Coat the hub cap with a light coat of grease B Oil lubricated bearings use a gear type oil SAE 90 and spread a light coat of oil on all parts before assembly To prevent hot bearings and provide for maximum load carrying capacity bearings should be kept free of slack and play For 38 XL Specialized Trailers positive close adjustment a torque wrench should be used to tighte
34. n Off switch to On position Move Raise Lower lever clockwise to raise Move Raise Lower lever counter clockwise to lower Turn On Off switch to Off position the trailer will return to the set ride height XL Specialized Trailers 22 LIQUID FILLED AIR GAUGE Standard Style Reads air pressure in suspension air bags Two styles Standard Style Hooks to end of pressure hose Flange Style Mount to flat surface Flange Style XL Specialized Trailers 23 HONDA POWER UNIT 13 HP UNIT 24 HP UNIT Model GX390 13 HP unit e Oil alert e 12 volt starter Dual Element air cleaner 6 9 QT fuel tank Net weight 75 Ibs XL Specialized Trailers Model GX670 24 HP unit Heavy Duty Dual Element Air Cleaner Net Weight 94 8 Ibs 24 2 COMPONENT IDENTIFICATION MUFFLER THROTTLE LEVER ENGINE SWITCH SPARK PLUG CIRCUIT BREAKER CHOKE LEVER type RECOIL STARTER FUEL VALVE STARTER GRIP FUEL FILLER CAP FUEL TANK ELECTRIC STARTER type SERIAL NUMBER AND ENGINE TYPE DRAIN PLUG OIL FILLER CAP XL Specialized Trailers 25 CONTROLS 8 FEATURES COMPONENT amp CONTROL LOCATIONS lt GX610 GX620 gt FUEL FILTER AIR CLEANER d SS IQ az E y SPARK PLUG THROTTLE LEVER OIL FILTER ENGINE SWITCH OIL PRESSURE SWIT
35. n the bearing to the manufacturer s specification The following procedure however will provide for satisfactory bearing adjustment when the torque method is not feasible It should be noted that whenever wheels hubs and drums are removed for any purpose the bearings will require re adjustment 1 2 With the wheel raised off the ground and the component parts on the spindle the inner spindle nut should be tightened until there is no slack or play in the bearings The inner nut should then be backed off approximately one half turn The lock thrust washer is then placed in position Next the outer spindle nut is tightened against the washer Once this procedure is completed the bearings should be given a final check for any play and this condition corrected by progressive tightening of the inner nut followed by a re adjustment of the lock washer and outer nut NOTE Spindle nut wrenches for the various axle models can be purchased from our Parts Department 39 7 ABS Anti Lock Braking System ABS e 25 1 45 2 Sealco Air Brake Systems Section 5 Diagnostics MERITOR WAECO Using the Blink Code f the blink code lamp is flashing count the number of flashes to identify the fault Check For ECU Part Number 472 500 011 0 without Table D ECU Part Number 472 500 0110 diagnostic connector Blink Codes to determine the problem 1 Make sure the vehicle is stationary Follow the suggeste
36. ould avoid conditions where several of these factors are combined The factor under greatest control by the operator is the vehicle s speed 7 0 THE DRIVER 7 1 The driver can compensate for the characteristics and condition of his vehicle for the road conditions and weather 7 2 Either braking or accelerating while cornering can significantly reduce the controllability and stability of the vehicle and should be avoided The best driving practice is to decelerate to a safe conservative speed before entering a corner or approaching congested traffic and then apply only moderate power until an essential straight path has been established 7 3 It is imperative that a safe speed always be maintained The safe speed is that speed at which control can be maintained over the vehicle at all times This speed will allow an emergency change of lane maneuver travel off an exit ramp with a tightening radius and recovery from pavement drop off or wet pavement This speed will vary from one combination of vehicle to another and takes into consideration such factors as road conditions weather traffic visibility type of load and experience of the driver XL Specialized Trailers 14 5 ACCESSORIES HYDRAULIC 5 GASOLINE OR DIESEL POWER 1 Start power system and let the unit warm up 2 Pull hydraulic ramp valve up to rotate ramps toward trailer 3 Disconnect the lock bar from the ramp at the top and position lock bar out of the wa
37. r on clear level ground Disconnect air and electrical lines at front of gooseneck This will automatically set the trailer brakes Start the engine and allow it to warm up If equipped with self contained power unit Operate platform control valve to lower lifting pads to the ground Continue to raise trailer to remove load from the tractor s fifth wheel Release fifth wheel lock and drive tractor away from the loading area Operate platform control valve to lower front of the trailer to the ground gooseneck control valve rotating neck rearward slightly Remove lock pins and check to make sure lock pins release One each side Operate gooseneck control valve to lower neck to ground Turnoff engine Trailer is ready to load equipment TO RAISE TRAILER FOR TRANSIT JI O UT Start engine Operate gooseneck control valve to raise gooseneck to travel position Insert lock pins in gooseneck Operate platform control valve to raise trailer frame Raising gooseneck to tractor fifth wheel height Back tractor into position for king pin connection Lower gooseneck onto fifth wheel Operate platform control valve to raise the trailer lifting pads to full height Travel position Stop engine Blockloaded equipment Trailer is ready for transit XL Specialized Trailers 4 4 USER S MANUAL LOW BED AND HEAVY DUTY PLATFORM TRAILERS GENERAL OPERATING RE
38. s to how to repair or service the trailer contact the manufacturer as improper welding could cause future damage to the product Also check for worn parts and loose nuts and consult the instruction manual for recommended procedures concerning this matter Safety first last and always can be accomplished if operators are well informed and when EVERYONE IS AWARE OF THE IMPORTANCE OF THE OPERATING AND SERVICE MANUAL published by the trailer manufacturer 52 LOAD Vehicle handling limits can be greatly affected by the weight of a load its placement the amount of weight distributed over the tractor axles and whether or not the load is secured properly Overloading a vehicle should never be permitted Overloads result in tire blowouts spring breakage frame breakage insufficient braking capacity and will severely alter a vehicle s handling characteristics All vehicles are designed with a maximum load capability and to best utilize these vehicles in the safest manner the loads as shown on the certification label should not be exceeded XL Specialized Trailers 9 One of the major contributing factors to vehicle rollover is a high center of gravity on tall loads Extreme caution should be used in maneuvering a vehicle tractor trailer combination or any unit that has a tall load This can be done by reducing speed Fifth wheel placement on tractors can have an adverse effect on handling characteristics Avoid moving the fifth wheel be
39. sed roll resistance of the trailer or combination decreased effectiveness of brakes at the tire ground interface and reduced resistance to lateral skidding Tire under and over inflation has an adverse effect on traction Therefore proper inflation is essential for safety 5 1 2 BRAKES Another extremely important item that should be checked is the brakes are they properly adjusted and are the linings in good condition Air brakes can easily be checked by simply checking the travel of the slack adjuster Electric brakes in most cases are self adjusting and therefore generally are in proper adjustment A routine check for air leaks or worn hoses should be made on air brake trailers whereas on electric brake trailers the wiring should be checked regularly Maintaining brake balance is the key to safe braking and stopping distances Erratic or unequal brake action from side to side on either tractor or trailer can cause handling problems in braking situations Balance between tractor and trailer on application and release brake timing and pressure will reduce push pull characteristics between tractor and trailer which when excessive may result in jackknife Brake torque is one other important factor in smooth safe braking The use of properly matched brake lining of identical friction properties is a must For additional information on brake balance see the Truck Trailer Brake Compatibility booklet published jointly by the Truck Trail
40. suspension and other vehicle characteristics Typical Application Single Axle Dolly Single and Tandem Axle Semi Trailer XL Specialized Trailers 42 GD AIR SYSTEMS ABS Single Axle Lead Semi Trailer Supply Control Red Blue In Po i Out 432 500 005 0 2550 110580 10200 1 2 400 500 101 0 110700 110000 Lecsseaseuesscucenen 110500 Supply Control Red Rear XL Specialized Trailers GD AIR SYSTEMS Tandem Axle Trailer Spring Brake Priority 110500 or 110800 Service Reservoir Priority 110700 Supply Control Red Blue 5 CH Uu 432 500 005 0 2550 400 500 103 0 or 400 500 102 0 or 400 500 101 0 110700 or 110800 or 110500 XL Specialized Trailers 44 ED AIR SYSTEMS Tri Axle Trailer ABS Exempt 2 Tanks 2 Valves Supply Control Red Blue Control Tube Service Hose m Out 1 110700 110800 or 110500 2 2550 3 110415 or 4 Port Service Relay Valve 4 110410 or 2 Port Service Relay Valve t i gt NZ XL Specialized Trailers 45 8 KITS Haldex HALDEX AIR CONTROL KITS 78 1 Series Function Lowering Exhausting Systems from Ride Height Application Truck or Trailer with One Height Control Valve Pressure Protection
41. temperatures be held to a safe level EXIT AND ENTRANCE RAMPS Sixteen 16 percent of tractor semi trailer overturns occur at exit and entrance ramps of super highways 11 All exit ramps are not uniform in curvature and banking and may not have a speed advisory sign proper for all truck and load combinations Recent information indicates that jackknifing can occur without brakes being applied if a tractor semi trailer enters a curved exit ramp at a too high rate of speed 4 LEVEL STRAIGHT ROADS Many overturns appear to occur due to the driver falling asleep and driving off the pavement A high crowned road coupled with excessive speed can cause trailer sway and loss of stability Driver attentiveness is essential 544 BUMPS AND DEPRESSIONS Driving over a bump or depression in the road surface or running off the pavement and back on can cause the vehicle to sway and result in momentary reduction of lateral friction Reduced speed and increased driver attentiveness are best deterrents VERY LOW VEHICLES CAN BE HUNG UP AT ELEVATED RAILROAD CROSSINGS OR DRIVEWAYS SO PAY CLOSE ATTENTION TO THE ROAD SURFACE WHEN USING THESE VEHICLES 5 4 5 CURVES The forces trying to roll a vehicle over increase according to the square of the speed and are inversely proportional to the radius of a curve i e the smaller the radius the greater the force trying to pull the vehicle over Therefore the tighter the curve the slower the speed must be in ord
42. ty works against the driver in maintaining control of his vehicle particularly if the road is covered with rain snow ice or loose material On upgrades the problem is spinning out due to insufficient traction at the drive wheels particularly on snow and ice Failure to control speed by down shifting has resulted in 6 of the interstate truck accidents 9 Drivers should use the same gear in descending a long grade as they would in climbing it Gear selection should be made before descending a grade to minimize the chance of missing a shift 10 Great care must be taken to avoid excessive use of brakes on long downgrades as over heated brakes are dangerously inefficient Drivers should use engine compression as the principal means of controlling speed on long grades 10 Unless the road is slippery the brakes should not be fanned alternately applied and released since fanning brakes on a long downhill grade may reduce air pressure below the minimum pressure needed for proper brake operation 10 If the low air pressure warning device operates at any time drivers must stop immediately in the safest available place and correct the loss of air pressure before proceeding It is very dangerous to brake on a downgrade using only the trailer brakes If this is done the trailer brakes heat up and fade and the tractor brakes alone will not be able to stop the combination by themselves Only by downshifting and using all brakes can the brake
43. ult Code Table below for Normal Mode fault codes See Figure 5 5 XL Specialized Trailers 6 When there are existing faults You must repair existing faults 7 After you identify an existing fault turn the power tothe ECU Repair the fault Turn the power to the ECU back ON 8 ECU Part Number 472500 001 amp Repeat Steps 3 5 6 and 7 until the blink code lamp oes OFF comes back ON and remains ON his sequence signals that there no other existing faults ECU Part Numbers 472 500 012 0 and 472 500 013 0 Repeat Step 3 there are no faults in the system the blink code lamp will come ON go OFF and remain OFF 9 st repaired sensor fault the ECU is waiting to see 4 mph signal on sensed wheels Until this 4 mph is sensed by the ECU the ABS warning lamp on the trailer will remain ON Table E Normal Mode Fault Code Table 212 EN ECU Modulator ME 41 Section 4 System Configurations 2S 1M Trailer ABS Configuration with External Diagnostics Capability Installation Diagram Service Control Lines Sensor Cables Service to Brake Lines Delivery Lines Supply Emergency Lines Assembly YE Tanks For direct tank mounted installations see How to NOTE Install the ECU Valve Assembly in Section 6 Component Replacement Sensors may be installed on either axle depending upon
44. use extra caution on highways farm roads and when approaching bridges overpasses and underpasse ot 919 XL Specialized Trailers 1 2 GENERAL TRAILER INFORMATION TRAILER INFORMATION SHEET Fill out at time of sale MODEL NO VIN 4 TRAILER CAPACITY DIST CONC DIMENSIONS OAL OAW DATE INSPECTED BY PARTS ORDERING INFORMATION WHEN ORDERING PARTS PLEASE REFER TO THE VEHICLE ID NUMBER VIN VEHICLE REGISTRATION NUMBERS PART NUMBER AND DESCRIPTION OF ITEM CONTACT XL SPECIALIZED TRAILERS PARTS DEPARTMENT PHONE 563 927 4900 FAX 563 927 4883 www xlspecialziedtrailer com XL Specialized Trailers 2 3 OPERATING INSTRUCTIONS VEHICLE ALIGNMENT 10 Back truck fifth wheel in line with trailer king pin 11 Visual check to assure trailer height will clear truck fifth wheel 12 Raise landing gear if necessary TRAILER CONNECTION 13 Back truck under trailer slowly 14 Assure king pin is locked 15 Raise landing gear 16 Connect the air lines and electrical connections INSPECTION 10 Accomplish a walk around inspection 11 Check the tire pressure If loaded assure load is secure 12 Check all lights for proper operation Move truck and trailer forward slowly and apply brakes to assure proper braking action XL Specialized Trailers XL HYDRAULIC FOLDING GOOSENECK OPERATIONS TO LOWER GOOSENECK TO THE GROUND O UT Locate tractor and traile
45. y 4 A STAND CLEAR WHILE FOLDING 5 Push handle down to lower ramps to the ground 6 Reverse procedure to raise ramps XL Specialized Trailers 15 SWINGOUTS OUTRIGGERS 1 Lift and rotate swingouts out away from trailer 2 Place boards on outriggers according to your safety practices 3 Load cargo and secure to trailer 4 Make sure the cargo is not solely on the outrigger REMOVABLE OUTRIGGERS 1 Remove outriggers from storage compartment 2 Place outriggers in pockets provided on the side of the trailer Top and bottom pockets are provided on most units 3 Insert lock pin in bottom pockets P WA D r pe GLEN a a M XL Specialized Trailers 16 LANDING GEAR HOLLAND BINKLEY BULLDOG GO THE DISTANCE L CONTENDER XL Specialized Trailers 17 XL Specialized Trailers GO THE OIGATANCE L MARK V GO THE DISTANCE NALZY DROP LEG JACK SUPPORT TOUGH amp TRUSTED BULLDOG n A BULLDOG Heavy duty jacks MANUAL DUMP VALVE lt DUMP bh gt ARD RIDE 1 To lower trailer turn knob from Standard Ride Height Position shown to Dump Air position 2 Turn knob back to Standard Ride Height Position once the desired height has been reached XL Specialized Trailers 21 RAISE AND LOWER VALVE RAISE LOWER LEVER Turn O
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