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XPOM-100 XP Manual

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1. NX iss Drop Deck Trailer Owner s Manual Felling Trailers Inc e 1 800 245 2809 Sauk Centre MN XPOM 100 FELLING 2 FRA MERS Quality Craftsmanship Pride Since 1974 Dear Customer Thank you for purchasing a XPress Trailer You are now part of an ever growing group of XPress Felling Trailers owners across North America and internationally that have made the Felling Style their own At XPress Felling Trailers Quality Craftsmanship amp Pride are central in everything we do and we want you to know that you can count on us Felling Trailers manufactures a large range of trailers from small Utility to large Hydraulic Detachable Gooseneck trailers be it a standard model or highly customized we know your satisfaction is essential Felling Trailers knows that the most important thing about your trailer is the cargo that it is carrying That is why the features of all Felling Trailers are designed and engineered with you and your cargo in mind We take tremendous Pride in the trailers we build and it shows in everything that we do From our innovative designs to our world class parts amp service department we stand behind everything that we do to ensure ultimate customer satisfaction Please know that Felling Trailers dedicated dealer network and employees are here for you Let Felling Trailers know how we can be of service now and in the future Thanksyagnin and bestwishes Merle J Felling Traile
2. Pin Should Be Plugged In Switch Box For Towing amp Storage Secure load to trailer Balance load side to side Less load behind wheels More load in front of wheels Check if lug nuts are tight Check tires amp wheels for wear XPress 17 Ad WARNING Operator And Others Stand Clear Of Ramps When Lowering And Raising Failure To Do So Could Lead To Serious Injury Or Death Stand At The gt Side Of The Trailer When In Use J A WARNING To protect you and others against death or serious injury all appli cable labels shown must be on the trailer and must be legible If any of these labels are missing or cannot be read contact your dealer for replacement labels 2 2 18 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 Felling Trailers 1525 Main St S Sauk Centre MN 56378 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 Felling Trailers 1525 Main St S Sauk Centre MN 56378 To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153
3. A 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 Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up if the trailer comes loose 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 XPress 44 4 3 4 CONNECT ELECTRICAL CABLE 1 Connect the trailer lights to the tow vehicle s electrical system using trailer electrical cable 2 Check all lights for proper operation Repair or replace non working lights before towing trailer 3 Check electric brakes for proper operation using brake controller mounted in the cab A 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 e Check that the electric brakes work by operating the brake controller inside the tow vehicle e Check that all lights and turn signals work 4 3 5 ATTACH BREAKAWAY BRAKE LANYARD If the coupler or hitch fails a properly connected and working breakaway brake system will apply the trailer brakes The safety chains will keep the tow vehicle attached and as the trailer brakes are applied the trailer tow vehicle combination will come to a
4. GTW and maximum Gross Combined Weight Rating GCWR can be found in the tow vehicle Owner s Manual A DANGER Use of an under rated hitch ball or tow vehicle can result in loss of control leading situation result in death or serious injury Make certain your hitch and tow vehicle are rated for your trailer 2 2 2 DRIVING TOO FAST With ideal road conditions the maximum recommended speed for safely towing a trailer is 55 mph Driving too fast can cause the trailer to sway thus increasing the possibility for loss of control Also your tires may overheat increasing the possibility of a blowout XPress 7 A WARNING Driving too fast for conditions can result in loss of control and cause death or serious injury Adjust speed down when towing trailer 2 2 3 ADJUST DRIVING WHEN TOWING TRAILER When towing a trailer you will have decreased acceleration increased stopping distance and increased turning radius The trailer will change the handling characteristics of the tow 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 this in mind e When encountering trailer sway take your foot off the accelerator and steer as little as possible in order to stay on the road Use small trim like steer ing adjustments
5. If you have uni servo or duo servo brakes and stroking the actuator as described above causes the trailer to roll away from you freely or with only mini mal resistance the brakes are NOT applying properly If you have free backing brakes and stroking the actuator as described above causes the trailer to roll away without initial resistance then the brakes are NOT applying properly The brake system MUST be evaluated to determine the cause of the problem and corrective action MUST be taken before the trailer is used Use this procedure each time you tow your trailer to check your surge brake system operation 4 3 5 4 TEST SURGE BREAKAWAY SYSTEM Before towing check that the breakaway lever and lanyard are properly positioned If the breakaway lever and lanyard are not located correctly due to either the lanyard being pulled during use or by accident it MUST be reset prior to the trailer being moved See the Surge Brake Actuator manual for the correct resetting and testing procedure A WARNING The breakaway system is designed to operate if the trailer separates from the tow vehicle DO NOT use the breakaway system as a parking brake XPress 48 4 4 UNCOUPLE TRAILER Follow these steps to uncouple trailer from the tow vehicle 1 Park the trailer on a firm level surface and block trailer tires Disconnect electrical connector Disconnect breakaway brake switch lanyard 2 3 4 Disconnect safety chains from tow ve
6. or go to http www safercar gov or write to Administrator NHTSA 1200 New Jersey SE Washington DC 20590 You can also obtain other information about motor vehicle safety from http www safercar gov XPress 18 3 TIRE SAFETY INFORMATION This portion of the User s Manual contains tire safety information as required by 49 CFR 575 6 Section 3 1 contains Trailer Tire Information Section 3 2 contains Steps for Determining Correct Load Limit Trailer Section 3 3 contains Steps for Determining Correct Load Limit Tow Vehicle Section 3 4 contains a Glossary of Tire Terminology including cold inflation pressure maximum inflation pressure recommended inflation pressure and other non technical terms Section 3 5 contains information from the NHTSA brochure entitled Tire Safety Everything Rides On It This brochure as well as preceding subsections describes the following items e Tire labeling including a description and explanation of each marking on the tires and information about the DOT Tire Identification Number TIN e 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 e Tire Care including maintenance and safety pr
7. 4 3 2 3 COUPLE GOOSENECK TRAILER TO TOW VEHICLE 4 3 2 4 COUPLE TRAILER TO TOW VEHICLE 4 3 3 CONNECT SAFETY CHAINS asen 4 3 4 CONNECT ELECTRICAL CABLE 4 3 5 ATTACH BREAKAWAY BRAKE LANYARD eee 4 3 5 1 TEST ELECTRIC BRARE S 4 3 5 2 TEST ELECTRIC BREAKAWAY DRAREG eee 4 3 5 3 TEST SURGE BRAKES IF EQUIPPED XPress 3 28 28 28 29 29 29 30 30 30 32 33 34 35 35 35 36 36 37 37 38 39 39 40 40 41 42 43 44 45 45 46 46 47 4 3 5 4 TEST SURGE BREAKAWAY SYSTEM cece 4 4 Uncouple Trailer 4 5 Tongue Weight 4 5 1 CHECKING TONGUE 4 6 Adjust Hitch Height If E 5 LOADING AND UNLOADING 5 1 Loading Trailer WEIGHT siiistectsiineisiaiieniidiacnch GUID DOR RE 5 1 1 PREPARING TRAILER FOR LOADING 5 1 2 LOADING A RIGID DECK TRAILER 5 2 Securing Cargo 6 PRE TOW CHECKLIST 6 1 Pre Tow Checklist 6 2 Make Regular Stops 7 BREAKING IN A NEW TRAILER AAA 7 1 Retighten Lugs At First 10 25 amp 50 Miles eects 7 2 Adjust Brake At First 20 7 3 Synchronizing Brake Sy 8 ACCESSORIES nsise 8 1 Accessory Battery 9 INSPECTION SERVICE AND O Miles woo eeeeceeeeeeeeeeeeaeeees S EMS sei ctecunwsas piveswenctadsentenvodeeswass anes MAINTENANCE ce ceecce nsec eee 9 1 Inspection Service amp Maintenance Summary Charts 9 2 Inspection And Service INSTUCTIONS nei i sisses 9 2 1 TRAILER S
8. And Unloading XPress 51 5 LOADING AND UNLOADING Improper trailer loading causes many accidents and deaths To safely load a trailer you must consider e Overall load weight e Load weight distribution e Proper tongue weight e Securing the load properly To determine that you have loaded the trailer within its rating you must consider the distribution of weight as well as the total weight of the trailer and its con tents The trailer axles carry most of the total weight of the trailer and its contents Gross Vehicle Weight or GVW The remainder of the total weight is carried by the tow vehicle hitch It is essential for safe towing that the trailer tongue and tow vehicle hitch carry the proper amount of the loaded trailer weight otherwise the trailer can develop an undesirable sway at towing speeds or the rear of the towing vehicle can be overloaded Read the Tongue Weight information in Section 4 The load distribution must be such that no component part of the trailer is loaded beyond its rating You must consider the rating of the tires wheels and axles For tandem and triple axle trailers you must make sure that the front to rear load distribution does not result in overloading any axle Towing stability also depends on keeping the center of gravity as low as possible Load heavy items on the floor and over the axles When loading additional items be sure to maintain even side to side weight distribu
9. controlled stop Connect the lanyard to the tow vehicle so that the hydraulic actuator will engage or the electric brake pull pin will be pulled out before all of the slack in the safety chains is taken up Do not connect the lanyard to a safety chain hitch ball or hitch ball assembly This would keep the breakaway brake system from operating when it is needed XPress 45 4 3 5 1 TEST ELECTRIC BRAKES 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 You should feel the operation of the trailer brakes If the trailer brakes are not functioning the brake system MUST be evaluated to determine the cause of the problem and corrective action MUST be taken before the trailer is used Take the unit to your dealer or a qualified brake specialist Use this procedure each time you tow the trailer to check brake system operation 4 3 5 2 TEST ELECTRIC BREAKAWAY BRAKES The breakaway brake system includes a battery a switch with a pull pin and lanyard and a breakaway brake controller Read and follow the instructions here as well as the instructions that have been prepared by the
10. for the vehicle Wheel and Rim Torque Requirements Descriot Applicat Min ft lbs Max T ft lbs 1 2 Cone Nut 14 16 Wheel 90 120 5 8 Cone Nut Flat Disc Wheel 175 225 3 4 Spherical Nut ingle Wheel 450 50 3 4 Spherical Nut Inner Dual 450 500 3 4 Solid Flange Nut Dual Wheels 215 325 5 8 Swivel Flange Nut Dual Wheel 175 225 4 4 Swivel Flange 1 095 ve Aluminum Wheel Torque Description Application Min Tor ft lbs Max Tori ft lbs XPress 34 4 COUPLING TO 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 4 1 TOW VEHICLE AND HITCH If the vehicle and hitch are 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 make certain the trailer s rated capacity is less than or equal to the tow vehicle s rated towing capacity A DANGER 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 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 Verify hitch and tow vehicle are rated for the Gross Vehicle Weig
11. hazards which will result in serious injury or death if not avoided A WARNING WARNING Potentially hazardous situation which could result in serious injury or death if not avoided XPress 6 A CAUTION CAUTION Potentially hazardous situation which may result in minor moderate injury if not avoided NOTICE Alert against unsafe practices that could result in damage to the trailer or other property 2 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 e Improper sizing the trailer for the tow vehicle or vice versa e Excessive Speed Driving too fast for the conditions e Improper braking and steering under sway conditions e Overloading and or improper weight distribution e Not keeping lug nuts tight e Failure to adjust driving behavior when towing a trailer e Not maintaining proper tire pressure e Improper or mis coupling of the trailer to the hitch 2 2 1 IMPROPER SIZING OF TRAILER TO TOW VEHICLE Trailers that weigh too much for the tow vehicle can cause stability problems which can lead to death or serious injury The additional strain put on the engine and drive train may lead to serious tow vehicle maintenance problems Do not exceed the maximum towing capacity of your tow vehicle The towing capacity of your tow vehicle in terms of maximum Gross Trailer Weight
12. recommended cold inflation pressure in pounds per square inch PSI stated on the vehicle s Federal Certification Label or Tire Placard when the trailer is loaded to its gross vehicle weight rating GVWR If the tires are inflated to less than the recommended inflation level or the GVWR of the trailer is exceeded the load carrying capacity of the tire could be dramati cally affected If the tires are inflated more than the recommended inflation level handling characteristics of the tow vehicle trailer combination could be affected Refer to the owner s manual or talk to your dealer or vehicle manufacturer if you have any questions regarding proper inflation practices Tires can lose air over a period of time In fact tires can lose 1 to 3 PSI per month This is because molecules of air under pressure weave their way from the inside of the tire through the rubber to the outside A drop in tire pressure could cause the tire to become overloaded leading to excessive heat build up If a trailer tire is under inflated even for a short period of time the tire could suffer internal damage High speed towing in hot conditions degrades trailer tires significantly As heat builds up during driving the tire s internal structure starts to breakdown compromising the strength of the tire It is recommended to drive at moderate speeds Statistics indicate the average life of a trailer tire is about five years under normal use and maintenanc
13. so hot that they stop working Then you will potentially have a runaway tow vehicle and trailer Do not apply the tow vehicle brakes to correct extreme trailer swaying Instead lightly apply the trailer brakes with the hand controller XPress 15 Make regular stops about once each hour Confirm that e The coupler is secure to the hitch and is locked e Electrical connectors are made e There is appropriate slack in safety chains e There is appropriate slack in breakaway lanyard e The tires are not visibly low on pressure e The cargo is secure and in good condition Slow down for bumps in the road Do not brake while in a curve unless absolutely necessary Instead slow down before you enter the curve Do not drive so fast that the trailer begins to sway due to speed Generally never drive faster than 55 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 2 2 17 SAFETY WARNING LABELS ON YOUR TRAILER Depending on trailer configuration your trailer may not be equipped with all safety labels shown Open Clamp Uncoupling will cause trailer to come loose from tow vehicle d Gen Pin in Place 1 Check that pintle LOAD RATING is the same or greater than the ring LOAD RATING 2 LOCK the clamp in place using the pin or Pin Removed if connection fails Operator MUST 1 CROSS chains underneath coupler 2 ALLOW slack f
14. tire before towing If a tire has uneven tread wear take the trailer to a trailer service center for diagnosis Uneven tread wear can be caused by tire imbalance axle misalign ment or incorrect inflation 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 The proper tire pressure is listed on the Certification VIN label normally mounted on the 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 XPress 10 A WARNING Inflate tires to pressure stated on the Certification VIN label Improper tire pressure may cause unstable trailer Blowout and loss of control may occur Death or serious injury can result Make sure of proper tire pressure before towing trailer The tightness of the wheel nuts or bolts is very important in keeping the wheels properly seated to the hub Before each tow check to make sure they are tight A WARNING Metal creep between the wheel rim and wheel nuts or bolts may cause rim to loosen Death or injury can occur if wheel comes off Tighten lug nuts or bolts b
15. with a maximum speed capability over 149 mph tire manufacturers sometimes use the letters ZR For those with a maximum speed capability over 186 mph tire manufacturers always use the letters ZR lt s lt zrcuHdHo H TO NOTE You may not find this information on all tires because it is not required by law U S DOT Tire Identification Number This begins with the letters DOT and indicates that the tire meets all federal stan dards The next two numbers or letters are the plant code where it was manufac tured 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 XPress 31 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 3 5 10 2 UTQGS INFORMATI
16. CONNECTION TO TOW VEHICLE 9 2 4 1 COUPLER AND BALL Before each tow coat the ball with a thin layer of automotive bearing grease to reduce wear and ensure proper operation and check the locking device that secures the coupler to the ball for proper operation See the coupler manufacturer s manual for other inspection and maintenance procedures If you do not have this manual contact your dealer for assistance If you see or feel evidence of wear such as flat spots deformations pitting or corrosion on the ball or coupler immediately have your dealer inspect them to determine the proper action to prevent possible failure of the ball and coupler system All bent or broken coupler parts must be replaced before towing the trailer The coupler latch lever must be able to rotate freely and automatically snap into the latched position Oil the pivot points sliding surfaces and spring ends with SAE 30W motor oil Keep the ball pocket and latch mechanism clean Dirt or contamination can prevent proper operation of the latching mechanism When replacing a ball the load rating must match or exceed the GVWR of the trailer 9 2 4 2 RING AND PINTLE Before each tow coat the ring with a thin layer of automotive bearing grease to reduce wear and ensure proper operation and check the locking device that secures the pintle to the ring for proper operation See the pintle manufacturer s manual for other inspection and maintenance acti
17. 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 sway ing On the other hand application of the trailer brakes alone will tend to straighten out the combination especially when going downhill e Check rearview mirrors frequently to observe trailer and traffic e Be aware of trailer height especially when approaching bridges roofed areas and trees e Bealert 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 e Anticipate the trailer swaying Swaying can be caused by excessive steer ing wind gusts roadway edges or by the trailer reaction to the pressure wave created by passing trucks and busses e 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 2 2 4 TRAILER NOT PROPERLY COUPLED TO HITCH It is critical that the trailer be securely coupled to the hitch and that the safety chains and emergency breakaway brake lanyard are correctly attached Uncou pling may result in death or serious injury to you and to others XPress 8 A WARNING Proper selection and condition of the coupler and hitch are essential to safely towing a trailer A loss of coupling may result in death or serious injury e Hitch size m
18. N OF BREAKAWAY BRAKE If equipped with brakes your trailer will be equipped with a breakaway brake system that can apply the brakes on your trailer if your trailer comes loose from the hitch You may have a separate set of instructions for the breakaway brake if the trailer is so equipped The breakaway brake system including battery must be in good condition and properly rigged to be effective A 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 Breakaway lanyard must be connected to the tow vehicle NOT to any part of the hitch Before towing 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 2 2 7 MATCHING TRAILER AND HITCH A DANGER Be sure hitch and tow vehicle are rated for the Gross Vehicle Weight Rating GVWR of your trailer 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 2 2 8 WORN TIRES LOOSE WHEELS AND LUG NUTS Inspect all trailer tires before each tow If a tire has a bald spot bulge cut cracks or is showing any cords replace the
19. 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 XPress 30 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 M S The M S or M S indicates that the tire has some mud and snow capabil ity Most radial tires have these markings hence they have some mud and snow capability Speed Rating The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time The ratings range from 99 miles per hour mph to 186 mph These ratings are listed below Note You may not find this information on all tires because it is not required by law Letter Rating Speed Rating 99 mph 106 mph 112 mph 118 mph 124 mph 130 mph 149 mph 168 mph 186 mph For tires
20. ON 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 O 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 XPress 32 3 5 10 3 ADDITIONAL INFORMATION ON LIGHT TRUCK TIRES Please refer to the following diagram Maximum load amp inflation when used as a dual Severe snow conditions a Light truck tire L fo Mi Ori 4 OW PE EFE Chi D 4 Ter zk pea met wave Kenn Oh aut ror CONU aa aan t IW Self D Zo AT Dia aal aus aad go D z ceun erot R U H i Maximum load i amp inflation when Load inflation used as a single limits Tires for light trucks
21. TRUCTURE geet getetegregt dees Seege EeeeggEUAee d 9 2 1 1 FASTENERS AND FRAME MEMDERZ AAA 9 2 1 2 WELDS siris iiniieiasis 9 2 2 TRAILER BRAKES E LEIBIG eeugeetagesg beeserk teeegceegude 9 2 2 1 BRAKE DISCS SHOES AND DRUMS A 9 2 2 2 MANUALLY ADJUSTING BRAKE GHOES 9 2 2 3 ELECTRIC BRAKES XPress 4 48 49 49 50 50 52 53 53 53 54 55 55 55 56 56 56 56 57 57 58 58 59 59 59 60 60 60 60 61 9 2 2 4 TOW VEHICLE OPERATED ELECTRIC BRAKEG 9 2 2 5 ELECTRIC BRAKE MAGNETS cece eee eee 9 2 3 TRAILER BRAKES 9 2 3 1 SURGE BRAKE M SURGE IF EQUIPPED sssrini ASTER CYLINDER eege zeeeresekeegeg 9 2 3 2 HYDRAULIC SURGE BRAKE isisisi deiina 9 2 3 3 MASTER CYLINDER BLEEDING 0 cece 9 2 4 TRAILER CONNECTION TO TOW VEHILE eee 9 2 4 1 COUPLER AND BALL eidir a 9 2 4 2 RING AND PIN TLE iiisge 9 2 5 LANDING LEG OR JACK cciscstenccccctssesscctsveeceesstitenceasrseccets 9 2 6 LIGHTS AND SIGNALS eee eee eee eee eteneeeeeeeeaeeenaees 9 2 7 WHEEL RIMG 9 2 8 URBES ogousseeesseeg 9 2 9 WHEEL BEARINGS 9 2 10 LUG NUTS OR BO 9 2 11 WIRING DIAGRAM KEE XPress 5 62 62 62 62 62 63 64 64 64 64 65 65 65 66 67 68 1 INTRODUCTION For your safety read and understand this manual before operating your trailer If there are any questions about information in this manual please consult your dealer When calling about your trailer please have the VIN nu
22. actices e 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 3 1 TRAILER TIRE INFORMATION Trailer tires may be worn out even though they still have plenty of tread left This is because trailer tires have to carry a lot of weight all the time even when not in use XPress 19 It is actually better for the tire to be rolling down the road than to be idle During use the tire releases lubricants that are beneficial to tire life Using the trailer tires often also helps prevent flat spots from developing The main cause of tire failure is improper inflation Check the cold tire inflation pressures at least once a week for proper inflation levels Cold means that the tires are at the same temperature as the surrounding air such as when the vehicle has been parked overnight Wheel and tire manufacturers recommend adjusting the air pressure to the trailer manufacturer s
23. ailer jack test to see that you can raise the rear of the tow vehicle by 1 inch after the pintle is closed and locked A NOTICE The tongue jack can be damaged by overloading Do not use the tongue jack to raise the tow vehicle more than 1 inch 5 If the ring cannot be secured to the pintle do not tow the trailer Contact your dealer for assistance 6 Lower the trailer so that its entire tongue weight is held by the hitch and continue retracting the jack to its fully retraced position A CAUTION Drop leg jacks may be spring loaded and may rapidly return to the raise position when released Keep clear when releasing drop legs 7 Fully retract jack drop leg if equipped Go to Section 4 3 3 Connect Safety Chains to continue connecting trailer to tow vehicle XPress 43 4 3 3 CONNECT SAFETY CHAINS Visually inspect the safety chains and hooks for wear or damage Replace worn or damaged safety chains and hooks before towing l 2 Safety chains must crisscross under 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 3 Attach hooks up from underneath the hole Do not just drop into hole 4 Provide enough slack in chains to permit tight turns but not be close to the road surface to drag
24. aired Connect breakaway lanyard to the tow vehicle NOT to the safety chain ball pintle hitch or support Do not tow the trailer with the breakaway brake system ON because the brakes will overheat which can result in permanent brake failure A WARNING Failure to replace the pull pin can result in ineffective brakes leading to loss of control serious injury or death If you do not use your trailer for three or more months or during winter months e Store the battery indoors and e Charge the battery every three months Replace the breakaway brake battery according to the intervals specified by battery manufacturer 4 3 5 3 TEST SURGE BRAKES IF EQUIPPED Hydraulic surge actuator systems provide automatic and smooth trailer braking without special application by the tow vehicle driver While this is extremely convenient it can sometimes be difficult to determine if the surge setup is functioning properly The following steps provide a quick field test to confirm that the trailer brake system is operational A WARNING The field test procedure indicates only if the trailer brake system is functional but DOES NOT provide information on how efficiently it will operate Regular inspection maintenance and adjustment of all brake system components including the surge actuator tubing hoses brake clusters drums and associated hardware support structure are still required to ensure maximum brake performance and smo
25. 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 XPress 14 Find an open area with little or no traffic for your first practice 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 t
26. before loading trailer 2 Lower rear stabilizers if equipped or place blocking under rear of trailer so the weight of the cargo does not raise the front of the trailer during loading A CAUTION Use a safe lifting procedure to avoid injury when handling ramps 3 Remove ramps from storage position and secure to rear of trailer Adjust ramp position to align with equipment tires or tracks A WARNING Load can suddenly move or topple which can result in death or serious injury Do not load or unload trailer unless coupled to tow vehicle and is ona firm and level surface XPress 53 A NOTICE Ramps are not rated for load bearing capacity They will NOT support the load bearing capacity of the trailer Do not overload ramps 4 Load the cargo on trailer with approximately 60 of the cargo in the front half of the trailer 5 Secure the load to the trailer using appropriate straps chains and tensioning devices Refer to www fmcsa dot gov for regulations regarding cargo securement rules 6 Remove ramps and place in storage position 7 Secure ramps to trailer 8 Raise rear stabilizers if equipped or remove blocking under rear of trailer 5 2 SECURING CARGO A WARNING Shifting cargo can result loss of control of the trailer and can lead to death or serious injury Tie down all loads with proper sized fasteners chains straps etc Refer to www fmcsa dot gov for regulations regarding car
27. breakaway brake manufacturer If you do not have these instructions contact your dealer for assistance Most trailers are setup to charge the battery from the tow vehicle If the electri cal system on your tow vehicle does not provide power to the battery you must periodically charge the battery with a commercial battery charger to keep the battery charged A CAUTION Extreme cold weather can degrade battery performance and cause brakes to not operate properly Check battery charge level before towing Do not tow trailer if the battery requires recharging A discharged brake battery will not activate the brakes if the trailer uncouples from the tow vehicle The battery must be fully charged before towing trailer To test the breakaway brake battery remove the pull pin from the switch and attempt to pull the trailer forward You should feel the trailer resisting being towed but the wheels will not necessarily be locked If the brakes do not function do not tow the trailer until brakes or battery are repaired Immediately replace the pull pin The breakaway brake battery discharges rapidly when the pull pin is removed XPress 46 A WARNING An ineffective breakaway brake system can result in a runaway trailer leading to death or serious injury if the coupler fails Test the function of the breakaway brake system before towing trailer Do not tow trailer if breakaway brake system is not working have it serviced or rep
28. c ing to find this information If you have any doubt about the correct size to choose consult with the tire dealer 3 5 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 3 5 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 counter balance 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 adjust XPress 29 ments require special equipment and should be performed by a qualified technician 3 5 9 TIRE REPAIR The proper repair o
29. cale In addition you must distribute the load in the trailer such that the load on any axle does not exceed the Gross Axle Weight Rating GAWR If your trailer is equipped with a Tire amp Loading Information Placard mounted next to the Certification VIN label the cargo capacity weight stated on that placard is only a close estimate The GVWR and GAWR are listed on the Certification VIN label normally located on the inside of the trailer tongue A WARNING An overloaded trailer can result in failure or loss of control of the trailer leading to death or serious injury Never load a trailer so that the weight on any tire exceeds its rating Never exceed the trailer Gross Vehicle Weight Rating GVWR or axle Gross Axle Weight Rating GAWR 2 2 10 UNSAFE LOAD DISTRIBUTION Improper front rear load distribution can lead to an unstable trailer or poor tow vehicle handling Poor trailer stability results from tongue weights that are too low and poor tow vehicle stability results from tongue weights that are too high Refer to the Loading And Unloading section for more information In the following table the second column shows the rule of thumb percentage of total weight of the trailer plus its cargo Gross Trailer Weight or GTW that should appear on the tongue of the trailer For example a large trailer with a loaded weight of 6 000 pounds should have 10 15 of 6 000 pounds 600 900 lbs on the hitch T
30. ceed their Gross Axle Weight Rating GAWR In the follow ing table the second column shows the rule of thumb percentage of total weight of the trailer plus its cargo Gross Trailer Weight or GTW that should appear on the tongue of the trailer For example a large trailer with a loaded weight of 6 000 pounds should have 10 15 of 6 000 pounds 600 900 Ibs on the hitch Tongue Weight as a Percentage of Loaded Trailer Weight Type of Hitch Ball Hitch or 10 15 for large trailers Ring amp Pintle 6 10 for small trailers XPress 49 The numbers quoted are for example purposes only and should be tailored to the specific trailer For questions regarding the actual percent of tongue weight for the trailer check with the manufacturer for specifics A WARNING Improper tongue weight load distribution can result in loss of control of the trailer leading to death or serious injury Make certain that tongue weight is within the allowable range Be sure to e Distribute the load evenly right and left e Keep the center of gravity low e Distribute the load front to rear to provide proper tongue weight see chart on page 49 4 5 1 CHECKING TONGUE WEIGHT To check the tongue weight the tow vehicle and trailer must be on level ground as they will be when the trailer is being towed Take the trailer to a truck stop or grain elevator where there is a certified scale Place the tow vehicle only onto the scal
31. ch and pintle must have a rated towing capacity equal to or greater than the trailer gross vehicle weight rating GVWR It is essential that the pintle be the same size as the coupler The pintle size and load rating capacity are marked on the pintle ring capacity is marked on the ring 4 3 2 1 BEFORE COUPLING TRAILER TO TOW VEHICLE 1 Be sure the size and rating of pintle match the size and rating of the ring Hitch ring and pintles are marked with their size and rating A WARNING Ring to pintle mismatch can result in uncoupling leading to death or serious injury Be sure the LOAD RATING of the pintle is equal or greater than the load rating of the ring Be sure the SIZE of the pintle matches the size of the ring 2 Wipe the pintle clean and inspect it visually and by feel for flat spots cracks and pits XPress 40 A WARNING A worn cracked or corroded pintle can fail while towing and may result in death or serious injury Before coupling trailer inspect the pintle for wear corrosion and cracks Replace worn or damaged pintle 3 Rock the pintle to make sure it is tight to the hitch and visually check that the pintle fasteners are solid against the hitch frame 4 Wipe the inside and outside of the ring clean and inspect it visually for cracks and deformations feel the inside of the ring for worn spots and pits 5 Be sure the ring is tight to the tongue of the trailer All ring fasteners must be v
32. cturer A WARNING Improper hitch height adjustment can result in overloaded tires blowout and loss of control leading to death or serious injury Adjust the hitch height so that the loaded trailer is level 1 Connect trailer to tow vehicle and load the trailer to rated capacity See Loading And Unloading 2 Park the tow vehicle and trailer on a firm level surface 3 Stand away from the trailer and visually verify if the trailer is level front to rear If the front of the trailer is higher than the rear the hitch must be raised If the front of the trailer is lower than the rear the hitch must be lowered 4 Uncouple trailer from tow vehicle See Coupling And Uncoupling 5 Remove the lock nuts and bolts 1 on hitch Discard lock nuts Inspect bolts for damage and replace if necessary Contact your dealer for the correct size and grade of bolts 6 Raise or lower the hitch as necessary A WARNING Used lock nuts are prone to loosen resulting in the hitch separating from the trailer which can lead to death or serious injury NEVER re use a lock nut Use new lock nuts each time the hitch height is adjusted Contact your dealer for the proper grade and size of lock nut 7 Install bolts and new lock nuts 8 Tighten lock nuts to torque specified by your dealer 9 Couple the trailer to the tow vehicle and verify that the trailer is level front to rear Adjust if necessary 10 Unload trailer See Loading
33. d adjacent to or near the trailer s VIN Certification label at the left front of the trailer 3 2 2 TRAILERS OVER 10 000 POUNDS GVWR NOTE These Trailers Are Not Required to Have a Tire Information Placard on the Vehicle 1 Determine the empty weight of your trailer by weighing the trailer using a public scale or other means This step does not have to be repeated 2 Locate the GVWR Gross Vehicle Weight Rating of the trailer on your trailer s VIN Certification label 3 Subtract the empty weight of your trailer from the GVWR stated on the VIN label That weight is the maximum available cargo capacity of the trailer and may not be safely exceeded National Highway Transportation Safety Administration NHTSA in addition to notifying us 3 3 STEPS FOR DETERMINING CORRECT LOAD LIMIT TOW VEHICLE 1 Locate the statement The combined weight of occupants and cargo should never exceed XXX Ibs on your vehicle s placard 2 Determine the combined weight of the driver and passengers who will be riding in your vehicle 3 Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds 4 The resulting figure equals the available amount of cargo capacity For example if the XXX amount equals 1400 Ibs and there will be five 150 Ib passengers in your vehicle the amount of available cargo and luggage capacity is 650 Ibs 1400 750 6 x 150 650 Ibs 5 Determine the combi
34. d to carry e 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 3 5 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 be low 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 side wall This number is the highest amount of air pressure that should ever be put in the tire under normal driving con
35. ditions 3 5 4 SAFETY FIRST BASIC MAINTENANCE It is important to check your vehicle s tire pressure at least once a month for the following reasons e Most tires may naturally lose air over time e Tires can lose air suddenly if you drive over a pothole or other object or if you strike the curb when parking e 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 out side 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 3 5 5 STEPS FOR MAINTAINING PROPER TIRE PRESSURE e Step 1 Locate the recommended tire pressure on the vehicle s tire information placard certification label or in the owner s manual XPress 28 e Step 2 Record the tire pressure of all tires e Step 3 If the tire pressure is too high in any of the tires slowly release air by gently pressing on the ti
36. e and get the weight This weight must be less than your tow vehicle s GVWR Pull the trailer onto the scale and uncouple it from the tow vehicle leaving just the trailer on the scale Get a ticket which lists the total trailer weight Re connect the trailer to your tow vehicle and the drive the tow vehicle wheels off the scale just leaving the trailer axles on the scale Get a ticket which lists the trailer s axle weight Simply subtract the axle weight from the total weight to determine the hitch weight While you are at the scale you should weigh the entire combination vehicle This result should be less than the Gross Combined Weight Rating GCWR for your towing vehicle Some scales allow you to get individual axle weights also If this is possible get the tow vehicles front and rear axle weights to make sure they are in the same proportion as the tow vehicle alone and that the rear axle is not overloaded 4 6 ADJUST HITCH HEIGHT IF EQUIPPED The height of the hitch on the trailer must be adjusted so that the trailer when loaded to rated capacity is level while connected to the tow vehicle A level trailer allows equal weight distribution on the axles Your dealer or a trailer service center can perform this adjustment or you can use the following steps to adjust the hitch height yourself If the trailer is not equipped with an adjustable hitch an offset ball mount may be XPress 50 available from your hitch manufa
37. e conditions After three years replacing the trailer tires with new ones should be considered even if the tires have adequate tread depth Some experts claim that after five years trailer tires are considered worn out and should be replaced even if they have had minimal or no use This is such a general statement that it may not apply in all cases It is best to have your tires inspected by a tire supplier to determine if your tires need to be replaced If you are storing your trailer for an extended period make sure the tires are fully inflated to the maximum rated pressure and that you store them in a cool dry place such as a garage Use tire covers to protect the trailer tires from the harsh effects of the sun 3 2 STEPS FOR DETERMINING CORRECT LOAD LIMIT TRAILER Determining the load limits of a trailer includes more than understanding the load limits of the tires alone On all Felling Trailers there is a Federal certification VIN label that is located on the forward half of the left road side of the unit This certifi cation VIN label will indicate the trailer s Gross Vehicle Weight Rating GVWR This is the most weight the fully loaded trailer can weigh It will also provide the Gross Axle Weight Rating GAWR This is the most a particular axle can carry If there are XPress 20 multiple axles the GAWR of each axle will be provided If your trailer has a GVWR of 10 000 pounds or less there is a vehicle placard located
38. e tow vehicle before installing the trailer to prevent damage to the gooseneck coupler and the tow vehicle Back the tow vehicle up to the trailer and line up the gooseneck coupler to the gooseneck ball 2 Raise the jack so the gooseneck coupler drops down and attaches to the gooseneck ball 3 Close the lock plate on the gooseneck ball coupler and install the locking pin 4 Test if the trailer is secure by raising the jack up 1 inch The tow vehicle bed should raise with the jack Wu Secure the trailer chains and breakaway switch to the tow vehicle A WARNING Connect the breakaway lanyard to the tow vehicle NOT to safety chain and NOT to the hitch ball or support Note Close the tow vehicles tailgate before operating on the roadway e Raise the jack and the drop leg supports XPress 42 4 3 2 4 COUPLE TRAILER TO TOW VEHICLE 1 Lower the trailer tongue until the ring fully engages the pintle If the ring does not line up with the pintle adjust the position of the tow vehicle 2 Close pintle and engage the pintle locking mechanism In the engaged position the locking mechanism securely holds the ring to the pintle 3 Insert the safety lock pin through the hole in the locking mechanism 4 Be sure the ring is all the way on the pintle and the locking mechanism is engaged A properly engaged locking mechanism will allow the pintle to raise the rear of the tow vehicle Using the tr
39. ed here have your dealer do them Note In addition to this manual also check the relevant component manufacturer s manual MAINTENANCE SCHEDULE REQUIRED 3 000 MILES 12 000 MILES 25 000 MILES WHEEL TORQUE BRAKE AIR SYSTEM BRAKE ADJ amp WEAR SLACK ADJUSTERS are operational WIRING amp CONNECTIONS FASTENERS RELAY VALVES Inspect amp Clean CAMSHAFT ASSEMBLY Inspect amp Lubricate a CS EE DE Ee ECH RE NEE DE LI TT El EE EE 3 a S S QNGPNAPLATE Inspect Gene e IW WEE EECH EC a es EECH HUB OIL Inspect lubricate amp when mee d Ir WHEEL BEARINGS amp CUP Inspect for corrosion or i ot fod wear Clean amp repack ae BEE e ECH a NEE D ECH E EE EECHER NR AIR RIDE SUSPENSION Inspect Tighten adj torque as needed UNDERCARRIAGE ROLLERS HYDRAULIC OIL HYDRAULIC FILTER Hoses WINCH GEAR CASE TIRE INFLATION amp WEAR Inflate tires to mio specifications WHEEL LUG NUTS Tighten to specified torque values SUSPENSION Inspect for bending loose ALIGNMENT fasteners amp wear XPress 58 9 2 INSPECTION AND SERVICE INSTRUCTIONS A WARNING Worn or broken suspension parts can cause loss of control and injury may result Have trailer professionally inspected annually and after any impact To perform many of the inspection and maintenance activities you must jack up the trailer When jacking and using jack stands place them so as to clear wiring brake lines and s
40. eert Square Axles Pisa Frame or Have Alignment Incorrect Toe In Checked Loose Check Bearing Bearings or Adjustment and Cupping Wheel Wheel amp Balance Tire Balance Wheel Adjust Brakes Lockup Flat Spots A WARNING Worn damaged or under inflated tires can cause loss of control injury and damage Check tires before each tow 9 2 9 WHEEL BEARINGS A loose worn or damaged wheel bearing is the most common cause of brakes that grab To check your bearings jack up the trailer and secure it on adequate capacity jack stands Check wheels for side to side looseness If the wheels are loose or spin with a wobble the bearings must be serviced or replaced XPress 66 A WARNING Never go under trailer unless it is on firm and level ground and resting on properly placed and secured jack stands If your axle s are equipped with a grease zerk on the ends of the axle s the bearings must be greased every 6 months or 6 000 miles to ensure reliable and safe operation of your trailer 1 Remove the rubber plug from the axle end 2 Place grease gun on zerk 3 Pump grease until new grease begins to appear Use a different color grease each time so you will know when the new grease begins to appear 4 Install rubber plug and cap Repeat for remaining wheel bearings If your trailer axle S are not equipped with grease zerks refer to the axle manufacturer s manual for service and maintenance informatio
41. efore each tow The proper tightness torque for wheel nuts or bolts and tightening sequence is listed in the Inspection Service and Maintenance section of this manual Use a torque wrench to tighten the lug nuts and use the crisscross star pattern sequence Improper tightening of the lug nuts voids the axle warranty Wheel nuts or bolts are also prone to loosen after first being assembled When driving a new trailer or after wheels have been remounted check to make sure they are tight after the first 10 25 and 50 miles of driving and before each tow thereafter Failure to perform this check can result in a wheel separating from the trailer and a crash leading to death or serious injury A WARNING Wheel nuts or bolts are prone to loosen after being first assembled Death or serious injury can result Check wheel nuts or bolts for tightness on a new trailer and after re mounting a wheel at 10 25 and 50 miles A WARNING Inadequate wheel nut or bolt torque can cause a wheel to separate from the trailer leading to death or serious injury Verify wheel nuts or bolts are tight before each tow XPress 11 2 2 9 IMPROPER LOADING The total weight of the load you put on the trailer plus the empty weight of the trailer itself must not exceed the trailer s Gross Vehicle Weight Rating GVWR If you do not know the empty weight of the trailer plus the cargo weight you must weigh the loaded trailer at a commercial s
42. el over one inch indicates that the brakes need adjustment or that the actuator has been structurally damaged Actuator travel is the distance the coupler case assembly moves to the outer case during braking Adjust the brakes following the instructions given in the brake installation manual Failure to adjust brakes will result in loss of braking Wu Before storage or after extended use apply motor oil to the coupler components and the internal rollers to keep them moving freely and to prevent corrosion 6 See the surge brake manufacturer s manual for other inspection and maintenance activities If you do not have this manual contact your dealer for assistance XPress 62 9 2 3 3 MASTER CYLINDER BLEEDING Remove the master cylinder s cap and fill the reservoir to three quarters full with DOT 3 or DOT 4 brake fluid DO NOT allow brake fluid to contact painted surfaces since it will damage the finish Wipe up any spills immediately and wash the area with water Bleed the brake system manually or with a pressure bleeder Pressure bleeding equipment simplifies the process and is available at most automotive supply stores Use the instructions provided with the pressure bleeder If you chose to manually bleed the system an assistant is required Use the following steps to manually bleed the brake system d Disconnect the trailer from the tow vehicle and jack the trailer s tongue until it is horizontal Make sure that t
43. er 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 68 kilograms 150 Ibs times the number of occupants specified in the second column of Table of 49 CFR 571 110 Occupant distribution The distribution of occupants in a vehicle as specified in the third column of Table 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 XPress 24 Overall width The linear distance between the exte riors 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 autom
44. erious injury can occur Road test the brakes in a safe area at no more than 30 m p h before each tow To insure safe brake performance and synchronization read and follow the axle brake and the brake controller manufacturers instructions If you do not have these instructions contact your dealer for assistance XPress 56 8 ACCESSORIES This section provides some basic information for the safe operation of accessories You must read and follow these instructions before using the accessory If you are uncertain whether you have all of the instructions contact your dealer before operating the accessory 8 1 ACCESSORY BATTERY Your trailer may be equipped with an accessory battery The battery may be kept charged either by the tow vehicle by an auxiliary charger or by using an onboard battery maintainer charger if equipped If the trailer is used daily it is recommended that the battery charger be plugged in after each days use The battery may be located in a tongue mounted battery box or a side mounted box The accessory battery must be kept in a charged condition during storage The battery could freeze and break if it becomes discharged XPress 57 9 INSPECTION SERVICE AND MAINTENANCE 9 1 INSPECTION SERVICE amp MAINTENANCE SUMMARY CHARTS You must inspect maintain and service your trailer regularly to insure safe and reliable operation If you cannot or are unsure how to perform the items list
45. f 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 3 5 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 3 5 10 1 INFORMATION ON PASSENGER VEHICLE TIRES Please refer to the diagram below Radial Rim diameter code Ratio of height to width aspect ratio Load index amp speed symbol depy 5 Passenger an Aol Spy car tire Ap GM e Nominal width of tire in millimeters i _ U S DOT tire identification number Severe snow conditions Max permissable Inflation pressure composition and materials used To Bau kW Ir ews oi fr r bezwCgIpi di Treadwear traction f and temperature grades Max load rating 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
46. go securement rules XPress 54 6 PRE TOW CHECKLIST 6 1 PRE TOW CHECKLIST Before towing double check all of these items e Tires wheels and lug nuts See Breaking In A New Trailer section of this manual e Tire Pressure inflate tires on trailer and tow vehicle to the pressure stated on the Certification VIN label e Coupler secured and locked See Coupling To Tow Vehicle section of this manual e Safety chains properly rigged to tow vehicle not to hitch or ball See Coupling To Tow Vehicle section of this manual e Test Tail Stop and Turn Lights e Test trailer brakes e Safety breakaway lanyard fastened to tow vehicle not to safety chains See Coupling To Tow Vehicle section of this manual e Cargo properly loaded balanced and tied down See the appropriate Loading And Unloading section of this manual e Tongue weight and weight distribution set up e Ramps secured for travel e Fire extinguisher e Flares and reflectors 6 2 MAKE REGULAR STOPS After each 50 miles or one hour of towing stop and check the following items e Coupler secured e Safety chains are fastened and not dragging e Cargo secured XPress 55 7 BREAKING IN A NEW TRAILER 7 1 RETIGHTEN LUGS AT FIRST 10 25 amp 50 MILES Wheel lugs can shift and settle quickly after being first assembled and must be checked after the first 10 25 and 50 miles of driving Failure to perform this check ma
47. h and the breakaway pin is pulled The other brake is an electric braking system that acts whenever the brakes of the tow vehicle are applied Breakaway Battery This battery supplies the power to operate the trailer brakes if the trailer uncouples from the tow vehicle Be sure to check maintain and replace the battery according to the battery manufacturer s instructions Your trailer may use the hydraulic system battery to operate the breakaway brakes A CAUTION Extreme cold weather can degrade battery performance and cause brakes to not operate properly Check battery charge level before towing Breakaway Switch This switch engages the electric brakes if the trailer uncouples from the tow vehicle To check for proper functioning of the switch battery and brakes you must pull the pin from the switch and confirm that the brakes apply to each wheel You can do this by trying to pull the trailer with the tow vehicle after pulling the pin The trailer brakes may not lock but you will notice that a greater force is needed to pull the trailer A WARNING If electric breakaway brakes do not operate when trailer is uncoupled from the tow vehicle death or serious injury can occur Check emergency breakaway brake system before each tow XPress 61 9 2 2 4 TOW VEHICLE OPERATED ELECTRIC BRAKES The electric brakes that operate in conjunction with the tow vehicle brakes must be synchronized so that braking is prope
48. h ball is tight to the hitch before coupling the trailer 6 Raise the bottom surface of the coupler to be above the top of the hitch ball XPress 38 4 3 1 2 PREPARE COUPLER AND HITCH 1 Lubricate hitch ball and inside of coupler with a thin layer of automotive bearing grease 2 Remove safety latch pin and open coupler locking mechanism In the open position coupler is able to drop fully onto hitch ball See the coupler instructions for details of placing the coupler in the open position 3 Slowly back up tow vehicle so that hitch ball is near or aligned under coupler Engaged Released Your trailer may be equipped with a different style coupler If so see the coupler manufacturers operating instructions 4 3 1 3 COUPLE TRAILER TO TOW VEHICLE 1 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 2 Close latch and engage the coupler locking mechanism In the engaged position the locking mechanism securely holds the coupler to the hitch ball 3 Insert the safety lock pin through the hole in the locking mechanism 4 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 veh
49. 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 Ibs 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 Ibs 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 XPress 33 3 5 10 4 TIRE SAFETY TIPS Preventing Tire Damage e Slow down if you have to go over a pothole or other object in the road e Do not run over curbs or other foreign objects in the roadway and try not to strike the curb when parking Tire Safety Checklist e Check tire pressure regularly at least once a month including the spare e Inspect tires for uneven wear patterns on the tread cracks foreign objects or other signs of wear or trauma e Remove bits of glass and foreign objects wedged in the tread e Make sure your tire valves have valve caps e Check tire pressure before going on a long trip e Do not overload your vehicle Check the Tire Information and Loading Placard or User s Manual for the maximum recommended load
50. have this manual contact your dealer for assistance 9 2 2 2 MANUALLY ADJUSTING BRAKE SHOES Some braking systems are not automatically adjusted These brakes require manual adjustment The following steps apply to adjust most manually adjustable brakes Read your axle and brake manual to see how to adjust your brakes If you do not have this manual contact your dealer for assistance 1 Jack up the trailer and secure it on adequate capacity jack stands XPress 60 2 Be sure the wheel and brake drum rotate freely 3 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 4 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn Note Your trailer maybe equipped with drop spindle axles See axle manual for your axle type You will need a modified adjusting tool for adjusting the brakes in these axles 5 Rotate the star wheel in the opposite direction until the wheel turns freely with a slight drag 6 Replace the adjusting hole cover 7 Repeat the above procedure on all brakes 8 Lower the trailer to the ground 9 2 2 3 ELECTRIC BRAKES Two different types of electric brakes may be present on the trailer an emergency electric breakaway system which acts only if the trailer comes loose from the hitc
51. he wheels are blocked so that the trailer will not roll away 2 Fill the master cylinder with correct fluid 3 Install a bleeder hose on the bleeder screw of the farthest wheel cylinder from the actuator If the trailer has multiple axles bleed the rear axle first Submerse the other end of the hose in a glass container of brake fluid so that air bubbles can be observed Open the bleeder screw and have an assistant stroke but not release the actuator Brake fluid and or air bubbles will flow into the jar Close the bleeder screw The helper can then allow the actuator to return to its rest position Repeat the process until no more bubbles are released with the stroke Air trapped in the brake lines will greatly reduce your braking efficiency Be sure to close the bleeder screw securely when the cylinder is fully bled Repeat the bleeding operation at each wheel cylinder During the bleeding process replenish the master cylinder reservoir with fresh brake fluid so that the level does not fall below half full This will ensure that no air is drawn into the system After all brakes have been bled refill the master cylinder before operating Be sure to install the master cylinder filler cap A WARNING Use only fresh brake fluid from a sealed container DO NOT reuse fluid After filling and bleeding refill the actuator Failure to maintain an adequate fluid level may cause brake failure XPress 63 9 2 4 TRAILER
52. here 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 bot tom of the wheel will move the rear of the trailer to the left while backing up 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 2 2 16 SAFE TRAILER TOWING GUIDELINES Before towing check coupling safety chain brakes tires wheels and lights Check the lug nuts or bolts for tightness Re check the load tie downs to make sure the load will not shift during towing Check coupler tightness after towing 50 miles Adjust the brake controller to engage the trailer brakes before the tow vehicle brakes Follow the brake controller manufacturer s literature Use your mirrors to verify that you have room to change lanes or pull into traffic Use your turn signals well in advance Allow plenty of stopping space for your trailer and tow vehicle Use lower gears for climbing and descending grades Do not ride the brakes while descending grades they may get
53. hicle 5 Unlock the coupler and open it 6 Before extending jack make certain the ground surface below the jack pad will support the tongue load N Rotate jack handle to extend the jack and transfer the weight of the trailer tongue to the jack 8 Raise the trailer coupler above the tow vehicle hitch 9 Drive tow vehicle forward 4 5 TONGUE WEIGHT It is critical to have a portion of the trailer load carried by the tow vehicle That is the trailer tongue must exert a downward force on the hitch This is necessary for two reasons First the proper amount of tongue weight is necessary for the tow vehicle to be able to maintain control of the tow vehicle trailer system If for example the tongue exerts an upward pull on the hitch instead of pushing down on it because the trailer is overloaded behind its axle s the rear wheel of the tow vehicle can lose traction or grip and cause loss of control Also even if there is some weight on the tongue but not enough weight on the tongue the trailer can become unstable at high speeds Remember the faster you go the more likely the trailer is to sway If there is too much tongue weight the tow vehicle is prone to jack knife The front wheels of the tow vehicle can be too lightly loaded and cause loss of steer ing control and traction if the front wheels are driving In addition to tow vehicle control tongue weight is necessary to insure that the trailer axle s do not ex
54. ht Rating of your trailer 4 1 1 TRAILER INFORMATION The Certification Vehicle Identification Number VIN tag is located on the front curb side of the trailer The trailer Certification VIN tag contains the following critical safety information for the use of your trailer MANUFACTURER Name of trailer manufacturer DATE OF MANUFACTURE Morth 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 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 and load range for your trailer RIM SIZE The rim size and load range for your trailer PSI The tire air pressure kPa PSI measured with tires cold XPress 35 VIN The Vehicle Identifi cation Number VEHICLE TYPE Model or style
55. hts on a trailer are controlled via a connection to the tow vehicle generally a multi pin electrical connector A 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 e Check that the electric brakes work by operating the brake controller inside the tow vehicle e Check that all lights and turn signals work You must provide mirrors that allow you to safely observe approaching traffic Standard mirrors usually do not provide adequate visibility for viewing traffic to the sides and rear a towed trailer 2 2 14 TRAILER MODIFICATIONS Modification of the trailer structure or alteration of your trailer can make the trailer unsafe and will void all warranty options Before making any alteration to the trailer contact your dealer or the manufacturer and describe the alteration you are contemplating 2 2 15 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
56. icle by 1 inch after the coupler is locked to the hitch A NOTICE The tongue jack can be damaged by overloading Do not use the tongue jack to raise the tow vehicle more than 1 inch 5 If the coupler cannot be secured to the hitch ball do not tow the trailer Contact your dealer for assistance 6 Lower the trailer so that its entire tongue weight is held by the hitch and continue retracting the jack to its fully retraced position XPress 39 A CAUTION Drop leg jacks may be spring loaded and may rapidly return to the raise position when released Keep clear when releasing drop legs 7 Fully retract jack drop leg if equipped Go to Section 4 3 3 Connect Safety Chains to continue connecting trailer to tow vehicle 4 3 2 TRAILER WITH RING AND PINTLE COUPLER A ring on the trailer connects to the pintle that is located on or under the rear bumper of tow vehicle We have utilized a ring that is suitable for the size and weight of the trailer The load rating of the ring and the necessary pintle size are listed on the trailer tongue You must provide a pintle for your tow vehicle where the load rating of the hitch and pintle is equal to or greater than that of your trailer The pintle size must be the same as the ring size If the pintle is too small too large is underrated is loose or is worn the trailer can come loose from the tow vehicle and may cause death or serious injury The tow vehicle hit
57. in the same location as the certification label described above This placard provides tire and loading information In addition this placard will show a statement regarding maximum cargo capacity Cargo can be added to the trailer up to the maximum weight specified on the placard The combined weight of the cargo is provided as a single number In any case remember the total weight of a fully loaded trailer can not exceed the stated GVWR For trailers with living quarters installed the weight of water and propane also need to be considered The weight of fully filled propane containers is considered part of the weight of the trailer before it is loaded with cargo and is not considered part of the disposable cargo load Water however is a disposable cargo weight and is treated as such If there is a fresh water storage tank of 100 gallons this tank when filled would weigh about 800 pounds If more cargo is being transported water can be off loaded to keep the total amount of cargo added to the vehicle within the limits of the GVWR so as not to overload the vehicle Understanding this flexibility will allow you the owner to make choices that fit your travel needs When loading your cargo be sure it is distributed evenly to prevent overloading front to back and side to side Heavy items should be placed low and as close to the axle positions as reasonable Too many items on one side may overload a tire The best way to know the actual weigh
58. isibly solid against the trailer frame A WARNING A loose pintle can result in uncoupling leading to death or serious injury Make sure the pintle is tight to the hitch before coupling the trailer 6 Raise the bottom surface of the ring to be above the top of the open pintle 4 3 2 2 PREPARE RING AND PINTLE 1 Lubricate the inside of the pintle with a thin layer of automotive bearing grease 2 Remove the safety latch pin and open the pintle locking mechanism 3 In the open position the ring is able to drop fully onto the pintle Pintle Open Pintle Closed 4 See the coupler instructions for details of placing the pintle in the open position XPress 41 5 Slowly back up the tow vehicle so that the pintle is aligned under the ring 4 3 2 3 COUPLE GOOSENECK TRAILER TO TOW VEHICLE The gooseneck coupler installs onto a gooseneck ball that is pre installed on the bed of the tow vehicle A WARNING If the gooseneck ball on the tow vehicle does not meet or exceed the gooseneck coupler on the trailer in load rating and size the trailer could become uncoupled from the tow vehicle and injury or death could occur The gooseneck ball installed on the tow vehicle must be properly rated for size and weight of the trailer Check load ratings for size and weight of your trailer the gooseneck ball on the tow vehicle must meet or exceed the trailers ratings A CAUTION Lower the tailgate on th
59. kers Red O Brown O Red Blue Blue Electric Brake Brown Green RT Turn Brake White Blue Blue White Red Yellow LT Turn Brake Black Black Battery Charger TRAILER TOW VEHICLE 6 Round TM TM Plug Says Trailer Wired Function Yellow LT Yellow LT Left Turn Stop Green RT Green RT Right Turn Stop S S Blue S Blue S Electric Brake cp White GD White GD Ground Brown TM Brown TM Tail Marker Black A Black A Auxillary RT LT LT RT 4 Flat TRAILER TOW VEHICLE Ge White Ground S Green Brown Tail Marker ae Lisch Brown Yellow Left Turn _ Green Right Turn White TRAILER TOW VEHICLE White White 7 Semi Plug Says Trailer Wired Function Yellow Yellow Left Turn Green Green Right Turn Brown Brown Tail Marker White White Common Ground Red Red Stop Black Black ID amp Marker Blue Blue ABS Elec Brakes XPress 68 lp IRESS Manufactured and Distributed by Felling Trailers Inc 1525 Main St S e Sauk Centre MN 56378 1 800 245 2809 320 352 5230 Fax www felling com e trailers felling com 2015 Felling Trailers Inc Form XPOM 100 5 15 Printed in U S A
60. mber available for the dealer The VIN number is normally on the front left side of the trailer For future reference please write your VIN number in the space below This manual covers the basic trailer You must read understand and follow the instructions given by the trailer manu facturer tow vehicle and trailer hitch manufacturers Keep all manuals provided with your trailer in a safe place at all times Inserts providing information on axles and tire warranty are provided with this manual Please keep these inserts for future reference 2 SAFETY 2 1 SAFETY ALERT SYMBOLS AND SIGNAL WORDS 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 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 Our trailers are built with components produced by various manufacturers Some of these items have separate instruction manuals Where this manual indicates that you should read another manual and you do not have that manual contact your dealer for assistance The safety information in this manual is denoted by the safety alert symbol A This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The level of risk is indicated by the following signal words A DANGER DANGER Immediate
61. mining Correct Load Limit Tow Vehicle 22 3 4 Glossary Of Tire Terminologie 23 3 5 Tire Safety Everything Rides On It eee eeeesseeeeeeenteeeeeees 27 3 5 1 SAFETY FIRST BASIC TIRE MAINTENANCE oe 27 3 5 2 FINDING YOUR VEHICLE S RECOMMENDED TIRE PRESSURE AND LOAD LIMI TS asrasin 27 XPress 2 3 5 3 UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS 3 5 4 SAFETY FIRST BASIC TIRE MAINTENANCE n ssssieennen 3 5 5 STEPS FOR MAINTAINING PROPER TIRE PRESSURE 3 5 0 TIRE SIZE sonidan teninde 3 9 7 TIRE TREAD siiicar gadir 3 5 8 TIRE BALANCE AND WHEEL AUIOGNMENT ee 3 0 9 TIRE REPAIR sisssccssssccccctecetesvesencsccanecesasees 3 5 10 TIRE FUNDAMENTALS eee 3 5 10 1 INFORMATION ON PASSENGER VEHICLE TIRES 3 5 10 2 UTQGS Information en 3 5 10 3 Additional Information On Light Truck 3 5 10 4 Tire Safety TipS ceccceeeeseeeeeeeeees 4 COUPLING TO TOW VEHICLE 4 1 Tow Vehicle And Hitch 4 1 1 TRAILER INFORMATION nsen 41 2 TOW VEHICLE sssrinin inii ainena 4 2 Coupling And Uncoupling The Trailer 4 3 Couple Trailer To Tow Vebicle 4 3 1 BALL HITCH COUPLER nviisrerisssiusssuiisisss Tree 4 3 1 1 BEFORE COUPLING TRAILER TO TOW VEHICLE 4 3 1 2 PREPARE COUPLER AND HITCH 4 3 1 3 COUPLE TRAILER TO TOW VEHICLE 4 3 2 TRAILER WITH RING AND PINTLE COUPDLER 4 3 2 1 BEFORE COUPLING TRAILER TO TOW VEHICLE 4 3 2 2 PREPARE RING AND PINTLE
62. n 9 2 10 LUG NUTS OR BOLTS Lug nuts or bolts are prone to loosen right after a wheel is mounted to a hub When driving on a remounted wheel check to see if the lug nuts or bolts are tight after the first 10 25 and 50 miles of driving and before each tow thereafter A WARNING Tighten lug nuts or bolts before each tow Lug nuts or bolts are prone to loosen after being first assembled Metal creep between the wheel rim and lug nuts or bolts can cause rim to loosen Death or injury can occur if wheel comes off Tighten the lug nuts or bolts in three stages to the final torque for the axle size on your trailer to prevent wheels from coming loose Tighten each lug nut or bolt in the order shown in the following figure 1 1 1 4 3 3 4 3 8 A 4 5 2 2 2 2 4 BOLT 5 BOLT 6 BOLT 8 BOLT Use a calibrated torque wrench to tighten the fasteners Verify that wheel studs are free of contaminates such as paint or grease which may result in inaccurate torque readings Over tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels and will void the axle warranty See your axle manufacturers manual or your dealer for wheel nut or bolt torque specifications XPress 67 9 2 11 WIRING DIAGRAMS 7 RV TRAILER TOW VEHICLE Plug Says Trailer Wired Function Green Black Black Green White White Common Ground Center Pole Red Back up Lights Green Brown Tail Mar
63. n death or serious injury Do not move the trailer until e Coupler is secured and locked to hitch e Safety chains are secured to tow vehicle e Trailer jack s are fully retracted e Trailer brakes are checked e Tires and wheels are checked e Breakaway switch is connected to tow vehicle e The trailer lights are connected and checked e Load is secured to trailer 4 3 COUPLE TRAILER TO TOW VEHICLE The trailer may be equipped with a ball hitch coupler or a ring amp pintle coupler See the appropriate section for the coupler on your trailer 4 3 1 BALL HITCH COUPLER A ball hitch coupler connects to a ball that is located on or under the rear bumper of tow vehicle We have utilized a ball hitch coupler that is suitable for the size and weight of the trailer The load rating of the coupler and the necessary ball size are listed on the trailer tongue You must provide a hitch and ball for your tow vehicle that meets or exceeds the GVWR of the trailer The ball size must be the same as the coupler size If the hitch ball is too small too large is underrated is loose or is worn the trailer can come loose from the tow vehicle and may cause death or serious injury 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 the same size as the coupler The ball size and load rating capaci
64. ned weight of cargo being loaded on the vehicle That weight may not safely exceed the available cargo capacity calculated in Step 4 6 If your vehicle will be towing a trailer load from your trailer will be transferred to your vehicle Consult the vehicle s owner s manual to determine how this weight transfer reduces the available cargo and luggage capacity of your vehicle XPress 22 3 4 GLOSSARY OF TIRE TERMINOLOGY 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 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
65. oad from shifting while towing 2 2 12 INAPPROPRIATE CARGO The trailer may be designed for specific cargo If your trailer is designed for specific cargo only carry that cargo in the trailer A trailer must not be used to carry certain items such as people containers of hazardous substances or containers of flammable substances A WARNING Do not transport people on your trailer Besides putting their lives at risk the transport of people on a trailer is illegal A WARNING Do not transport flammable explosive poisonous or other dangerous materials on your trailer The exception is fuel in the tank of a vehicle or equipment being hauled XPress 13 2 2 13 INOPERABLE BRAKES OR 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 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 If your trailer has hydraulic surge brakes pull the emergency breakaway brake lanyard to check the operation of the surge mechanism Be sure that the electric brakes and all of the lights on your trailer are function ing properly before towing the trailer Electric brakes and lig
66. odel name molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing side wall 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 maxi mum permissible inflation pressure for that tire Maximum permissible inflation pressure The maximum cold inflation pressure to which a tire may be inflated 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 Pin Weight The downward force applied to the 5th wheel or gooseneck ball by the trailer kingpin or gooseneck coupler Non pneumatic rim A mechanical device which when a non pneumatic tire assembly incorpo rates 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 passeng
67. of trailer CERTIFICATION STATEMENT This trailer meets all the Federal Motor Vehicle Safety Standards in effect on the date of manufacture shown above 4 1 2 TOW VEHICLE When equipping a new vehicle or an older vehicle to tow a trailer ask the vehicle dealer for advice on how to outfit the tow vehicle Vehicle manufacturers will provide you with the maximum towing capacities of their various models as well as the GCWR No amount of reinforcement will give a 100 horsepower 2 500 pound truck the towing capacity that a 300 horsepower 5 000 pound truck has 4 2 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 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 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 Safety chains Chains permanently attached to the trailer such that if the coupler connection comes loose the safety chain
68. 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 maxi mum 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 Gross Axle Weight Rating The maximum weight that any axle can support as published on the Certifica tion VIN label on the front left side of the trailer Actual weight determined by weighing each axle on a public scale with the trailer attached to the towing vehicle Gross Vehicle Weight Rating The maximum weight of the fully loaded trailer as published on the Certification VIN label Actual weight determined by weighing trailer on a public scale without being attached to the towing vehicle Hitch weight The downward force exerted on the hitch ball by the trailer coupler 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 XPress 23 Intended outboard sidewall The sidewall that contains a white wall bears white lettering or bears manufac turer brand and or m
69. ongue Weight as a Percentage of Loaded Trailer Weight Type of Hitch Ball Hitch or 10 15 for large trailers Ring amp Pintle 6 10 for small trailers The numbers quoted are for example purposes only and should be tailored to the specific trailer For questions regarding the actual percent of tongue weight for the trailer check with the manufacturer for specifics After loading be sure to check that none of the axles are overloaded Uneven left right load distribution can cause tire wheel axle or structural failure XPress 12 Be sure your trailer is evenly loaded left right Towing stability also depends on keeping the center of gravity as low as possible A WARNING Improper tongue weight load distribution can result in loss of control of the trailer leading to death or serious injury Make certain that tongue weight is within the allowable range Be sure to e Distribute the load evenly right and left e Keep the center of gravity low e Distribute the load front to rear to provide proper tongue weight see chart 2 2 11 SHIFTING CARGO Since the trailer ride can be bumpy and rough you must secure the cargo so that it does not shift while the trailer is being towed A WARNING A shifting load can result in failure or to loss of control of the trailer and can lead to death or serious injury You must tie down all loads with proper sized fasteners chains straps etc to prevent the l
70. or trailer to turn D Gei 5 Allow Slack for Turni 3 ATTACH chain hooks securely to tow hs vehicle frame Cross Chains Under Coupler XPress 16 Trailer can roll if it comes loose Safety brake applies when chain pulls brake lever 1 ATTACH brake CHAIN securely to tow vehicle so lever will be pulled if trailer separates 2 Check brake fluid level 3 DO NOT tow trailer if brake fluid is not full Trailer can roll if it comes loose Electric safety brake applies when cable pulls pin out of switch box 1 PULL hard to get pin out of switch box 2 Check brake by pulling trailer with tow vehicle 3 Attach pin cable to tow vehicle so pin will be pulled out if trailer separates 4 Promptly replace pin in switch box Improper loading can cause trailer sway and sudden loss of control Operator MUST e Make certain weight of load plus trailer weight DO NOT exceed trailer s capacity GVWR Gross Vehicle Weight Rating e Load heavier items in front of wheels e Load evenly side to side e Secure load to trailer Tire wheel or lug nut failure can cause loss of control Before towing Operator MUST check 1 Tire pressure and tread wear 2 Tires and wheels for damage 3 Lug nuts for tightness For new remounted wheels re tighten lug nuts at the first 10 25 and 50 miles of driving Break Away Attach To Brake Chain Tow Vehicle Pull Pin Out Only To Test Brakes Attach Cable To Tow Vehicle
71. oth even brake operation XPress 47 Move the trailer to flat level ground pulling FORWARD several feet before park ing This forward motion will ensure trailers equipped with free backing brakes are in their normal operating mode Disconnect the trailer from the tow vehicle and jack up the trailer s tongue until it is horizontal Hook the trailer s safety chains NOT the actuator s breakaway cable together to form a loop which is centered below the actuator s coupler Place wheel chock blocks two feet behind the trailer to prevent a runaway trailer Place a sturdy board such as a 2 inch by 4 inch piece of lumber into the chain loop below the coupler The board should be 4 feet or longer so it will extend several feet above the actuator Keep the end of the board a few inches off the ground and position it to press against the front end of the actuator s coupler Press the board towards the rear of the trailer Keep pressing the top of the board to stroke the actuator and its internal master cylinder If the trailer brake system is operational the brakes will apply and keep the trailer from rolling away from you Properly adjusted uni servo or duo servo type brakes will prevent you from moving the trailer back more than a few inches Free backing type brakes will initially provide rolling resistance but continued force on the board will switch them into free backing mode and you ll be able to move the trailer backwards
72. otive 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 6 Ibs 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 The nominal diameter of the bead seat Rim size designation The rim diameter and width Rim type designation The industry of manufacturer s designa tion for a rim by style or code Rim width The nominal distance between rim flanges Section width The linear distance between the exte riors of the sidewalls of an inflated tire excluding elevations due to labeling decoration or protective bands Sidewall That portion of a tire between
73. ous impact has occurred 9 2 8 TIRES Before each tow check the tire pressure to make sure it is at the level indicated on the tire sidewall or VIN label Tire pressure must be checked while the tire is cold Do not check tire pressure immediately after towing the trailer Allow at least three hours for the tires to cool if the trailer has been towed for as much as one mile Tires can lose air over a period of time Replace the tire before towing the trailer if the tire treads have less than 2 32 inch depth or the telltale bands are visible A bubble cut or bulge in a side wall can result in a tire blowout Inspect both side walls of each tire for any bubble cut or bulge and replace a damaged tire before towing the trailer If you are storing your trailer for an extended period make sure the tires are inflated to the maximum rated pressure indicated on the sidewall or VIN label and that you store them in a cool dry place such as a garage Use tire covers to protect the tires from the harsh effects of the sun XPress 65 TIRE INSPECTION CHART Check amp Adjust Pressure When Cold Even Center Wear Over Inflation Check amp Inside amp Under Adjust Outside Wear Inflation Pressure When Cold Check amp Unload As Necessary Smooth Loss of Side Wear Camber or One Side Overloading Have Alignment Checked Feathering G
74. re valve stem with the edge of your tire gauge until you get to the correct pressure e 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 e Step 5 At a service station add the missing pounds of air pressure to each tire that is underinflated e 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 informa tion 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 3 5 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 repla
75. revent severe damage to your trailer inspect all of the welds for cracks or failure at least once a year If a weld failure is detected contact your dealer A WARNING Do not attempt to repair a cracked or broken weld unless you have the skills and equipment to make the repair Improper weld repair will lead to early failure of the trailer structure and serious injury or death See your dealer for weld repairs A WARNING Broken or damaged welds can cause injury or damage to trailer and contents Inspect for and repair all damaged parts at least once a year 9 2 2 TRAILER BRAKES ELECTRIC 9 2 2 1 BRAKE DISCS SHOES AND DRUMS Properly functioning brake shoes and drums are essential to ensure safety You must have your dealer inspect these components at least once per year or each 12 000 miles Brake adjustment is not covered under the axle warranty The brake shoes must be adjusted after the first 200 miles of use and each 3 000 miles thereafter Most axles are fitted with a brake mechanism that will automatically adjust the brake shoes when the trailer is hard braked from a rearward direction Trailer disc brakes are self adjusting and do not need to be periodically adjusted Using pads or shoes without enough brake lining material can result in brake damage create excessive heat and potentially cause the loss of braking capacity Read your axle and brake manual to see how to adjust your brakes If you do not
76. rly distributed to the tow vehicle brakes and the trailer brakes For proper operation and synchronization read and follow the axle brake and the brake controller manufacturers instructions If you do not have these instructions contact your dealer for assistance 9 2 2 5 ELECTRIC BRAKE MAGNETS To make certain an electrically operated braking system will function properly you must have your dealer inspect the magnets at least once a year or each 12 000 miles See the brake manual for wear and current inspection instructions 9 2 3 TRAILER BRAKES SURGE IF EQUIPPED 9 2 3 1 SURGE BRAKE MASTER CYLINDER Check fluid level prior to using the trailer The master cylinder is normally located on the tongue of the trailer The fluid level must be maintained at full mark on reservoir Check with your dealer for the type of brake fluid used in the brake system 9 2 3 2 HYDRAULIC SURGE BRAKE Before each tow perform the following steps 1 Check that the brake master cylinder level is as instructed above Check for leaks and repair as required 2 Examine the actuator for wear bent parts corroded seized parts or other damage Have the affected components replaced with genuine service parts 3 Check to determine that the actuator mounting bolts are tightened to the manufacturer s specification 4 Test the actuator and brake function as described in the Coupling To Tow Vehicle section of this manual Actuator trav
77. rs Quality Craftsmanship and Pride 1525 Main Street South e Sauk Centre MN 56378 e Office 320 352 5239 1 800 245 2809 e Fax 320 352 5230 www felling com e trailers felling com e Felling Trailers Inc XPress 1 1 INTRODUC TON irinari 6 2 SAPETY ersinnen ara ete ence ede ed 6 2 1 Safety Alert Symbols And Signal Words A 6 22 M jor e EE EE 7 2 2 1 IMPROPER SIZING OF TRAILER TO TOW VEHICLE 7 2 2 2 DRIVING TOO FAST apisan inie 7 2 2 3 ADJUST DRIVING WHEN TOWING TRAILER osceecen 8 2 2 4 TRAILER NOT PROPERLY COUPLED TO HITCH oaaasaiaaa 8 2 2 5 PROPER USE OF SAFETY CHAINS A 9 2 2 6 PROPER CONNECTION OF BREAKAWAY DDAKE 10 2 2 7 MATCHING TRAILER AND HITCH A 10 2 2 8 WORN TIRES LOOSE WHEELS AND LUG NUTS 10 2 2 9 IMPROPER LOADING AAA 12 2 2 10 UNSAFE LOAD DISTRIBUTION AA 12 22d SHIFTING CARGO eebe ege oora egee diese te 13 2 2 12 INAPPROPRIATE CARGO cc cceeeceeeeeeeeeteeeeeettaeeeeeeees 13 2 2 13 INOPERABLE BRAKES OR LIGHTS o ae 14 2 2 14 TRAILER MODIFICATIONS AA 14 2 2 15 TRAILER TOWING GUIDE AA 14 2 2 16 SAFE TRAILER TOWING GUIDELINES cere 15 2 2 17 SAFETY WARNING LABELS ON YOUR TRAILER 16 2 2 18 REPORTING SAFETY DEFECTS AAA 18 3 TIRE SAFETY INFORMATION cessum 19 3 1 Trailer Tire INfOrmation sanimin 19 3 2 Steps For Determining Correct Load Limit Trailer 20 3 2 1 TRAILERS 10 000 POUNDS GVWR OR LESS eee 21 3 2 2 TRAILERS OVER 10 000 POUNDS GW 22 3 3 Steps For Deter
78. s can keep the trailer attached to the tow vehicle With properly rigged safety chains 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 Trailer lighting and braking connector A device that connects electrical power from the tow vehicle to the trailer In addition if your trailer has a sepa rate braking system the electrical connector will also supply power to the trailer brakes from the tow vehicle Breakaway switch If the trailer becomes uncoupled from the tow vehicle the breakaway switch lanyard attached independently to the tow vehicle hitch will pull a pin in the emergency electrical breakaway switch on the trailer The break away switch is activated by a battery on the trailer to energize the trailer brakes independently of the towing vehicle It is important to check the state of charge of the emergency breakaway 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 signifi cant drag force the brakes are activated Be sure to re insert the pin in the breakaway switch Also be sure to allow enough slack in the breakaway brake lanyard such that the switch will only activate pin pulls out XPress 36 if the coupler connection comes loose Jack A device on the trailer that is used to raise and lower the trailer tongue A WARNING An improperly coupled trailer can result i
79. t of the vehicle is to weigh it at a public scale Talk to your dealer to discuss the weighing methods needed to capture the various weights related to the trailer This would include the weight empty or unloaded weights per axle wheel hitch or king pin and total weight Excessive loads and or underinflation cause tire overloading and as a result abnormal tire flexing occurs This situation can generate an excessive amount of heat within the tire Excessive heat may lead to tire failure It is the air pressure that enables a tire to support the load so proper inflation is critical The proper air pressure may be found on the certification VIN label and or on the Tire Placard This value should never exceed the maximum cold inflation pressure stamped on the tire 3 2 1 Trailers 10 000 Pound GVWR or Less DA TIRE AND LOADING INFORMATION 24010118 The weight of cargo should never exceed 907 kg or 2000 Ibs m Le COLD TIRE PRESSURE SEE OWNER S ADDITIONAL a ane XPress 21 1 Locate the statement The weight of cargo should never exceed XXX kg or XXX Ibs on your vehicle s placard 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 4 The trailer s placard refers to the Tire Information Placard attache
80. 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 XPress 25 Treadwear indicators TWI The projections within the principal grooves designed to give a visual indica tion of the degree of wear of the tread Vehicle capacity weight The rated cargo and luggage load plus 68 kilograms 150 Ibs 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 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
81. thers from avoidable breakdowns and accidents e Improve fuel economy e Increase the life of your tires This booklet presents a comprehensive overview of tire safety including information on the following topics e Basic tire maintenance e Uniform Tire Quality Grading System e Fundamental characteristics of tires e 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 inconve nience and safety consequences of a flat tire or other tire failure 3 5 1 SAFETY FIRST BASIC MAINTENANCE Properly maintained tires improve the steering stopping traction and load car rying 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 3 5 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 e Recommended tire size e Recommended tire inflation pressure e Vehicle capacity weight VCW the maximum occupant and cargo weight a XPress 27 vehicle is designe
82. tion and proper tongue weight The total weight of the trailer and its contents must never exceed the total weight rating of the trailer Gross Vehicle Weight Rating or GVWR Do not transport people containers of hazardous substances or flammable liquids The exception is fuel in the tank of vehicles or equipment being hauled A WARNING Do not transport flammable explosive poisonous or other dangerous materials on your trailer The exception is fuel in the tank of a vehicle or equipment being hauled A WARNING Do not transport people on your trailer Besides putting their lives at risk the transport of people on a trailer is illegal XPress 52 5 1 LOADING TRAILER 5 1 1 PREPARING TRAILER FOR LOADING 1 Inspect the floor of the trailer 2 Inspect the tie down rings and track system for damage looseness or signs of bending before loading the trailer A WARNING Damaged or loose tie down rings or track can break allowing cargo to become loose Loose cargo can shift the center of gravity and result in loss of control of the trailer Inspect and test tie downs and track before loading cargo Do not use a damaged or loose tie downs or track to secure cargo 3 Park the tow vehicle and trailer on a firm and level surface 4 Clear the area around the trailer 5 1 2 LOADING A RIGID DECK TRAILER 1 Couple the trailer to the tow vehicle A WARNING Trailer must be coupled to tow vehicle
83. ty are marked on the ball hitch capacity is marked on the hitch XPress 37 4 3 1 1 BEFORE COUPLING TRAILER TO TOW VEHICLE 1 Be sure the size and rating of hitch ball match the size and rating of the coupler Hitch balls and couplers are marked with their size and rating A 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 2 Wipe the hitch ball clean and inspect it visually and by feel for flat spots cracks and pits A 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 3 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 4 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 5 Be sure the coupler is tight to the tongue of the trailer All coupler fasteners must be visibly solid against the trailer frame A WARNING A loose hitch ball nut can result in uncoupling leading to death or serious injury Make sure the hitc
84. uspension parts springs torsion bars etc Place jacks and jack stands under the outer frame rail to which the axles are attached A WARNING Never go under trailer unless it is on firm and level ground and resting on properly placed and secured jack stands A WARNING Crushing hazard The tow vehicle and trailer could be inadvertently moved while a person is under the trailer The tow vehicle engine must be off ignition key removed and parking brakes set before entering the area under the trailer 9 2 1 TRAILER STRUCTURE Wash the trailer as needed with a power washer and a detergent solution 9 2 1 1 FASTENERS AND FRAME MEMBERS Inspect all fasteners and structural frame members for bending and other damage cracks or failure Repair or replace any damaged fastener and repair the frame member If you have any questions about the condition or method of repair of fasteners or frame members get the recommendation of or have the repair done by your dealer A WARNING Broken or damaged fasteners can cause injury or damage to trailer and contents Inspect for and repair all damaged parts at least once a year XPress 59 9 2 1 2 WELDS All welds can crack or fail when subjected to heavy loads or movement of cargo that was not properly secured Any time that you know or suspect that the trailer has been subjected to heavy loads or movement of cargo immediately inspect the welds and fasteners for damage To p
85. ust match coupler size e Be sure hitch load rating is equal to or greater than load rating of the coupler e Be sure hitch components are tight before coupling trailer to tow vehicle e Observe hitch for wear corrosion and cracks before coupling e Replace worn corroded or cracked hitch components before coupling trailer to tow vehicle A WARNING An improperly coupled trailer can result in death or serious injury Do not move the trailer until e Coupler is secured and locked to hitch e Safety chains are secured to tow vehicle e Trailer jack s are fully retracted e Trailer brakes are checked e Tires and wheels are checked e Breakaway switch is connected to tow vehicle e The trailer lights are connected and checked e Load is secured to trailer 2 2 5 PROPER USE OF SAFETY CHAINS Safety chains are provided so that control of the trailer can be maintained if your trailer comes loose from the hitch A 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 Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up if the trailer comes loose 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 XPress 9 2 2 6 PROPER CONNECTIO
86. vities If you do not have this manual contact your dealer for assistance If you see or feel evidence of wear such as flat spots deformations pitting or corrosion on the ring or pintle immediately have your dealer inspect them to determine the proper action to prevent possible failure of the ring and pintle system All bent or broken coupler parts must be replaced before towing the trailer The pintle handle lever must be able to rotate freely and automatically snap into the latched position Oil the pivot points sliding surfaces and spring ends with SAE 30W motor oil Keep the ring pocket and latch mechanism clean Dirt or contamination can prevent proper operation of the latching mechanism When replacing a ring the load rating must match or exceed the GVWR of the trailer 9 2 5 LANDING LEG OR JACK If a grease fitting is present use a grease gun to lubricate the jack mechanism Grease the gears in the top of hand cranked jacks once a year by removing the top of the jack and pumping or hand packing grease into the gears XPress 64 9 2 6 LIGHTS AND SIGNALS Before each tow check all trailer lights for proper operation A WARNING To avoid risk of collisions all lights must work 9 2 7 WHEEL RIMS If the trailer has been struck or impacted on or near the wheels or if the trailer has struck a curb inspect the rims for damage Replace any damaged wheel Inspect the wheels for damage every year even if no obvi
87. wheel a mechanical device which attaches either integrally or separably to the non pneu matic rim and provides the connection between the non pneumatic rim and the vehicle or in the case of a non pneu matic tire assembly not incorporating a wheel a mechanical device which attaches either integrally or separably to the non pneumatic 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 XPress 26 3 5 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 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 e Improve vehicle handling e Help protect you and o
88. y result in a wheel coming loose from the trailer causing a crash leading to death or serious injury Improper tightening of the lug nuts or bolts voids the axle warranty Refer to the Inspection Service and Maintenance section of this manual A WARNING Lug nuts or bolts are prone to loosen after being first assembled Death or serious injury can result Check lug nuts or bolts for tightness on a new trailer and after re mounting a wheel at 10 25 and 50 miles 7 2 ADJUST BRAKE AT FIRST 200 MILES Brake shoes and drums experience a rapid initial wear The brakes must be adjusted after the first 200 miles of use and each 3 000 miles thereafter Some axles are fitted with a mechanism that will automatically adjust the brake shoes Read your axle and brake manual to see if your brakes adjust automatically If you do not have the axle and brake manual contact your dealer for assistance If your trailer is not fitted with automatically adjusting brakes the brakes will need to be manually adjusted See section 9 for instructions 7 3 SYNCHRONIZING BRAKE SYSTEMS Trailer brakes are designed to work in synchronization with the brakes on the tow vehicle When the tow vehicle and trailer braking systems are synchronized both braking systems contribute to slowing and the tongue of the trailer will neither dive nor rise sharply A WARNING If trailer and tow vehicle brakes do not work properly together death or s

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