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Table of Contents i SECTION 1

1. Section 1 Safety Information An improperly coupled trailer can result in death or serious injury Do not move the trailer until e The coupler is secured and locked e The safety chains are secured to the tow vehicle and e The trailer jacks are fully retracted Do not tow the trailer on the road until The trailer brakes are checked The breakaway switch is connected to the tow vehicle The load is secured to the trailer and The trailer lights are connected and checked 1 2 6 Proper Use of Safety Chains Safety chains are provided so that control of the trailer can still be maintained if the trailer comes loose from the tow vehicle for any reason Incorrect 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 Chains must e Fasten to frame of tow vehicle not to hitch or ball e Cross underneath hitch and coupler with minimum slack to permit turning and to hold tongue up if the trailer comes loose 1 2 7 Proper Connection 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 for any reason You will have a separate set of instructions for the breakaway brake if your trailer is so equipped The breakaway brake system including battery mus
2. 10 17 2008 Page 64 To avoid collisions taillights stoplights and turn signals must work 8 2 9 Accessory Battery Your trailer may be outfitted with an accessory battery that operates lighting electric landing gear slide outs or other accessories An accessory battery may be kept charged either by the tow vehicle or by the generator or shore power See the manual for the accessory battery A disconnect switch may be provided to disconnect the accessory battery when you do not plan to be using the trailer for an extended period such as seasonal storage If there is no disconnect switch then remove the cables from the battery terminals The accessory battery must be kept in a charged condition during storage The battery could freeze and break if it becomes discharged 8 2 10 Tires Before each tow be sure the tire pressure is at the value indicated on the Certification VIN label Tire pressure must be checked while the tire is cold Do not check the tire pressure immediately after towing the trailer Allow at least three hours for a tire to cool if the trailer has been towed for as much as one mile 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 W
3. 55 6 4 TIRE PRESSURE orirsiscsinieinciivadosesodeeasatiinosiiornan 55 SECTION 7 ACCESSORIES scscssssssiscssssonsesosnsssesesees3 56 7 1 GASOLINE OR DIESEL POWERED ELECTRIC GENERATOR seacasecaynsuyauenovesarereuscnisanesaunrueoeennecncaeaeieasas 56 1 2 ACCESSORY BATTERY secsnccncecsnsncwaaaareene stants 56 ko SHORE POWER c ccanecesteoraranacarqussenscugesenareateeacaseonans 56 7 4 LP GAS FUEL SYSTEM sscceossarecesseesatenncarqacerneencecones 37 7 4 1 LP Gas System Troubleshooting ccccccceeee 58 L3 VENDING amp ACCESSORY DOORG seeeeeeees 58 Table of Contents 7 6 ELECTRIC POWERED LANDING GEAR 000008 58 SECTION 8 INSPECTION SERVICE amp MAINTENANCE icisscstcccrescctcesdecenscheveticisteacesesebedasziestasseesiced 59 8 1 INSPECTION SERVICE amp MAINTENANCE SUMMARY ATA IR US E E P A E TE E S 59 8 2 INSPECTION AND SERVICE INSTRUCTIONS 61 6 2 1 Axle Bolts Frame Suspension amp Structure 61 Sle Trailer SUC 0 ec sass sctsacusv cons dbastoasacasceueeustneses 6l 8 2 2 a Fasteners and Frame Members 0008 61 8 2 2 b Fe 0 ae ree ee ee N 61 8 2 3 Drop Ramp Torsion Springs 62 8 2 4 Slide OuUtS csessserssesrsisrisarrsarorarsisresarrsarrsarrsaacs 62 6 2 93 Trailer Braks cosarcccaracadscacesncinsntsaosorsescnenendsaaiass 62 8 2 5 a Initial INS PC CHO scscss sovorcurseremeancactiaeaushsenbeanccives 62 S250 Periodic Inspection scisiiucneaetasuccnnsuciereaemes
4. Section 2 Tire Safety Information CT A pneumatic tire with an inverted flange tire and rim system in which the rim is designed with rim flanges pointed radially inward and the tire is designed to fit on the underside of the rim in a manner that encloses the rim flanges inside the air cavity of the tire Curb weight The weight of a motor vehicle with standard equipment including the maximum capacity of fuel oil and coolant and if so equipped air conditioning and additional weight optional engine Extra load tire A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire Groove The space between two adjacent tread ribs Gross Axle Weight Rating The maximum weight that any axle can support as published on the Certification 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
5. A loose gooseneck ball can result in uncoupling leading to death or serious injury Make sure the gooseneck ball nut is tight before coupling the trailer e Wipe the inside and outside of the receiver clean and inspect it visually for cracks and feel the inside of the receiver for worn spots and pits If any of 3 2 2 0 Section 3 Coupling To The Tow Vehicle these conditions exist have the receiver replaced before coupling the trailer Lubricate the inside of the gooseneck ball receiver with automotive bearing grease Be sure the receiver is tight to the trailer All receiver fasteners must be visibly solid against the trailer frame Release the jack handle or crank from its holder see Drop Leg Jack figure 3 9 Rotate the handle crank clockwise to raise the bottom surface of the gooseneck to be above the top of the gooseneck ball If the tow vehicle has a tailgate lower it Prepare the Ball Receiver and Gooseneck Ball Release the lock plate on the gooseneck ball receiver With the spring loaded lock plate locking pin in the OPEN position rotate the lock plate to a position that allows the gooseneck ball to enter the receiver see Gooseneck Ball Receiver and Height Adjustment figure 3 8 Slowly back up the tow vehicle so that the gooseneck ball is aligned under the gooseneck ball receiver jack test to see that you can raise the rear of the tow vehicle by 1 inch NOTICE The drop leg
6. by feel for flat spots cracks and pits Check the condition of the kingpin mounting in the bed of the tow vehicle Section 3 Coupling To The Tow Vehicle A worn bent cracked or corroded kingpin can fail while towing and may result in death or serious Check the kingpin and kingpin plate for wear bending cracks or corrosion before coupling Replace worn bent cracked or corroded kingpin before coupling the trailer e Be sure the fifth wheel mechanism operates freely Lubricate the fifth wheel plate surface with a light coat of Lithium base waterproof grease e Be sure the fifth wheel and kingpin fasteners are tight and any welds are solid A loose fifth wheel or kingpin can result in uncoupling leading to death or serious injury Make sure the fifth wheel and kingpin are tight before coupling the trailer e Be sure the brake line electrical line and any other lines are clear of the coupling area 3 2 3 b Adjust Hitch Height It is your responsibility to have the height of the king pin or fifth wheel adjusted to match the height of the fifth wheel or king pin in your tow vehicle Proper height adjustment is required to provide clearance between the bottom of the trailer and sides of the tow vehicle bed to obtain level running of the trailer and to permit equal weight distribution on the axles Your Haulmark dealer is able to perform the coupler height adjustment to match the trailer to your towing vehicl
7. 25 and 50 miles of driving and before each tow thereafter Failure to perform this check can result in a wheel parting from the trailer and a crash leading to death or serious injury Lug nuts are prone to loosen after being first assembled Death or serious injury can result Check lug nuts for tightness on a new trailer and after re mounting a wheel at 10 25 and 50 miles 10 17 2008 Page 4 Inadequate lug nut torque can cause a wheel to part while towing Death or serious injury can result Make sure lug nuts are tight before towing trailer 1 2 10 Weight And Load Distribution Proper loading of your trailer is essential for your safety Tire wheel axle or structural failure can be caused by overloading An overloaded trailer can result in failure or in 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 Never exceed an axle Gross Axle Weight Rating GAWR Improper front rear load distribution can lead to poor trailer sway stability or poor tow vehicle handling Poor trailer sway stability results from tongue weights that are too low and poor tow vehicle stability results from tongue weights that are too high In figure 1 1 the second column shows the rule of thumb percentage of total weight of the trailer plus its cargo Gross Trailer W
8. 5 c Manually Adjusting Brake Shoes for instructions 6 3 SYNCHRONIZING THE BRAKE SYSTEMS Trailer brakes are designed to work in synchronization with the brakes on the tow vehicle 10 17 2008 Page 55 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 If trailer and tow vehicle brakes do not work properly together death or serious 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 6 4 TIRE PRESSURE Check tire pressures on both the trailer and tow vehicle Inflate to the value indicated on the Certification VIN label Section 7 This section provides some basic information for the safe operation of several accessories For many accessories such as generators and LP appliances the manufacturer of the accessory has also provided instructions You must read and follow these instructions before using the accessory If you are uncertain whether you have all of the instructions call Haulmark Industries Inc at 800 348 7530 or your dealer before operating the accessory The following accessories are described in this section e Gasoline or LP and Diesel Generators e Accessory Battery e Shore
9. Do not use an extension cord to connect to shore power Open doors for ventilation Shut off LP gas supply at the LP tank Leave the area until odor clears 1 2 18 LP Gas Fuel System Correct the source of LP gas leakage A DANGER Replace fuses with like rating before using LP appliances Do not use a flame to locate the source of an LP gas leak You can die or be brain damaged by Carbon Monoxide Make certain the exhaust from LP 1 2 19 Gas And Fuel Storage appliances is directed to the outdoors Have a working carbon monoxide detector in the accommodation spaces of your trailer before operating any LP gas appliance Do not transport flammable explosive poisonous or other dangerous materials in your trailer Exceptions Do not operate portable grills portable stoves portable lanterns or portable heaters inside the trailer e Fuel in the tanks of vehicles that are being towed e Fuel stored in proper containers used in trailer living quarters for cooking Fuel stored in the tank of an on board generator Risk of death due to fire or explosion Do not connect an LP gas system to a supply of natural gas Extinguish all pilot lights and turn off all Accumulation of hazardous fumes can appliances before refilling fuel or LP gas cause death or serious injury tanks Saa Do not block access to ventilation ports Do not fill the tank with any gas other than LP butane or propane Do not store LP gas
10. E a We gage 5 see Located on interior sidewall of trailer Electrical Inspected By Located on swing out lamp arm Located inside closet door 10 17 2008 Page 17 Section 1 Safety Information Any motorized vehicle or any motorized mag eaj powered with flammable liquid can cause fire or explosion or asphyxiation if stored or transported within the recreational vehicle To reduce the risk of fire explosion or asphyxiation 1 Do not allow passengers to ride inside internal combustion engine vehicle storage area while vehicles are present 2 Doors and windows in walls of separation are to be closed while the vehicles are present 3 a fuel out of engine after shutting off fuel at the Tank 4 Do not store or transport supplementary motor fuel within this vehicle 5 Ventilate the interior of the vehicle to reduce the risk ol fire explosion or asphyxiation 6 Do nol operate gas appliances pilot lights or electrical equipment when motorized vehicles or motorized equipment are inside vehicle ia im Stickers in location 1 ICC Tire and Loading Information HA2006 Overload Hazard Warning Wheel Lug Tightness Notice NATM Warning Labels and Locations Figure 1 1 10 17 2008 Page 18 Section 1 Safety Information Stickers in location 2 OK to Ship Inspection Read Owner s Manual Warning HA2068 Breakaway Battery Notice HA2049 on battery box if applicable Breakaway Battery C
11. In addition you will need a longer distance to pass due to slower acceleration and increased length With this in mind e Be alert for slippery conditions You are more likely to be affected by slippery road surfaces when driving a tow vehicle with a trailer than driving a tow vehicle without a trailer e Anticipate the trailer swaying Swaying can be caused by excessive steering wind gusts roadway edges or by the trailer reaction to the pressure wave created by passing trucks and busses 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 steering adjustments Do not attempt to steer out of the sway you ll only make it worse Also do not apply the tow vehicle brakes to correct trailer swaying The application of the trailer brakes alone will tend to straighten out the combination especially when going downhill e Check rearview mirrors frequently to observe the trailer and traffic 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 e Be aware of your trailer height especially when approaching bridges roofed areas and around trees 10 17 2008 Page 2 1 2 4 Improper Loading The total weight of the load you put in or on the trailer plus the empty weight of the trailer itself must not exceed
12. LT The LT indicates the tire is for light trucks or trailers Max Load Dual kg lbs at kPa psi Cold This information indicates the maximum load and tire pressure when the tire is used as a dual that is when four tires are put on each rear axle a total of six or more tires on the vehicle Max Load Single kg lbs at kPa psi Cold This information indicates the maximum load and tire pressure when the tire is used as a single Load Rating This information identifies the tire s load carrying capabilities and its inflation limits 2 6 10 d Information on Special Trailer ST Tires Please refer to the following diagram 10 17 2008 Page 30 Approved Rim Manufacturer Load Range Safety Special Trailer US DOT ID Number Yost Sd S9 ya nos AN ay tL By OSti GvOl ys Load amp Inflation Limits Tires designated for trailers only have other markings besides those found on the sidewalls of passenger tires ST An ST is an indication the tire is for trailer use only ST tires are designed for carrying heavy loads at lower speeds The Tire and Rim Association Standard indicates that for operation at speeds up to 65 mph no change in maximum cold tire inflation pressure or load is required For speeds between 66 75 mph increase the maximum cold tire inflation pressure 10 psi Max Load Dual kg lbs at kPa psi Cold This information indicates the maximum load and tire pressure when the tire is
13. Power connections which provide power by plugging the trailer in to an external source of electrical power e LP Gas Fuel System e Vending or Accessory Doors e Electric powered Landing Gear Many accessories introduce the risk of fire and carbon monoxide poisoning If you have an accessory on your trailer make sure you have a fire extinguisher charged and ready before operating the accessory Check the fire extinguisher at least once a month If the fire extinguisher is discharged even partially it must be recharged Follow the fire extinguisher manufacturer s instructions for recharging the extinguisher after use 7 1 GASOLINE OR DIESEL POWERED ELECTRIC GENERATORS If your trailer is equipped with a generator you must have and follow the generator manufacturer s instructions Carbon monoxide gas is present in the exhaust of all gasoline and diesel engines as well as from other burning fuels such as LP gas and charcoal Carbon Monoxide is an odorless gas that can cause death Be certain exhaust from any running engine or burning fuels can not accumulate in areas where people or animals are likely to be present Conditions that can redirect exhaust fumes are for example e Being drawn in by fans or ventilators operated in a trailer e Prevailing wind e Being trapped between adjacent trailers vehicles or buildings or e Being trapped between or in a snow bank or other materials that can redirect fumes You
14. Shore power is the delivery of electrical power from another source to a power inlet on your trailer To connect your trailer to this source you must have a shore power cord specifically designed for this use DO NOT USE AN ORDINARY EXTENSION CORD Section Accessories The trailer end of this cord is connected to an electrical box on the trailer sometimes referred to as a motor base This box contains circuit breakers and or fuses and may include a power converter to change the shore power usually 110 volts alternating current into 12 volts direct current Do not assume that a shore power supply is correctly wired Shore power may have incorrect polarity or not have the safety ground Before connecting your trailer test shore power by using a polarity and ground tester which can be purchased at electronic stores If you have shore power your trailer may be fitted with Ground Fault Interrupting outlets GFI If you have GFI protection you must periodically test the outlets by pressing the TEST button that is located on the GFI equipped outlet Shore power poses a risk of death due to electrocution Always use a grounded connection Never connect to an ungrounded source of shore power Never remove the third prong from the shore power plug Risk of fire Connect only to source of correct voltage Do not overload electrical circuits Do not use an extension cord to connect to sho
15. a cold reading 2 6 6 Tire Size To maintain tire safety purchase new tires that are the same size as the vehicle s original tires or another size recommended by the manufacturer Look at the tire information placard the owner s manual or the sidewall of the tire you are replacing to find this information If you have any doubt about the correct size to choose consult with the tire dealer 2 6 7 Tire Tread The tire tread provides the gripping action and traction that prevent your vehicle from slipping or sliding especially when the road is wet or icy In general tires are not safe and should be replaced when the tread is worn down to 1 16 of an inch Tires have built in treadwear indicators that let you know when it is time to replace your tires These indicators are raised sections spaced intermittently in the bottom of the tread grooves When they appear even with the outside of the tread it is time to replace your tires Another method for checking tread depth is to place a penny in the tread with Lincoln s head upside down and facing you If you can see the top of Lincoln s head you are ready for new tires 2 6 8 Tire Balance and Wheel Alignment To avoid vibration or shaking of the vehicle when a tire rotates the tire must be properly balanced This balance is achieved by positioning weights on the wheel to counterbalance heavy spots on the wheel and tire assembly A wheel alignment adjusts the angles of the wheels so
16. all ramp doors A WARNING Stand clear of cables while loading amp unloading Failure to comply can result in Located on or near slide out generator SECURELY IN PLACE WHILE THE VEHICLE IS IN MOTION ioan 10 17 2008 Page 15 Section 1 Safety Information Located above water inlet on exterior for trailers with city water connections CITY WATER CONNECTION WARNING POTABLE WATER ONLY SANITIZE FLUSH AND DRAIN BEFORE USING SEE INSTRUCTION MANUAL LD 10 Located on roadside exterior WASTE WATER HOLDING TANK Located on roadside exterior SEWER OUTLET CONNECTION _ Located next to smoke detector WARNING Test Smoke Detector operation after vehicle has been in storage before each trip and at least once per week during US e no WARNING DO NOT STORE COM BUSTIBLE MATERIAL IN THIS AREA sio Located on all roof and luggage racks a oF Luggage rack only not for HUMAN occupancy Located on roof rack 10 17 2008 Page 16 Section 1 Safety Information Racks MUST be up and ALL pins must be in place Do NOT lean on or crawl over rack onto roof Located on all roof and luggage racks LOAD CAPACITY 1000 LBS Located on roof rack Racks MUST be up and ALL pins must bein place Do NOT lean on or crawl over rack onto roof Located on electrical box cover of trailers with electrical connections This Panelboard shall be connected by a Feeder ee
17. ana uni ockor cinara 5 Have the gas system checked and leakage source corected belora using again Section 1 Safety Information Do not walk on roof lf not avoided could result in injury Roadside location inside trailer A DANGER The torsion spring assembly has been designed to counterbalance the weight transferred when opening and closing the ramp door The entire torsion spring assembly mounting hardware and cables are loaded with tremendous energy REPAIRS OR ADJUSTMENTS BY INEXPERIENCED PERSONS OR WITHOUT PROPER TOOLS IS HAZARDOUS AND COULD CAUSE INJURY Do not attempt to remove or repair any door components hardware or the structure to which these components are attached Periodic inspection of the entire assembly to include but not limited to cable wear fastener integrity and proper lubrication is required ALL REPAIRS OR ADJUSTMENTS MUST BE PERFORMED BY EXPERIENCED DOOR SERVICE PERSONNEL ONLY Roadside location inside trailer indicating slippery ramp door SLIPPERY WHEN WET Located on all trailers with ladder racks and all Edge trailers NOT A STEP Located above doors with low openings LOW CLEARANCE 10 17 2008 Page 14 Section 1 Safety Information Located near all ramp doors A DANGER Heavy Door Located on or near generator A WARNING Gas tank must be outside of trailer when generator 1s in use Located near awning door A WARNING Located on
18. area as well as flat spotting from the prolonged strain of sidewall and tread deflection Adjust inflation to recommended operating pressure before putting the vehicle back into service 2 3 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 trailers there is a Federal Certification VIN label that is located on the forward half of the left road side of the unit This certification 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 weigh If there are 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 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 10 17 2008 Page 23 For trailers with living quarters installed the weight of water and propane also
19. correct extreme trailer swaying The application of the trailer brakes alone will tend to straighten out the combination especially when going downhill 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 the safety chains e there is appropriate slack in the breakaway switch pullpin lanyard e the tires are not visibly low on pressure and e the cargo is secure and in good condition Section 1 Safety Information 1 2 22 Safety Warning Labels on Your Trailer Check your Haulmark trailer for the warning and instruction labels on the following pages Many of those listed are mandated by the U S government and others will help you in the safe operation of your trailer The following information is provided in the event that any of the labels are missing Federal Certification VIN plate mounted on driver side of trailer PRACTISED BY y PABRIOUE FAR DATE Haulmark Ind INC PO Box 281 Bristol IN 48507 0281 574 825 5867 GWWRPWBY i COLD INAL PRESSJPRESS DE GOMPL A FAMID A SAGE AL a Pour A SE DUAL L Puro LJ THIS VEKI LF COMFORMES TO AlL pm LUGLRLE D S FEDERAL MOTOR VERICLE SAFET y STANDARD SDS IN EFFECT DA THE DATE DF MAW FACTIRE SHOWN ABE THIS VERICLE CONFORMS TO ALL APPLICABLE STANDARDIS PRESCRIBED UNDER THE CANADIAN MOTOS VEHICLE SAFETY REGULATIONS IN EFRECT ON THE DATE Q
20. damage to trailer and conienis Inspect trailer before each use and repair or replace all damaged parts 8 2 3 Drop Ramp Torsion Springs If your trailer has a drop ramp door the weight of the door may be partially held by a torsion spring and a cable Stand to the side when opening the drop ramp You could be hurt if you are behind the drop ramp and the counterbalance does not work A spring and cable counterbalance can inflict serious injury if it breaks or if incorrectly adjusted Inspect the cable and cable ends each time the door is operated Do not attempt to service the counterbalance Take the trailer to your Haulmark dealer for service Inspect the cable and cable ends regularly for fraying and signs of loosening If released a torsion spring can inflict serious injury The torsion spring and cable are not user serviceable The torsion spring must be serviced by a person who is trained in torsion spring safety 8 2 4 Slide Outs The optional slide out facility is fitted with shafts bushing gears and sliding members located on the underside of the trailer These parts are exposed to road grime water and possible salt spray Clean and lubricate the moving parts regularly to keep the slide out from seizing Follow the instructions below to clean and lubricate the slide out mechanism at least once per season and more frequently if your trailer is operated in dusty or salt spray environments e C
21. death due to fire or explosion Do not connect an LP gas system to a supply of natural gas Extinguish all pilot lights and turn off all appliances before refilling fuel or LP gas tanks Do not fill the tank with any gas other than LP butane or propane Do not store LP gas tanks inside the trailer Keep the shutoff valve on your LP gas tank closed at all times except when you are operating an LP gas appliance Before opening the LP shutoff valve turn off all LP gas appliances If an appliance is on when you open the shutoff valve LP gas can accumulate in the trailer which can result in an explosion Do not use a wrench to open or close the shutoff valve If the shutoff does not completely stop the flow of LP gas when it is hand tightened replace the shutoff valve LP gas leaks can result in fire or explosion If your trailer is equipped with an LP gas system it must also be equipped with an LP gas detector The LP gas detector Section Accessories will be located near the floor to detect the heavier than air LP gas If a leak is suspected use a soapy water solution to search for the leak Do not use a solution that contains ammonia or chlorine common in window and other household cleaning compounds because those chemicals will cause LP piping corrosion Risk of fire or explosion If LP gas is detected by smell or by the LP gas detector e Do not touch electrical switches Extinguish flames and pilot
22. lights Open doors for ventilation Shut off LP gas supply at the LP tank Leave the area until odor clears Correct the source of LP gas leakage before using LP appliances Do not use a flame to locate the source of an LP gas leak LP gas is either propane or butane that is compressed into liquid form LP gas must be completely vaporized before being burned Butane gas will not operate if the outside temperature is below 32 degrees Fahrenheit NOTICE Use Butane only when the temperature is above freezing 32 degrees F Propane gas will operate at temperatures as low as minus 44 degrees Fahrenheit 44 F Keep the regulator for the LP gas system located near the LP gas tank covered with a guard to protect it from road debris LP gas is prohibited on some roadways bridges and tunnels Check a map and with Department of Transportation or with the AAA for travel routes that do not have such restrictions 7 4 1 LP Gas System Troubleshooting e Having liquid gas at your appliance is an indication that the LP gas tank is overfilled or that the temperature is too cold e If your LP gas appliances do not stay lit it might be because your LP gas system is contaminated with 10 17 2008 Page 58 air or moisture Many LP gas vendors have facilities to purge the air from an LP gas system e If your LP gas system is not providing gas even when the shutoff valve is open it might be because the LP gas regulator h
23. must have an operating carbon monoxide detector inside the accommodation spaces of your trailer 10 17 2008 Page 56 ACCESSORIES Gasoline and diesel generators pose a risk of death from Carbon Monoxide Fire and Explosion Electrocution Do not operate a generator without having a working carbon monoxide detector Do not refuel a running generator Do not refuel near ignition sources Before starting the generator check fuel and oil levels The generator may have to run for two or three minutes before it allows drawing electricity from it Read the generator instruction manual Never exceed the capacity of the generator Before turning off the generator remove the electrical load and let the engine to run for two or three minutes to cool the generator 7 2 ACCESSORY BATTERY Your trailer may be outfitted with an accessory battery that operates lighting electric landing gear slide outs or other accessories An accessory battery may be kept charged either by the tow vehicle or by the generator or shore power A disconnect switch may be provided to disconnect the accessory battery when you do not plan to be using the trailer for an extended period such as seasonal storage If there is no disconnect switch then remove the cables from the battery terminals The accessory battery must be kept in a charged condition during storage The battery could freeze and break if it becomes discharged 7 3 SHORE POWER
24. 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 weight 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 t
25. on Light Truck LT Tires 30 2 6 10 d Information on Special Trailer ST Tires 30 26 1 TIGL IIPS cacsaepeese err aeiercemna sean ennen 30 SECTION 3 COUPLING TO THE TOW VEHICLE2 3 1 USE AN ADEQUATE TOW VEHICLE AND HITCH 32 3 1 1 Trailer Information woccccccccccccssscccccccceeeeeeessessseees 32 Jd 2 Tow CHIC Cas aie avascattaontinatuat ann eei 33 3 2 COUPLING AND UNCOUPLING THE TRAILER 34 3 2 1 Trailer with Ball Hitch Coupler 0000006 35 3 2 l a Before Coupling the Trailer to Tow Vehicle 35 3 2 1 b Prepare the Coupler and Hitch a cecicccisessocsccdiens 36 3 21c Couple the Trailer to the Tow Vehicle 36 3 2 Ld Rig the Safety Chains srsissrcsssicrisriesisirscecsreses 37 3 2 1 Attach and Test the Breakaway Brake System37 3 2 LE Connect the Electrical CableSw cccccissssaresacececons 38 3 2 1 g Uncoupling the Ball Hitch Trailer 38 3 2 2 Trailer with Gooseneck Coupler and Drop Leg QC I ise oe 39 Bae Adjust Gooseneck Hitch Height 00 000 39 3 2 20 Drop Leg JACKS sucieiesiiesssutenrausrwnciesarvmessunawaotis 40 ERMA Before Coupling the Trailer to Tow Vehicle 40 3 2 2 d Prepare the Ball Receiver and Gooseneck Ball41 KaLe Couple the Trailer to the Tow Vehicle 41 PAA Rig the Safety Chains scioecscsessienascourtcaoncteenieieas 41 3 2 2 8 Attach and Test the Breakaway Brake System42 b PPAT Connect the Electrical ables a vsciicisecvasaeneivnns 43 AALi Un
26. 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 m p h manually operate the electric brake controller in the tow vehicle cab You should feel the operation of the trailer brakes Failure to connect the tow vehicle lighting and braking to the trailer will result in inoperable lights and brakes and can lead to collision Check that all the trailer lights and brakes work before each tow 3 2 1 9 Uncoupling the Ball Hitch Trailer Follow these steps to uncouple your ball hitch trailer from the tow vehicle e Block trailer tires to prevent the trailer from rolling before jacking the trailer up Disconnect the electrical connector Disconnect the breakaway brake switch lanyard Disconnect the safety chains from the tow vehicle Unlock the coupler and open it Before extending jack make certain the ground surface below the jack pad will support the tongue load e Rotate the jack handle or crank clockwise This will slowly extend the jack and transfer the weight of the trailer tongue to the jack Section 3 Coupling To The Tow Vehicle 3 2 2 Trailer with Gooseneck Coupler and Drop Leg Jack A gooseneck coupler on the trailer connects to a gooseneck ball that you must have installed in the bed of the tow vehicle This system of couplin
27. safely load a trailer you must consider e Overall load weight e Load weight distribution e Proper tongue weight and e Securing the load properly To determine that you have loaded the trailer within its rating you must consider the total weight of the trailer and its contents The trailer axles carry all of the total weight of the trailer and its contents Gross Vehicle Weight or GVW It is essential for safe towing that the trailer axles be capable of carrying 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 section that follows The load distribution must be such that no component part of the trailer is loaded beyond its rating This means that 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 distribution 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 An overloaded trailer can result in failure or i
28. the DOT Tire Identification Number TIN e Recommended tire inflation pressure including a description and explanation of e Cold inflation pressure e Vehicle Placard and location on the vehicle e Adverse safety consequences of under inflation including tire failure e Measuring and adjusting air pressure for proper inflation e Tire Care including maintenance and safety practices e Vehicle load limits including a description and explanation of the following items e Locating and understanding the load limit information total load capacity and cargo capacity e 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 e Determining compatibility of tire and vehicle load capabilities 10 17 2008 Page 22 e Adverse safety consequences of overloading on handling and stopping on tires 2 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 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 sp
29. towing season Inspect for cracks amp dents Replace as needed 8 2 12 After any impact or 1 yr 10 17 2008 Page 60 8 2 INSPECTION AND SERVICE INSTRUCTIONS 8 2 1 Axle Bolts Frame Suspension amp Structure 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 Figure 8 1 indicates the general areas where jacks and jack stands may be applied When jacking and using jack stands place them so as to clear wiring brake lines and suspension parts springs torsion bars etc Place jacks and jack stands inside of the perimeter strip on the supporting structure to which the axles are attached Jacking Points for Trailer Figure 8 1 Never crawl under your trailer unless it is on firm and level ground and resting on properly placed and secured jack stands 8 2 2 Trailer Structure Wash the entire trailer thoroughly immediately after exposure to road salt and liquid deicer The salt and liquid deicer will corrode and pit the aluminum Because the trailer floor receives the most abuse it will most likely corrode before any other part of the Structure 10 17 2008 Page 61 8 2 2 a Fasteners and Frame Members Inspect all of the fasteners and structural frame members for bending and other damage cracks or fa
30. 0 17 2008 Page 53 5 1 Section 5 CHECKING THE TRAILER BEFORE AND DURING EACH TOW PRE TOW CHECKLIST Before towing double check all of these items Tires wheels and lug nut tightness torque see the Safety Information section starting on Page 1 of this manual Tire Pressure Inflate tires on trailer and tow vehicle to value indicated on Certification VIN label Coupler secured and locked ball see the Coupling to the Tow Vehicle section starting at Page 23 of this manual Safety chains properly rigged to tow vehicle not to hitch or ball see the Coupling to the Tow Vehicle section starting at Page 23 of this manual Test Tail Stop and Turn Lights Test trailer brakes Safety breakaway switch lanyard fastened to tow vehicle not to safety chains see the Coupling to the Tow Vehicle chapter starting at Page 23 of this manual 10 17 2008 Page 54 e Cargo properly loaded balanced and tied down see the Loading The Trailer chapter starting at page 42 of this manual e Tongue weight and weight distribution set up e Doors and gates latched and secured e Lock all doors that are equipped with keyed locks e Fire extinguisher e Flares and reflectors 5 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 e Cargo door latched and secure
31. Alteration of the trailer structure or modification of mechanical electrical plumbing heating or other systems on your trailer must be performed only by qualified technicians who are familiar with the system as installed on your trailer Warrantor reserves the right for final determination whether or not the product has been abused or misused by the Purchaser WARRANTOR S OBLIGATION Warrantor may elect to remedy all defects in materials and workmanship by repair This is the only remedy available to Purchaser All defective products shall be delivered to an authorized Haulmark dealer repair center Warrantor will not be obligated in any way to pay for any repairs made without specific prior approval The repair facility will remedy all defects within a reasonable time not to exceed 60 sixty days after delivery by Purchaser PURCHASER S OBLIGATIONS HOW TO GET WARRANTY SERVICE Purchaser must notify his her selling dealer of any defects in material or workmanship within 30 thirty days from the date of discovery within the warranty period It is the selling dealer s responsibility to notify the Warrantor of any warrantable issues and to request authorization and replacement warranty parts The Purchaser is required to complete and return to Warrantor the attached warranty registration card within 15 fifteen days of product purchased to obtain Warranty service Warranty will not apply if warranty registration card is not on file Purchas
32. Coupler to hitch mismatch can result in uncoupling leading to death or serious injury Make sure the hitch and ball are rated for the trailer coupling Make sure the hitch ball size matches the coupler 3 2 2 a Adjust Gooseneck Hitch Height It is your responsibility to have the height of the coupler adjusted to match the height of the gooseneck ball in your tow vehicle Proper coupler height adjustment is required to provide clearance between the bottom of the trailer and sides of the tow vehicle bed to obtain level running of the trailer and to permit equal weight distribution on the axles Your Haulmark dealer is able to perform the coupler height adjustment to match the trailer to your towing vehicle e Loosen the jam nut and set screw A on the coupler See figure 3 8 e Remove retaining pin B and load bearing pin C e Extend or retract the coupler as needed up to a maximum of 8 inches from the fully retracted position e Fully insert load bearing pin B through one set of holes in coupler and outer tube NEVER use the set screw or any other device as a replacement for the load bearing pin B e Install retaining pin C on load bearing pin B e Tighten setscrew A to 75 100 Ib ft of torque e Tighten jam nuts to 80 90 lb ft of torque e Check tightness after 50 miles of towing Section 3 Coupling To The Tow Vehicle Coupler Height Adjustment Figure 3 8 Improper gooseneck height adjustment c
33. F WANUEACTURE CE VEHICULE EST QOMFORME A TOUTES LES FORMES QUI LII SONT APPLIGMBLES EN VERTU OU MESLEMEWT SUR LA SECURITE DES PLLA WEITE TRAILER HAS059 Located on the driver side wall of trailer NATIONAL ASSOCIATION OF The weight of cargo should never exceed Lbs LD TAE ES MEMBER Manufaciuned i atcerd dete with Hha HATM Guidalia ef ded Minimem Mangtaciunng Prectices Mark of Excellence TRAILER MANUFACTURERS UTUTELNTVEUTTTTTATT 16HGB24265H 130090 Located at transfer switch or junction box AIR CONDITIONING GENERATOR CIRCUIT THIS CIRCUIT THIS CONNECTION CONNECTION IS FOR IS FOR AIR CONDITIONERS GENERATORS RATED RATED 110 125 VOLT AC 110 125 vOLT AC 60 HZ____ AMPERES 60 HZ mer _ MAXIMUM DO NOT EXCEED CIRCUIT RATING iom 10 17 2008 Page 10 Section 1 Safety Information Located outside power supply THIS CONNECTION IS FOR 110 125 VOLT AC rae 30 AMPERE SUPPLY THIS CONNECTION FOR 120 240 VOLT 2 POLE 3 WIRE 60 HERTZ ME OAMPERE SUPPLY THIS CONNECTION IS FOR 110 125 VOLT AC 60 HZ AMPERE SUPPLY Located on battery box THE SUPPLIED BATTERY IN YOUR KIT IS RECHARGEABLE AND MUST BE MAINTAINED FOR PROPER USE FOR USE SINGLE TANDEM AND TRI AXLE TRAILERS CHECK CONDITION OF BATTERY AND CHARGE PRIOR TO TRIP NOTICE CHARGE BATTERY PER ENCLOSED INSTRUCTIONS DO NOT EXCEED 1 2 AMPS MAXIMUM CHARGE IAUNE CHARGER H AALARE THROU
34. GH HEULMARI 10 17 2008 THIS CONNECTION IS FOR 120 240 VOLT 3 POLE 4 WIRE 60 HERTZ 50 EVAAA L i i THIS CONNECTION IS FOR LOW VOLTAGE BATTERY OR DIRECT CURRENT ONLY DO NOT CONNECT TO 120 OR 240 VOLTS AC LO 104 Each Trip Disconnect electrical plug Pull breakaway pin Bright light battery o k No light charge battery Try to pull forward Page 11 Section 1 Safety Information Located above fuel filter door cap on trailers with tank for diesel fuel DIESEL FUEL ONLY Located on marine battery BATTERY HOOKUP POSITIVE TO BLACK WIRE _ NEGATIVE TO WHITE WIRE LD 101 Located above fuel filter door cap on trailers with tank for gasoline GASOLINE ONLY Located on breakaway switch SAFETY BREAK AWAY SWITCH WILL NOT OPERATE unless connected to a power source equivalent to or greater than an auto motive type 12 volt 12 amp hour wet Located over side door EAI L 10 17 2008 Page 12 Section 1 Safety Information Located at LP tank on trailers with LP systems THIS GAS PIPING SYSTEM IS DESIGNED FOR USE OF LIQUIFIED PETROLEUM GAS ONLY DO NOT DCORANECT NATURAL GAS TO THIS SYSTEM DO AT FILL CONTAINER S TO MORE THANE PERCENT OF CAPACITY Secu rely cap iniei s when nel connected for usg After tuming on gas okecepi aher normal container replacement test gas piping and connections to appliances for leakage with soapy waler or bubbl
35. See the brake manual for wear and current inspection instructions 8 2 5 e Brakes Hydraulic Air or Electric Operated If your trailer has hydraulically operated brakes they function the same way the hydraulic brakes do on your tow vehicle The hydraulic braking system must be inspected by a dealer at least as often as the brakes on the tow vehicle but no less than once per year This inspection includes an assessment of the condition and proper operation of the wheel cylinders brake shoes brake drums and hubs You must check the fluid level in the master cylinder reservoir at least every three months If you tow your trailer an average of 1 000 miles per month in a hot and dry environment you must check the brake fluid level once a month The brake fluid reservoir is located on the tongue of the trailer or near the gooseneck Fill with DOT 4 brake fluid Air Pressure Operated Hydraulic Ait hydraulic braking systems are typically used when the tow vehicle has a diesel engine The tow vehicle has an air compressor that routes the air to an air hydraulic mechanism which sends brake fluid to the wheel cylinders The air pressure gauge in your tow vehicle indicates the current air pressure See your tow vehicle manual for the proper air pressure Electrical Operated Hydraulic Electric hydraulic braking systems which are mounted on the trailer use a small electrically driven pump to generate hydraulic pressure which operate
36. Table of Contents SECTION 1 SAFETY INFORMATION cccccceeees 1 1 1 SAFETY ALERT SYMBOLS AND SIGNAL WORDS 1 Le MAJOR HAZARDS sicuneseoegioeoantsseoansioenemeenes 1 1 2 1 Improper Sizing of the Trailer to the Tow Vehicle E E ee pate ates aes oewe essences 1 L22 Driving Too TaSi a tesssaaihatatansiseeinsatiieuncaaroseeaniias 2 1 2 3 Failure to Adjust Driving Behavior When Towing a Trailer 2 1 2 4 Improper LOO O vcndavisin sinatinsasthigenanieviversautavens 2 1 2 5 Trailer Not Properly Coupled to the Hitch 2 1 2 6 Proper Use of Safety Chains cccccccccccetteeseee 3 1 2 7 Proper Connection of Breakaway Brake 3 1 2 8 Matching Trailer and Hitch cccccccccceeeeeeeees 3 1 2 9 Worn Tires Loose Wheels and Lug Nuts 3 1 2 10 Weight And Load Distribution ccccccceeeeees 4 L241 GOUT OG aires cierets te ine EREE EERTE NEEE 5 ED AAD PVOPIIGIC COI BO sucses pinis nran 5 1 2 13 Inoperable Brakes Lights or Mirrors 5 1 2 14 Hazards From Modifying Your Trailer 6 1 2 15 Hazards from Accessories vic vinctaxerieanetivcariecenvans 6 LLO CT OT eek r E A OE 6 L247 DOVE TON aseersristrr a inteni eE NEE 6 1 2 18 LP Gas Fuel SVC sscsnicsssccnivesnicnsvassontissstvestees 7 1 2 19 Gas And Fuel Stora ge ccccccccccccccssssscccccceesneeeseees 7 1 2 20 Trailer Towing Guide sicscicrsiesesvativinnssntecavetionvens 8 1 2 21 Safe Trailer Towing Guidelines cccccccceeeeee
37. 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 listed here have your dealer do them Note In addition to this manual also check the relevant component manufacturer s manual Haulmark Trailer Inspection and Service Intervals Manual Service Required Service Interval Section Reference Before Every 3 Every 6 Every Mo s Mo s Year Each Use Axle Attachment Axle Attachment Bolts Check Check by dealer dealer Check by dealer et e Canin Brakes Check operation 3 2 1 e 3 2 2 d 3 23 0 Breakaway Battery Fully charged connections clean charged connections clean sese ae Breakaway Switch Test operation connections Caaan ee def f Shoes and Drums and Drums Shoes and Drums Adjust 825b 0 2 5 825b 0 First 200 mi ea 3 000 miles SN O fortes eee S O s Braes hyaraure Creatu revera renterien Creo toreni ees T O T OOOO O Coupler and Hitch Ball Check for cracks pits flats Replace w ball amp coupler having La 2 6 a GVW Grease Check locking device amp replace when worn Gooseneck Coupler and Ball Check for cracks pits flats Replace w ball amp coupler having 8 2 6 b GVW Grease Check locking device amp replace when worn Fifth Wheel and Pin Grease Replace when worn seee fa w e Gc 10 17 2008 Page 59 Section 8 Inspection Service amp Maintenance Haulmark Trailer Inspec
38. ailer in tow is vastly different from driving the same vehicle without a trailer in tow Acceleration maneuverability and braking are all diminished with a trailer in tow It takes longer to get up to speed you need more room to turn and pass and more distance to stop when towing a trailer You will need to spend time adjusting to the different feel and maneuverability of the tow vehicle with a loaded trailer Because of the significant differences in all aspects of maneuverability when towing a trailer the hazards and risks of injury are also much greater than when driving without a trailer You are responsible for keeping your vehicle and trailer in control and for all the damage that is caused if you lose control of your vehicle and trailer As you did when learning to drive an automobile find an open area with little or no traffic for your first practice trailering Of course before you start towing the trailer you must follow all of the instructions for inspection testing loading and coupling Also before you start towing adjust the mirrors so you can see the trailer as well as the area to the rear of it Drive slowly at first 5 m p h 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 f
39. ailer on the road until The trailer brakes are checked The breakaway switch is connected to the tow vehicle The load is secured to the trailer and The trailer lights are connected and checked Couplers Haulmark trailers are produced with a variety of coupler devices One of the sections below will pertain to your trailer e Bumper pull Ball Hitch Coupler e Gooseneck Ball Hitch Coupler e Gooseneck Fifth Wheel Coupler If you need information or assistance with your coupler call Haulmark Industries Inc at 800 348 7530 or your dealer 3 2 1 Trailer with Ball Hitch Coupler A ball hitch coupler connects to a ball that is located on or under the rear bumper of the tow vehicle This system of coupling a trailer to a tow vehicle is sometimes referred to as bumper pull A ball hitch trailer may be fitted with a tongue jack that can raise and lower the coupler The tongue jack is mounted to the A frame front or tongue part of the trailer By rotating the jack handle clockwise the jack will extend and raise the tongue of the trailer Figure 3 3 shows a trailer with a ball hitch coupler 10 17 2008 Page 35 Tongue Jack Ball Hitch Coupler Trailer with Ball Hitch Coupler Figure I3 Be sure the Ball Hitch coupler 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
40. an result in overloaded tires blowout and loss of control leading to death or serious injury Adjust the gooseneck receiver so that the trailer runs level 3 2 2 6 Drop Leg Jack s A trailer having a gooseneck hitch will have one or two drop leg jacks for raising and lowering the gooseneck ball receiver Because several drop leg jack mechanisms are available the general instructions below may vary slightly from the jack manufacturer s instructions If the trailer jack on your trailer does not resemble the jack shown in the figure 3 9 follow the jack instructions provided by the jack manufacturer 10 17 2008 Page 40 Drop Leg Jack Arrangement Figure 3 9 3 2 2 C Before Coupling the Trailer to the Tow Vehicle e Be sure the size and rating of the gooseneck ball match the size and rating of the receiver Gooseneck balls and receivers are marked with their size and ratings e Wipe the gooseneck ball clean and inspect it visually and by feel for flat spots cracks and pits A worn cracked or corroded gooseneck ball can fail while towing and may result in death or serious injury Check the gooseneck ball for wear corrosion and cracks before coupling the trailer Replace worn corroded or cracked gooseneck ball before coupling the trailer e Rock the ball to make sure it is tight to the ball support and visually check that the gooseneck ball nut is solid against the lock washer and ball support frame
41. ants to the ORIGINAL CONSUMER PURCHASER for a period of THREE 3 YEARS from the date of purchase by PURCHASER WARRANTY PERIOD that the TRAILER the PRODUCT shall be free of DEFECTS in materials and workmanship attributable to Warrantor WARRANTY WARRANTY IS NOT TRANSFERABLE TO SECOND OWNER Excluded from this three year Warranty are electrical plumbing windows doors seals sealant electrolysis exterior metal fenders undercoating and fiberglass parts which are warranted for a ONE 1 YEAR period from the date of purchase by the original Purchaser Certain component and attachments are warranted separately by their respective Manufacturer ITEMS EXCLUDED FROM WARRANTY Warrantor is not responsible for claims relating to the following 1 Product rental 2 Defacing scratches dents chips tears and defacing on any surface not caused by Warrantor 3 Routine maintenance 4 Damage from unauthorized repairs abuse misuse or neglect including damage from heavy snow accumulation 5 Damage caused from improper hitch ball or tow vehicle hook up 6 Damage to the contents of any Product regardless of cause 7 Damages caused by loose or improperly torqued lug nuts 8 Decals or graphics regardless of cause 9 Off road usage 10 Tow vehicle wiring 11 Tire alignment 12 Before making any alteration to your trailer contact your dealer or Haulmark Industries Inc at 800 348 7530 and describe the alteration you are contemplating
42. are Instructions HA2059 on battery box if applicable k pe AA ett Warning Labels and Locations Figure 1 2 Stickers in location 3 Stand clear of cable warning HA2047 DANGER Heavy Door Stand Clear HA2067 Warning Labels and Locations Figure 1 3 10 17 2008 Page 19 Section 1 Safety Information Stickers in location 4 OK to Ship Inspection Read Owner s Manual Warning HA2068 a a i T d F F F F r er R a O Saa P a a Warning Labels and Locations Figure 1 4 Stickers in location 5 DANGER Heavy Door Stand Clear HA2067 2 places Warning Labels and Locations Figure 1 5 10 17 2008 Page 20 Section 1 Safety Information To protect you and others against death or serious injury all of the labels shown above must be on the trailer and must be legible If any of these safety labels are missing or cannot be read call Haulmark Industries Inc at 800 348 7530 for free replacement labels You will need to provide us with the number shown at the bottom of the label s in order for us to send the correct one s 1 2 23 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 us If NHTSA receives similar complaints it may open an investigation and if it finds that a safety
43. ared by the breakaway brake manufacturer The breakaway brake system may be fitted with a charging capability that draws power from the tow vehicle If the electrical system on your tow vehicle does not provide power to the breakaway brake battery you must periodically charge the battery to keep the breakaway brake system in working order Breakaway Brake Connection figure 3 6 Section 3 Coupling To The Tow Vehicle e Visually inspect the breakaway system for broken or missing parts Repair or replace worn damaged or missing parts before towing trailer e Connect the pullpin lanyard to the tow vehicle so that the pullpin will be pulled out before all of the slack in the safety chains is taken up see Breakaway Brake Connection figure 3 6 Do not connect the pullpin lanyard to a safety chain or to the hitch ball or hitch ball assembly This would keep the breakaway brake system from operating when it is needed e To test the breakaway brake battery remove the pullpin 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 e Immediately replace the pullpin The breakaway brake system battery discharges rapidly when the pullpin is removed An ineffective breakaway brake system can result in a runaway trailer leading to death or
44. aring is the most common cause of brakes that grab To check your bearings jack trailer and check wheels for side to side looseness If the wheels are loose or spin with a wobble the bearings must be serviced or replaced Your trailer will be equipped with one of the following types of wheel bearings e Standard Bearing are lubricated by grease or oil e E Z Lube or other grease fitting lubricated bearings Bearings are lubricated by grease and are identified by a grease fitting on the end of the axle 10 17 2008 Page 65 e Nev R Lube or other sealed bearings The bearings are sealed are require no routine lubrication e Refer to this manual and the axle manufacturer s information for inspection and service information 8 2 13 a Standard Bearings Bearing Lubrication Grease Disassemble inspect and re pack the wheel bearings every 12 months or 12 000 miles whichever occurs first If a trailer wheel bearing is immersed in water it must be repacked after each immersion If your trailer has not been used for an extended amount of time have the bearings inspected and packed more frequently at least every six months and prior to use 5 6 7 B 10 6 Outer Bearing 1 Grease Seal 2 Inner Bearing 7 Spindle Washer 3 Inner Cup 8 Spindie Nut 4 Hub Drum 9 Cotter Pin 5 Outer Cup 10 Grease Cap Standard Wheel Bearing figure 8 5 Follow the steps below to disassemble and service
45. ary use in place of one of the pneumatic tires and rims that are fitted to a passenger car in compliance with the requirements of this standard Non pneumatic tire A mechanical device which transmits either directly or through a wheel or wheel center member the vertical load and tractive forces from the roadway to the vehicle generates the tractive forces that provide the directional control of the vehicle and does not rely on the containment of any gas or fluid for providing those functions Non pneumatic tire assembly A non pneumatic tire alone or in combination with a wheel or wheel center member which can be mounted on a vehicle Normal occupant weight This means 68 kilograms 150 lbs times the number of occupants specified in the second column of Table I of 49 CFR 571 110 Occupant distribution The distribution of occupants in a vehicle as specified in the third column of Table I of 49 CFR 571 110 Section 2 Tire Safety Information Open splice Any parting at any junction of tread sidewall or innerliner that extends to cord material Outer diameter The overall diameter of an inflated new tire Overall width The linear distance between the exteriors of the sidewalls of an inflated tire including elevations due to labeling decorations or protective bands or ribs Pin Weight The downward force applied to the 5 wheel or gooseneck ball by the trailer kingpin or gooseneck coupler Ply A layer of ru
46. as frozen water in it Risk of fire or explosion Never use a flame heat lamp or hair dryer to thaw an LP gas regulator Use an incandescent light bulb to warm the regulator Do not remove the regulator cover or attempt to service the LP gas regulator 7 5 VENDING amp ACCESSORY DOORS A vending or accessory door opens vertically and has a hinge along its top edge These heavy doors are equipped with spring assisted lifting usually with a device known as a gas spring The gas spring lifting device is not designed to hold a vending door up You must use the provided solid prop rods to hold a vending door in the open position Gas springs lose their lifting capability with age and cold weather and can cause the door to fall resulting in injury Always hold the door open until the prop rods are in place Always use prop rods to hold vending or accessory doors open Be prepared to hold the weight of the door when removing prop rods 7 6 ELECTRIC POWERED LANDING GEAR The landing gear also known as the jack on your trailer may be powered with an electric motor The landing gear is operated up or down using controls located near the landing gear If the motor does not operate such as when the battery is fully discharged the landing gear can be operated manually with a socket wrench section 8 INSPECTION SERVICE amp MAINTENANCE 8 1 INSPECTION SERVICE amp MAINTENANCE SUMMARY CHARTS
47. battery is running both the trailer lights and tow vehicle lights 3 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 That part of the trailer connecting mechanism by which the connection is actually made to the trailer hitch This does not include any structural member extension of the trailer frame or brake controller per SAE J684 Hitch That part of the connecting mechanism including the ball support platform and ball and those components that extend and are attached to the towing vehicle 10 17 2008 Page 34 including bumpers intended to serve as hitches per SAE J684 Safety chains Chains are permanently attached to the trailer such that if the coupler connection comes loose the safety chains 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 Electricity is used to turn on brake lights running lights and turn si
48. bber coated parallel cords Ply separation A parting of rubber compound between adjacent plies Pneumatic tire A mechanical device made of rubber chemicals fabric and steel or other materials that when mounted on an automotive wheel provides the traction and contains the gas or fluid that sustains the load Production options weight The combined weight of those installed regular production options weighing over 2 3 kilograms 5 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 This means the nominal diameter of the bead seat 10 17 2008 Page 26 Rim size designation This means the rim diameter and width Rim type designation This means the industry of manufacturer s designation for a rim by style
49. c The best way to determine empty weight is to weigh the entire trailer on a Certified scale at a truck stop This requires detaching the trailer and leaving the entire trailer on the scale Furthermore it is desirable to weigh the tongue weight This can be done by re attaching the trailer to the tow vehicle after getting the empty weight and then just 10 17 2008 Page 33 weighing the trailer axles s Subtracting the axle weight from the empty weight gives you the tongue weight Knowing the empty weight now allows you to calculate the maximum cargo weight Simply subtract the empty weight from the GVWR shown on the Certification VIN tag While you re at the scale it 1s also a good idea to weigh the towing vehicle with driver in the typical towing scenario This will provide you with the total combination vehicle weight which can then be compared to the allowable Gross Combined Weight Rating GCWR provided by the tow vehicle manufacturer as discussed below 3 1 2 Tow Vehicle When equipping a new vehicle or an older vehicle to tow your trailer ask the vehicle dealer for advice on how to outfit the towing vehicle Discuss the following information and equipment with the vehicle dealer Overall Carrying and Towing Capacity of 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 horsepo
50. coupling the Gooseneck Trailer with Drop Leg JE A Aupewowsnndeniotidanenotesusnny 43 3 2 3 Trailer with Fifth Wheel Coupler and Drop Leg JOCK EE E E A T A EAEAN 44 M290 Before Coupling the Trailer to Tow Vehicle 44 3 2 3 b Adjust Hitch Height ccccceceesseeeeeeeneees 45 3 22 93 Prepare the Fifth Wheel Coupler 45 3 2 3 d Couple the Trailer to the Tow Vehicle 45 3 2508 Attach and Test the Breakaway Brake System47 3 2 0 0 Connect the Electrical Cables iscssesseedsxees 47 3 2 3 8 Rig the Safety Chains si cscccissiacsessssseevesiseaaveies 48 Jaah Uncoupling the Fifth Wheel Trailer 48 SECTION 4 LOADING THE TRAILER 50 4 1 CHECKING TONGUE WEIGHT 0c00sseeeeeeeeeeeees 51 4 2 LOADING CARGO srccasssosarecnnasaveastasansssaianeecanatnnesees 51 4 2 1 Preparing the Trailer for Loading 0064 a 4 2 2 Loading the Trailer sacaseicsavsvasseersrcomnvansvaencenees J4 4 3 SECURING THE CARGO scrsciacnaskseonctncesachanucsagatnvesass 53 SECTION 5 CHECKING THE TRAILER BEFORE AND DURING EACH TOW cccccccssssssscsees 54 Dat PRE TOW CHECKLIST 000seeeeeeeeeeeeeeeeeeeeeeeeeees 54 5 2 WAKE REGULAR STOPS iccccascsansccenetarcaqerannecsnninneness 54 SECTION 6 BREAKING IN A NEW TRAILER 55 6 1 RETIGHTEN LUG NUTS AT FIRST 10 25 amp 50 MILESS 6 2 ADJUST BRAKE SHOES AT FIRST 200 MILES 53 6 3 SYNCHRONIZING THE BRAKE SYSTEMS
51. 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 others 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 10 17 2008 Page 27 Use this information to make tire safety a regular part of your vehicle maintenance routine Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure 2 6 1 Safety First Basic Tire Maintenance Properly maintained tires improve the steering stopping traction and load carrying capability of your vehicle Underinflated tires and overloaded vehicles are a major cause of tire failure Therefore as mentioned above to avoid flat tires and other types of tire failure you should maintain proper tire pressure observe tire and vehicle load limits avoid road hazards and regularly inspect your tires 2 6 2 Finding Your Vehicle s Recommended Tire Pressure and Load Limits Tire information placards and vehicle certificat
52. d e Check tires for signs of abnormal wear and loss of air pressure section 6 BREAKING IN A NEW TRAILER 6 1 RETIGHTEN LUG NUTS 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 may result in a wheel coming loose from the trailer causing a crash leading to death or serious injury Refer to the Inspection Service amp Maintenance section for the proper tightening sequence and torque value for the wheel lugs nuts bolts Lug nuts are prone to loosen after being first assembled Death or serious injury can result Check lug nuts for tightness on a new trailer and after re mounting a wheel at 10 25 and 50 miles 6 2 ADJUST BRAKE SHOES AT FIRST 200 MILES Brakes that are out of adjustment can result in death or serious injury Brakes must be adjusted at the intervals specified 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 Most axles are fitted with brake shoes that must be manually adjusted Read your axle and brake manual to see if your brakes must be adjusted manually or if they adjust automatically If you do not have the axle and brake manual call Haulmark Industries Inc at 800 348 7530 for assistance To adjust the trailer brakes see section 8 2
53. 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 us To contact NHTSA you may either call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 1200 New Jersey Ave SE Washington DC 20590 You can also obtain other information about motor vehicle safety from http www safercar gov Call 800 348 7530 to reach Haulmark Industries Inc 10 17 2008 Page 21 Section 2 TIRE SAFETY INFORMATION This portion of the User s Manual contains tire safety information as required by 49 CFR 575 6 Section 2 1 contains Trailer Tire Information Section 2 2 contains Steps for Determining Correct Load Limit Trailer Section 2 3 contains Steps for Determining Correct Load Limit Tow Vehicle Section 2 4 contains a Glossary of Tire Terminology 99 66 including cold inflation pressure maximum inflation 99 66 pressure recommended inflation pressure and other non technical terms Section 2 5 contains information from the NHTSA brochure entitled Tire Safety Everything Rides On This brochure as well as the preceding subsections describes the following items e Tire labeling including a description and explanation of each marking on the tires and information about
54. drop leg bases when releasing the drop legs 3 2 3 e Attach and Test the Breakaway Brake System If the coupler fails a properly connected and working breakaway brake system will apply electric brakes on the trailer See figure 3 18 The breakaway brake system includes a breakaway brake controller battery and a switch with a pullpin and lanyard Read and follow the instructions here as well as the instructions that have been prepared by the breakaway brake controller manufacturer Breakaway Brake Connection Figure 3 18 The breakaway brake system may be fitted with a charging facility that draws power from the tow vehicle If the electrical system on your tow vehicle does not provide power to the breakaway brake battery you must periodically charge the battery to keep the breakaway brake system in working order e Visually inspect the breakaway brake system for broken parts e Connect the pullpin lanyard to the tow vehicle see Breakaway Brake Connection figure 3 18 Do not connect to kingpin or its support 10 17 2008 Page 47 e To test the breakaway battery remove the pullpin 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 e Immediately replace the pullpin The breakaway brake system battery discharges rapidl
55. e e Loosen the jam nuts and set screws A on the rear side See figure 3 15 e Extend or retract the king pin or fifth wheel as needed but do not exceed 8 inches maximum extension e Tighten setscrews A to 75 100 Ib ft of torque e Tighten jam nuts to 80 90 lb ft of torque e Check tightness after 50 miles of towing 10 17 2008 Page 45 King Pin Height Adjustment Figure 3 15 3 29 0 Prepare the Fifth Wheel Coupler e Be sure the locks are open see Fifth Wheel Checks figure 3 16 e If the tow vehicle is equipped with a tailgate lower it e Block the trailer wheels front and rear e Make certain that trailer fifth wheel plate is slightly above the kingpin plate on the tow vehicle 3 2 30 Couple the Trailer to the Tow Vehicle Incorrect 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 Chains must e Fasten to frame of tow vehicle not to hitch or ball e Cross underneath hitch and coupler with minimum slack to permit turning and to hold tongue up if the trailer comes loose e Back tow vehicle up close to the trailer centering the kingpin in the slot of the fifth wheel e STOP before engaging the coupling Section 3 Coupling To The Tow Vehicle No one must be under the trailer or coupler during the coupling Death or serious injury can occur if the trailer d
56. e brakes pull the emergency breakaway brake lanyard to check the operation of the surge mechanism Standard mirrors usually do not provide adequate visibility for viewing traffic to the sides and rear a towed trailer You must provide mirrors that allow you to safely observe approaching traffic 1 2 14 Hazards From Modifying Your Trailer Essential safety items and structural integrity can be damaged by altering your trailer Even simply driving a nail or screw can damage an electrical circuit LP gas line or other feature of the trailer Before making any alteration to your trailer contact your dealer or Haulmark Industries Inc at 800 348 7530 and describe the alteration you are contemplating Alteration of the trailer structure or modification of mechanical electrical plumbing heating or other systems on your trailer must be performed only by qualified technicians who are familiar with the system as installed on your trailer 1 2 15 Hazards from Accessories The Accessories chapter of this manual contains some information about certain optional accessories that may be on your trailer Read and follow all of these instructions before operating the accessories The major hazards from some of these accessories are 1 2 16 Generator If your trailer is equipped with a gasoline or diesel generator you must have and follow the generator manufacturer s instructions You must also have one or 10 17 2008 Page 6 m
57. e Weight Rating GAWR In the following table the second column notes the rule of thumb percentage of total weight of the trailer plus its cargo Gross Vehicle Weight or GVW that should appear on the tongue of the trailer For example a trailer with a gooseneck hitch with a loaded weight of 12 000 pounds should have 20 25 of 12 000 pounds on the tongue That is the example trailer would have 2 400 to 3 000 pounds on its tongue This 2 400 to 3 000 pounds does not add to the GVWR of the trailer Approximate Tongue Weight as a Percentage of Loaded Trailer Weight Ball Hitch or Bumper Hitch Gooseneck Hitch Fifth Wheel Hitch 20 25 Section 4 Loading The Trailer An improperly distributed load can result in loss of control of the trailer and can lead to death or serious injury Proper tongue weight is essential for stable trailer handling Distribute the load front to rear to provide proper tongue weight Distribute the load evenly right and left to avoid tire overload Keeping the center of gravity low and centered is essential to minimize the risk of tip over 4 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 For lighter trailers the recommended method of checking tongue weight is to use an accessory called a tongue weight scale The tongue weight scales may be available from you
58. e drop leg to rise The plunger pin will engage a hole in the drop leg Section 3 Coupling To The Tow Vehicle The drop legs are heavily spring loaded in the lowered position They will rapidly return to the upper position when released and can inflict serious bruises scrapes or pinching Keep your feet shins and hands well clear of the drop legs and drop leg bases when releasing the drop legs e Be sure the plunger pin is fully engaged Push it in by hand if necessary The bent part of the plunger pin handle must be touching the plunger pin housing e If your trailer has two drop leg jacks lower them both to the same level following the above instructions NOTICE If the drop legs are not set at the same level one of the drop leg jacks can be overloaded and can be damaged e Release the handle or crank from its holder and engage it with the jack shaft see Drop Leg Jack Mechanism figure 3 10 e Rotate the handle or crank from its hold and engage it with the jack shaft e Rotate the handle or crank clockwise to slowly extend the jack and transfer the weight of the trailer tongue to the jack e On two speed jacks pushing the handle shaft toward the gearbox can perform rapid extension This shifts the gearbox into a high speed mode e When the drop leg base contacts the ground shift the gearbox into low speed mode by pulling out on the handle shaft until it locks into low gear NOTICE Do
59. e it on adequate capacity jack stands e Be sure the wheel and brake drum rotate freely e Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate e With a screwdriver or standard adjusting tool rotate the starwheel 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 e 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 With drop spindle axles a modified adjusting tool with about an 80 degree angle should be used Section 8 Inspection Service amp Maintenance e Rotate the starwheel in the opposite direction until the wheel turns freely with a slight drag e Replace the adjusting hole cover e Repeat the above procedure on all brakes e Lower the trailer to the ground 8 2 5 d Brakes Electric 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 hitch 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 mai
60. e operation of the trailer brakes Failure to connect the tow vehicle lighting and braking to the trailer will result in inoperable lights and brakes and can lead to collision Check that all the trailer lights and brakes work before each tow 3 2 2 i Uncoupling the Gooseneck Trailer with Drop Leg Jack Follow these steps to uncouple your gooseneck hitch trailer from the tow vehicle e Block trailer tires to prevent the trailer from rolling before jacking the trailer up Disconnect the electrical connector Disconnect the breakaway brake switch lanyard Disconnect the safety chains from the tow vehicle If the tow vehicle has a tailgate lower it Move the spring loaded gooseneck receiver lock plate locking pin to the OPEN position see Gooseneck Ball Receiver and Height Adjustment figure e Rotate the lock plate to a position that permits the gooseneck ball to exit the receiver e Before releasing dropleg jack make certain ground surface below jack base will support the trailer tongue load e Rotate the drop leg plunger pin handle so that the plunger pin is released from the drop leg see Releasing Drop Leg Mechanism figure e Push down on the drop leg base with your foot to place a drop leg to the desired lowered position e Rotate the plunger pin handle so that the plunger pin is attempting to engage the drop leg see Drop Leg Jack Mechanism figure e Slowly raise your foot permitting th
61. e solution Do not use Products thal contain ammonia of chlorine WARNING ALLPILOT LIGHTS amp APPLIANCES SHALL BE TURNED OFF DURING REFUELING OF MOTOR FUEL TANKS Located next to tongue tag at front side Do not operate this trailer unless you have read and understand the safety information in the owner s manual Failure to properly operate and maintain the towing vehicle and trailer can result in injury Mounted on round top caps THIS CAP MANUFACTURE IS PROTECTED UNDER ONE OR MORE OF THE PATENTS U S PATENT NO FOLLOWING Located above stove IT 15 NOT SAFE TO USE COOKING APPLIANCES FOR COMFORT HEATING Cooking Appliances need fresh air for sale operation BEFORE OPERATION 1 Open overhead vent or tum on exhaust fan and 2 Open window LEBEO Located on walk on roof platform 10 17 2008 Page 13 NOTICE CHECK WHEEL LUGS 1 On first trip tighten wheel ugs ai start and avery 50 miles for first 200 miles Tighten to manufacturers specifications Thereafter check wheel lugs before each trip 2 Following winter storage check before Beginning a ip Following excessive braking mspect wheel lugs LD 101 IF YOU SMELL GAS Esdinguish any open flames pilot lights and all smoking onatorials Do mol louch electrical switches 3 Shut off the gas supply al the container walvis Of gas supply connection Open doors and other ventilating openings 5 Lumet the
62. e tires are designed to be used on more than one type of vehicle tire manufacturers list the maximum permissible inflation pressure on the tire sidewall This Section 2 Tire Safety Information number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions 2 6 4 Checking Tire Pressure 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 outside temperature Rather a cold tire is one that has not been driven on for at least three hours When you drive your tires get warmer causing the air pressure within them to increase Therefore to get an accurate tire pressure reading you must measure tire pressure when the tires are cold or compensate for the extra pressure in warm tires 2 6 5 Steps for Maintaining Proper Tire Pressure e Step 1 Locate the recomm
63. eased tire wear and may reduce trailer stability which can result in a tire blowout or possible loss of control Therefore before each tow you must also check the tire pressure Remember the proper tire pressure is listed on the Certification VIN label and should be checked when tires are cold Allow 3 hours cool down after driving as much as mile at 40 mph before checking tire pressure Section 1 Safety Information Improper tire pressure may cause an unstable trailer Blowout and loss of control may occur Death or serious injury can result Make sure of proper tire pressure before towing trailer Inflate tires to pressure indicated on Certification VIN label The tightness of the lug nuts is very important in keeping the wheels properly seated to the hub Before each tow check to make sure they are tightened to the proper torque Metal creep between the wheel rim and lug nuts bolts will cause rim to loosen Death or injury can occur if wheel comes off Tighten lug nuts bolts before each tow The proper tightening sequence and tightness torque for lug nuts is listed in the Inspection Service amp Maintenance chapter of this manual Use a calibrated torque wrench to tighten the lug nuts Lug nuts 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 tightened to the proper torque after the first 10
64. eight or GTW that should appear on the tongue of the trailer For example a trailer with a gooseneck hitch with a loaded weight of 12 000 pounds should have 20 25 of 12 000 pounds 2400 3000 Ibs on the gooseneck After loading be sure to check that none of the axles are overloaded Approximate Tongue Weight as a Percentage of Loaded Trailer Weight Ball Hitch or Bumper Hitch Gooseneck Hitch Fifth Wheel Hitch 20 25 Tongue Weight Chart Figure 1 1 Section 1 Safety Information Uneven left right load distribution can cause tire wheel axle or structural failure Be sure your trailer is evenly loaded left right Towing stability also depends on keeping the center of gravity as low as possible An improperly distributed load can result in loss of control of the trailer and can lead to death or serious injury Proper tongue weight is essential for stable trailer handling Distribute the load front to rear to provide proper tongue weight Distribute the load evenly right and left to avoid tire overload Keeping the center of gravity low and centered is essential to minimize the risk of tip over 1 2 11 Shifting Cargo Since the trailer ride can be bumpy and rough you must secure your cargo so that it does not shift while the trailer is being towed 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
65. ended tire pressure on the vehicle s tire information placard certification label or in the owner s manual 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 tire 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 Ata 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 1s underinflated fill it to the recommended cold inflation pressure indicated on your vehicle s tire information placard or certification label While your tire may still be slightly underinflated due to the extra pounds of pressure in the warm tire it is safer to drive with air pressure that is slightly lower than the vehicle 10 17 2008 Page 28 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
66. er is responsible for all costs towing and transportation charges incurred to obtain Warranty service If selling dealer is not available then contact any authorized Haulmark dealer repair center LIMITATION OF LIABILITY Warrantor excludes liability whether based on contract or Tort including negligence for any damages to purchaser or Any other party other than as described in this warranty or any Punitive special indirect incidental or consequential damages Of any kind or for loss of revenue profits loss of business or other financial loss arising out of or in connection with the sale maintenance use or failure of the product even if warrantor has been advised of the possibility of such damages This disclaimer of liability shall not be affected even if any remedy provided for herein fails its essential purpose DISCLAIMER OF IMPLIED WARRANTIES 10 17 2008 Page 72 Section 10 Warranty Warrantor makes no express or implied warranties other than as specifically set out in this warranty Except for the express limited warranty set forth herein the product is sold as is and there are no implied warranties of merchantability fitness for a particular purpose compliance with description and non infringement in connection with any sale This limited warranty does not cover failure of the product resulting from causes other than product defects including but not limited to improper maintenance or use or any other such cause If an
67. ers Over 10 000 Pounds GVWR Note These trailers are not required to have a tire information placard on the trailer and may not have one installed 4 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 5 Locate the GVWR Gross Vehicle Weight Rating of the trailer on your trailer s VIN Certification label 6 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 2 4 STEPS FOR DETERMINING CORRECT LOAD LIMIT TOW VEHICLE 7 Locate the statement The combined weight of occupants and cargo should never exceed XXX Ibs on your vehicle s placard 8 Determine the combined weight of the driver and passengers who will be riding in your vehicle 9 Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds 10 17 2008 Page 24 10 The resulting figure equals the available amount of cargo and luggage capacity For example if the XXX amount equals 1400 Ibs and there will be five 150 lb passengers in your vehicle the amount of available cargo and luggage capacity is 650 Ibs 1400 750 5 x 150 650 Ibs 11 Determine the combined weight of luggage and cargo being loaded on the vehicle That weight may not safely exceed the available cargo and luggage capacit
68. ety chains so that they e Cris cross underneath the coupler so if the trailer uncouples the safety chains can hold the tongue up above the road See figure 3 5 e 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 e Attach hooks up from underneath the hole do not just drop into hole and e Provide enough slack to permit tight turns but not be close to the road surface to drag 10 17 2008 Page 37 Incorrect 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 Chains must e Fasten to frame of tow vehicle not to hitch or ball e Cross underneath hitch and coupler with minimum slack to permit turning and to hold tongue up if the trailer comes loose 3 2 1 e Attach and Test the Breakaway Brake System If the coupler or hitch fails a properly connected and working breakaway brake system will apply electric brakes on the trailer The safety chains will keep the tow vehicle attached and as the brakes are applied at the trailer s axles the trailer tow vehicle combination will come to a controlled stop The breakaway brake system includes a controller battery and a switch with a pullpin and lanyard Read and follow the instructions here as well as the instructions that have been prep
69. f the axle of a bumper pull trailer If the trailer has living quarters the cargo area of your trailer will have ventilation openings near the floor Do not block these ventilation openings These openings are provided to exhaust potentially deadly fumes 30 OF CARGO WEIGHT 70 OF CARGO WEIGHT 60 OF 40 OF CARGO CARGO WEIGHT WEIGHT Accumulation of hazardous fumes can cause death or serious injury Do not block access to ventilation ports Secure the cargo to the trailer using appropriate straps chains and tensioning devices Close the drop ramp door and secure the trailer door catch using a linchpin or other locking device so that the catch and door cannot open while the trailer is being towed Section 4 Loading The Trailer Always secure the door latch after closing Place a linchpin in the catch If the door opens your cargo may be ejected onto the road resulting in death or serious injury to other drivers 4 3 SECURING THE CARGO Since the trailer cargo is subjected to longitudinal front back and lateral side side forces you must secure all cargo so that it does not shift while the trailer is being towed 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 ropes straps etc to prevent the load from shifting while trailering 1
70. figure 3 11 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 e Fasten chains to safety chain receivers on the hitch not to ball e Have sufficient slack to permit turning and to keep gooseneck on bed of tow vehicle if the trailer comes loose 3 2 2 9 Attach and Test the Breakaway Brake System If the coupler or hitch fails a properly connected and working breakaway brake system will apply electric brakes on the trailer The safety chains will keep the tow vehicle attached and as the brakes are applied at the trailer s axles the trailer tow vehicle combination will come to a controlled stop See figure 3 12 The breakaway brake system includes a breakaway brake controller battery and a switch with a pullpin and lanyard Read and follow the instructions here as 10 17 2008 Page 42 well as the instructions that have been prepared by the breakaway brake controller manufacturer Breakaway Brake Connection Figure 3 12 The breakaway brake system may be fitted with a charging facility that draws power from the tow vehicle If the electrical system on your tow vehicle does not provide power to the breakaway brake battery you must periodically charge the battery on the trailer to keep the breakaway brake system in working order e Visually inspect the breakaway brake system fo
71. g a trailer to a tow vehicle permits the tow vehicle to turn to sharper angles than are permitted by a bumper hitch system A gooseneck coupler consists of a tube in an inverted U shape and a gooseneck ball receiver Figure 3 7 shows a trailer with a gooseneck coupler Gooseneck Coupler ed LL Trailer with Gooseneck Coupler Figure 3 7 We have utilized a Gooseneck ball receiver 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 gooseneck You must provide a gooseneck ball and support structure that is marked with a rating that meets or exceeds the GVW Rating of your trailer and matches the size of the gooseneck ball receiver If the gooseneck ball is too small is underrated is loose or is worn the trailer can come loose from the tow vehicle and may lead to death or serious injury THE TOW VEHICLE SUPPORT STRUCTURE AND GOOSENECK BALL MUST HAVE A RATED TOWING CAPACITY EQUAL TO OR GREATER THAN THE TRAILER Gross Vehicle Weight Rating GVWR IT IS ESSENTIAL THAT THE GOOSENECK BALL BE OF THE SAME SIZE AS THE GOOSENECK BALL RECEIVER IF THE GOOSENECK BALL IS TOO SMALL IS UNDERRATED IS LOOSE OR IS WORN THE TRAILER CAN COME LOOSE FROM THE TOW VEHICLE RESULTING IN DEATH OR SERIOUS INJURY The gooseneck ball size and load rating capacity are marked on the ball hitch capacity is marked on the hitch 10 17 2008 Page 39
72. gnals as required In addition if your trailer has a separate braking system the electrical connector will also supply power to the trailer brakes from the tow vehicle Breakaway switch If the trailer becomes de coupled from the towing vehicle the breakaway switch lanyard attached independently to the tow vehicle hitch will pull a pin in the emergency electrical breakaway switch on the trailer The breakaway switch is activated by a separate battery supply in the trailer such as to energize the trailer brakes independently of the towing vehicle It is important to check the state of charge of the emergency 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 significant 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 if the coupler connection comes loose Jack A device on the trailer that is used to raise and lower the trailer tongue On larger trailers the jack is sometimes called the landing gear Section 3 Coupling To The Tow Vehicle An improperly coupled trailer can result in death or serious injury Do not move the trailer until The coupler is secured and locked The safety chains are secured to the tow vehicle and The trailer jacks are fully retracted Do not tow the tr
73. hat 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 It is recommended that your fully loaded vehicle with any tow vehicles attached be weighed to determine the tire loading at each wheel position Inflation pressure should be adjusted to handle the maximum tire load and all tires on the axle should carry the same inflation pressure Tire pressure should be checked cold or before driving each day and at least once a month Valves and caps should be free of dirt and moisture Section 2 Tire Safety Information 2 3 1 Trailers 10 000 Pounds GVWR or Less The weight of cargo should never exceed Kg of Lbs PULL 16HG824265H130090 Tire Information Placard Figure 2 1 1 Locate the statement The weight of cargo should never exceed XXX kg or XXX lIbs on your vehicle s placard See figure 2 1 2 This figure equals the available amount of cargo and luggage load capacity 3 Determine the combined weight of luggage and cargo being loaded on the vehicle That weight may not safely exceed the available cargo and luggage load capacity The trailer s placard refers to the Tire Information Placard attached adjacent to or near the trailer s VIN Certification label at the left front of the trailer 2 3 2 Trail
74. hen the drop leg base contacts the ground shift the gearbox into low speed mode by pulling out on the handle shaft until it locks into low gear NOTICE Do not use high speed to lift the trailer the drop leg jack mechanism can be damaged High speed is used only to rapidly move the drop leg base into contact with the ground Continue to extend the jack s making sure that the ground is providing stable and level support for the trailer Section 3 Coupling To The Tow Vehicle e Turn the crank two or three turns to take some of the weight of the coupling Do not raise the fifth wheel off the kingpin plate e After the jack s are extended enough to permit driving the tow vehicle away disengage the jack handle from its shaft and return it to its holder Do NOT drive the tow vehicle yet TYPE B LOCKING MECHANISM AS VIEWED THRU THE TOP PLATE f LOCK a a ADJUSTMENT SECONDARY LOCK 360 DEGREE KINGPIN AND LOCK CONTACT NOTE 1 PIPE FRONT RELEASE HANDLE NOT SUPPLIED FRONT RELEASE CAM Opening Fifth Wheel Locks Figure 3 19 e Open the fifth wheel locks by e Pulling the release handle or e Using a separate pipe release handle to engage the solid stud on the secondary lock See figure 3 19 e Slowly drive the tow vehicle away from the trailer e Raise the tow vehicle tailgate 10 17 2008 Page 49 Section 4 LOADING THE TRAILER Improper trailer loading causes many accidents and deaths To
75. iced or repaired Do not tow the trailer with the breakaway brake system ON because the brakes will overheat which can result in permanent brake failure Failure to replace the pullpin 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 the battery manufacturer 3 2 2 h Connect the Electrical Cables Connect the trailer lights to the tow vehicle s electrical system using the electrical connectors e Check all lights for proper operation e Clearance and Running Lights Turn on tow vehicle headlights e Brake Lights Step on tow vehicle brake pedal e Turn Signals Operate tow vehicle directional signal lever e Check electric brakes for proper operation using the controller mounted in the cab 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 10 17 2008 Page 43 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 m p h manually operate the electric brake controller in the tow vehicle cab You should feel th
76. ilure 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 The various fastener types used on your trailer are e Bolts which are used mainly for attaching door and gate hinges to the trailer body e Buck Rivets which are used to attach the sides and roof panels of the body to each other and to the frame of the trailer Broken or damaged fasteners or welds can cause injury or damage to trailer and conienis Inspect trailer before each use and repair or replace all damaged parts 8 2 2 Welds All welds can crack or fail when subjected to heavy loads or movement of cargo that was not properly tied to prevent movement 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 prevent severe damage to your trailer inspect all of the welds for cracks or failure at least once a year Do not attempt to repair a cracked or broken weld unless you have the skills and equipment to make a proper repair Improper weld repair will lead to early failure of the trailer structure and serious injury or death Go to your Haulmark dealer Section 8 Inspection Service amp Maintenance Broken or damaged fasteners or welds can cause injury or
77. ing safety chain safety brake tires wheels and lights e Check the lug nuts or bolts for tightness e Check coupler tightness after towing 50 miles e Adjust the brake controller to engage the trailer brakes before the tow vehicle brakes Your dealer can assist you by making this adjustment e Use your mirrors to verify that you have room to change lanes or pull into traffic e Use your turn signals well in advance e Allow plenty of stopping space for your trailer and tow vehicle e Do not drive so fast that the trailer begins to sway due to speed Never drive faster than 60 m p h 10 17 2008 Page 9 Allow plenty of room for passing A rule of thumb is that the passing distance with a trailer is 4 times the passing distance without a trailer Shift your automatic transmission into a lower gear for city driving Use lower gears for climbing and descending grades Do not ride the brakes while descending grades they may get so hot that they stop working Then you will potentially have a runaway tow vehicle and trailer To conserve fuel don t use full throttle to climb a hill Instead build speed on the approach Slow down for bumps in the road Take your foot off the brake when crossing the bump Do not brake while in a curve unless absolutely necessary Instead slow down before you enter the curve and power through the curve This way the towing vehicle remains n charge Do not apply the brakes to
78. innerliner from cord material in the carcass Intended outboard sidewall The sidewall that contains a white wall bears white lettering or bears manufacturer brand and or model name molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle Light truck LT tire A tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose passenger vehicles May be used on trailers 10 17 2008 Page 25 Load rating The maximum load that a tire is rated to carry for a given inflation pressure Maximum load rating The load rating for a tire at the maximum permissible inflation pressure for that tire Maximum permissible inflation pressure The maximum cold inflation pressure to which a tire may be inflated Maximum loaded vehicle weight The sum of curb weight accessory weight vehicle capacity weight and production options weight Measuring rim The rim on which a tire is fitted for physical dimension requirements Non pneumatic rim A mechanical device which when a non pneumatic tire assembly incorporates a wheel supports the tire and attaches either integrally or separably to the wheel center member and upon which the tire is attached Non pneumatic spare tire assembly A non pneumatic tire assembly intended for tempor
79. ion 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 vehicle is designed 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 2 6 3 Understanding Tire Pressure and Load Limits Tire inflation pressure is the level of air in the tire that provides it with load carrying capacity and affects the overall performance of the vehicle The tire inflation pressure is a number that indicates the amount of air pressure measured in pounds per square inch psi a tire requires to be properly inflated You will also find this number on the vehicle information placard expressed in kilopascals kPa which is the metric measure used internationally Manufacturers of passenger vehicles and light trucks determine this number based on the vehicle s design load limit that is the greatest amount of weight a vehicle can safely carry and the vehicle s tire size The proper tire pressure for your vehicle is referred to as the recommended cold inflation pressure As you will read below it is difficult to obtain the recommended tire pressure if your tires are not cold Becaus
80. ions and instructions Portions of this manual were used with the expressed authority of Dexter Axle but Dexter Axle is not responsible for the accuracy of the information contained herein Section 1 SAFETY INFORMATION 1 1 SAFETY ALERT SYMBOLS AND SIGNAL WORDS This manual provides instructions for the operation and care of Haulmark Enclosed Trailers The instructions in this manual must be followed to ensure the safety of persons and cargo and satisfactory life of the trailer Safety precautions to protect against injury or property damage must be followed at all times An Owner s Manual that provides general trailer information cannot cover all of the specific details necessary for the proper combination of every trailer tow vehicle and hitch Therefore you must read understand and follow the instructions given by the tow vehicle and trailer hitch manufacturers as well as the instructions in this manual 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 call Haulmark Industries Inc at 800 348 7530 or your dealer for assistance The safety information in this manual is denoted by the safety alert symbol The level of risk is indicated by the following signal words A DANGER DANGER Immediate hazards which WILL resul
81. ism Figure 3 4 3 2 1 C Couple the Trailer to the Tow Vehicle Using the jack lower the trailer tongue until the coupler fully engages the hitch ball If the coupler does not line up with the hitch ball adjust the position of the tow vehicle Engage the coupler locking mechanism In the engaged position the locking mechanism securely holds the coupler to the hitch ball Insert a pin or lock through the hole in the locking mechanism Be sure the coupler is all the way on the hitch ball and the locking mechanism is engaged A properly engaged locking mechanism will allow the coupler to raise the rear of the tow vehicle Using the trailer jack test to see that you can raise the rear of the tow vehicle by 1 inch after the coupler is locked to the hitch NOTICE The tongue jack can be damaged by overloading Do not use the tongue jack to raise the tow vehicle more than 1 inch If the coupler cannot be secured to the hitch ball do not tow the trailer Call Haulmark Industries Inc at 800 348 7530 or your dealer for assistance Lower the trailer so that its entire tongue weight is held by the hitch and continue retracting the jack to its fully retracted position Section 3 Coupling To The Tow Vehicle 3 2 1 d Rig the Safety Chains Safety Chain Arrangement Figure 3 5 e Visually inspect the safety chains and hooks for wear or damage Replace worn or damaged safety chains and hooks before towing e Rig the saf
82. jack can be damaged by overloading Do not use the drop leg jack to raise the tow vehicle more than 1 inch If the gooseneck ball cannot be secured to the receiver do not tow the trailer Call Haulmark Industries Inc at 800 348 7530 or your dealer for assistance After testing to see that the receiver is properly secured and locked to the ball retract the jack to its fully retracted position Return the drop legs to their upper positions The drop legs are held in the lowered position with a plunger pin Rotating the plunger pin while pulling it outward will cause it to come out of engagement with the drop leg and the leg will rapidly rise See figure 3 10 If the tow vehicle is equipped with a tailgate raise IG e Pick up the trailer wheel blocks No one must be under the trailer or coupler The drop legs are heavily spring loaded in the lowered position They will rapidly return to the upper position when released and can inflict serious bruises scrapes or pinching during the coupling Death or serious injury can occur if the trailer drops Keep your feet shins and hands well clear of the drop legs and drop leg bases when releasing the drop legs 3 2 2 e Couple the Trailer to the Tow Vehicle e Rotate the jack handle counter clockwise This will retract the jack causing the gooseneck ball receiver to drop down so it can fully engage the gooseneck ball and transfer the weight of the trailer tongue to the
83. l indicated on the hub or cap 8 2 13 0 E Z Lube or Other Grease Fitting Lubricated Bearings Bearings should be lubricated every 12 months or 12 000 miles whichever occurs first e Remove the rubber plug if equipped from the hub end e Place a standard grease gun onto the grease fitting Make sure the grease gun nozzle is fully seated on the fitting e Pump grease into the fitting while rotating hub or drum The old displaced grease will begin to flow back out to the cap around the grease gun nozzle e Stop when new grease is observed e Wipe off excess and install rubber plug See figure Grease Fitting Spring Loaded Metal End Cap Double Lip Seal E Z Lube Bearing Shown Figure 8 6 8 2 13 c Nev R Lube or Other Sealed Bearings Bearing should be inspected every 12 months or 12 000 miles whichever occurs first Refer to the axle manufactures manual for information on checking wheel end play and clearance See figure 8 7 10 17 2008 Page 66 8 7 8 2 14 Lug Nuts Bolts Lug nuts are prone to loosen right after a wheel is mounted to a hub When driving on a remounted wheel check to see 1f the lug nuts are tight after the first 10 25 and 50 miles of driving and before each tow thereafter Lug Nut Tightening Torque Being sure wheel mounting nuts lug nuts on trailer wheels are tight and properly torqued is an important responsibili
84. ld ever be put in the tire under normal driving conditions 2 6 10 b UTQGS Information Treadwear Number This number indicates the tire s wear rate The higher the treadwear number is the longer it should take for the tread to wear down For example a tire graded 400 should last twice as long as a tire graded 200 Traction Number This letter indicates a tire s ability to stop on wet pavement A higher graded tire should allow you to stop your car on wet roads in a shorter distance than a tire with a lower grade Traction is graded from highest to lowest as AA A B and C Temperature Letter Section 2 Tire Safety Information This letter indicates a tire s resistance to heat The temperature grade is for a tire that is inflated properly and not overloaded Excessive speed underinflation or excessive loading either separately or in combination can cause heat build up and possible tire failure From highest to lowest a tire s resistance to heat is graded as A B or C 2 6 10 c Information on Light Truck LT Tires Please refer to the following diagram Maximum biag amp inflatian when uded as a dual Be ynds Sia conditions Load Light truck tire F y ts a qa Fria r OT pa LW ae wee i Po fr Maximum load amp inflation when Used as A aingle Load inflation limits Tires for light trucks have other markings besides those found on the sidewalls of passenger tires
85. lean the locations where the drive shaft passes through the bushings e Hand pack grease on the gears e Grease the sliding track 10 17 2008 Page 62 8 2 5 Trailer Brakes 8 2 5 a Initial Inspection Brakes that are out of adjustment can result in death or serious injury Brakes must be adjusted at the intervals specified The brake shoes must be adjusted after the first 200 miles of use and each 3 000 miles thereafter Most axles are not fitted with a brake mechanism that will adjust the brakes Brakes must be adjusted manually It is critical that the brakes be adjusted at the specified intervals Brakes that are out of adjustment can cause a collision which may result in death or serious injury 8 2 5 0 Periodic Inspection 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 8 2 5 Manually Adjusting Brake Shoes Most braking systems require periodic adjustment Read your axle and brake manual to see how to adjust your brakes If you do not have this manual call Haulmark Industries Inc at 800 348 7530 or your dealer for assistance The following steps apply to adjust most manually adjustable brakes If you are unsure or do not understand how to adjust your brakes have the brakes adjusted by your dealer Properly adjusted brakes are critical for safety e Jack up the trailer and secur
86. mounted ball on the towing vehicle The receiver ball and hitch transfer the towing forces between the tow vehicle and the trailer 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 receiver to the ball for proper operation If you see or can feel evidence of wear such as flat spots pitting or corrosion on the ball or receiver immediately have your dealer inspect them to determine the proper action to prevent possible failure of the ball and receiver system When replacing a ball the load rating must match or exceed the GVWR of the trailer 8 2 6 C Fifth Wheel Kingpin Before each tow inspect the fifth wheel and kingpin for wear and coat the contact surface of the fifth wheel plate with water resistant Lithium base grease If you see evidence of wear on the fifth wheel or kingpin immediately have your dealer inspect them to determine the proper action to prevent failure of the fifth wheel and kingpin system 8 2 7 Landing Leg or Jack If a grease fitting is present you must 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 8 2 8 Lights and Signals Before each tow check the trailer taillights stoplights turn signals and any clearance lights for proper operation
87. mp Hominal widih of Speed symbol tire in millimeters om 65R15 US DOT tire Passenger ot oe Spy r4 identification number ee a a conditions Max Wet oes PH gt Tire ply rmilssable ca ee OW OK Lee f composition niflation ty i p pressure 3 Ta used Fy Pr ggg T ol x3 PEF Hrga Ti Treadwear traction and temperature grades lMax 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 Next Number This two digit number known as the aspect ratio gives the tire s ratio of height to width Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement R The R stands for radial Radial ply construction of tires has been the industry standard for the past 20 years Next Number This two digit number is the wheel or rim diameter in inches If you change your wheel size you will have to purchase new tires to match the new wheel diameter Next Number This two or three digit number is the tire s load index It is a measurement of how much weight each tire can support You may find this information in your owner s 10 17 2008 Page 29 _ Severe snow and materials manual If not contact a local tire dealer Note You may not find this information on all
88. n 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 Never exceed an axle Gross Axle Weight Rating GAWR 10 17 2008 Page 50 Tongue Weight It is critical to have a portion of the trailer load carried by the hitch mechanism 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 on the other hand there is too much tongue weight the tow vehicle is prone to jack knife Furthermore the front wheels of the tow vehicle can be too lightly loaded and cause loss of steering 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 exceed their Gross Axl
89. nd couplers are not adequate grounds for your trailer If an auxiliary battery is added to your trailer there must be a fuse installed between the battery and the trailer If you have any questions regarding the wiring of either your tow vehicle or your trailer contact either your dealer or Haulmark 10 17 2008 Page 69 Section 9 Technical Reference White 1 Common Ground LJ 6 Red 5 Stop amp Left Turn dS Green icense Plate Brown htt urn BARGMAN BARGMAN 4 PIN MAIN 4 PIN MAIN TRAILER PLUG CONNECTOR Bargman 4 Circuit Harness Connector ooo White Ground Common Ground Red Stop amp Right Turn d T Yellow 7 i i Green 3 amp License Plate BARGMAN Sa 7 PINMAIN BARGMAN S4 TRAILER PLUG T PIN MAIN qp CONNECTOR D Bargman 7 Circuit Harness Connector 10 17 2008 Page 70 Section 9 Technical Reference T OO 000 White 1 Common Ground f Red 5 Stop amp Left Turn JS Black Battery Charge H Yellow 7 Back up Lights _ THe Green 3 Clearance and License Plate i Brown 6 Stop amp Right Turn _ Ly E I lt A Brown Stop amp Left Turn BARGMAN p Electri i Blue Op Electric Brake 7 PIN MAIN Blue 2 Electric Brake BARGMAN TRAILER PLUG 7 PIN MAIN CONNECTOR ite Ground Optional Battery Charger Brake Away Switch Bargman 7 Circuit Connector with Trickle Charger 9 2 HITCH SYSTEMS The various com
90. nd should be corrected Section 8 Inspection Service amp Maintenance e Contact your dealer or vehicle manufacturer immediately if you experience any persistent lug nut loosening or any other lug wheel or axle problems e If you find any loose lug nuts while tightening remove the wheel s and take them to your dealer for inspection The wheel may be damaged and if so must be replaced Lug nuts on a damaged wheel holes will not retain tightness e In the event of a wheel separation incident notify the vehicle manufacturer and dealer Seek prompt professional assistance in assessing the trailer and its gear and retain but don t re use involved lugs wheels and studs Don t repair or service the trailer yourself Contact a trained technician Lug nuts are prone to loosen after being first assembled Death or serious injury can result Check lug nuts for tightness on a new trailer and after re mounting a wheel at 10 25 and 50 miles Metal creep between the wheel rim and lug nuts bolts will cause rim to loosen Death or injury can occur if wheel comes off Tighten lug nuts bolts before each tow Tighten the lug nuts to the proper tightness to prevent wheels from coming loose Refer to the steps that follow and the axle manufacturer s information Use a calibrated torque wrench to tighten the lug nuts Over tightening may result in breaking the studs or permanently deforming the mounting stud holes in
91. ng is the maximum allowable gross weight of the trailer and its contents The gross weight of the trailer includes the weight of the trailer and all of the items within it such as cargo water food and other supplies GVWR is sometimes referred to as GTW Gross Trailer Weight or MGTW Maximum Gross Trailer Weight GVWR GTW and MGTW are all the same rating 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 PSIC The pounds per square inch cold is the tire pressure Kilopascals Pounds per Square Inch measured when Cold VIN The Vehicle Identification Number VEHICLE TYPE Trailer plus the model number of the trailer Certification Statement This trailer meets all the Federal Motor Vehicle Safety Standards in effect on the date of manufacture shown above There are two additional weights that are not provided on the Certification VIN tag that are important and that should be put somewhere on the trailer These are the empty weight and maximum cargo weight The empty weight is sometimes put on the Manufacturer s Certificate of Origin Title but may not be accurate for your particular trailer due to accessories optional equipment et
92. not use high speed to lift the trailer the drop leg jack mechanism can be damaged High speed is used only to rapidly move the drop leg base into contact with the ground Continue to extend the jack s making sure that the ground is providing stable and level support for the trailer After the jack s are extended and the gooseneck ball receiver is well clear of the gooseneck ball to permit 10 17 2008 Page 44 driving the tow vehicle away disengage the handle from its shaft and return to its holder 3 2 3 Trailer with Fifth Wheel Coupler and Drop Leg Jack A fifth wheel coupler on the trailer connects to a kingpin that is installed on the tow vehicle A fifth wheel coupler on the tow vehicle connects to a kingpin that is installed on the trailer See figures 3 13 and 3 14 A fifth wheel coupler includes a flat load bearing plate with a slot and a mechanism inside the slot that grips the kingpin Haulmark has selected a fifth wheel coupler that is suitable for the size and weight of the trailer You must provide a kingpin and kingpin plate that match the fifth wheel and that is rated for the Gross Vehicle Weight Rating GVWR of your trailer Trailer with Fifth Wheel Coupler Figure 3 13 Fifth Wheel Coupler Figure 3 14 3 2 3 a Before Coupling the Trailer to the Tow Vehicle e Be sure the size and rating of the fifth wheel and kingpin match e Wipe the kingpin clean and inspect it visually and
93. nst injury or property damage must be followed at all times This section of the manual is organized into the following subsections e Using an adequate tow vehicle and hitch e Coupling the trailer to the tow vehicle e Loading the trailer e Checking the trailer for safety before each tow e Breaking in a new trailer e Synchronizing the brakes e Uncoupling the trailer Trailer Accessories Haulmark offers trailers with a wide range of accessories Instructions for safe use of these accessories are located in separate instruction manuals some of which are provided by the accessory manufacturer Section 7 of this manual contains instructions regarding the use of some accessory items such as e Gasoline or diesel generators e Accessory Battery e Shore Power connections to provide power by plugging the trailer in to an external source of electrical power e LP Liquid Petroleum Gas facilities for heating or other uses e Electric powered hydraulic landing gear e Vending or Accessory Doors Your Haulmark trailer has been built using parts from various component manufacturers Where this manual indicates that you should read another manual and you do not have that manual call Haulmark Industries Inc at 1 800 348 7530 for assistance 3 1 USE AN ADEQUATE TOW VEHICLE AND HITCH If the tow vehicle or hitch is not properly selected and matched to the Gross Vehicle Weight Rating GVWR of your trailer you can ca
94. ntain and replace the battery according to the battery manufacturer instructions Breakaway Switch This switch causes the breakaway battery to operate the electric brakes if the trailer uncouples from the tow vehicle The lanyard for the pull pin is connected to the tow vehicle and the switch is connected to the trailer 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 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 Tow Vehicle Operated Electric Brakes The electric brakes that operate in conjunction with the tow vehicle brakes must be synchronized so that braking is properly 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 Magnets for all Electric Brakes 10 17 2008 Page 63 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
95. occupant weight Section 2 Tire Safety Information distributed in accordance with Table I of CRF 49 571 110 and dividing by 2 Weather side The surface area of the rim not covered by the inflated tire Wheel center member In the case of a non pneumatic tire assembly incorporating a wheel a mechanical device which attaches either integrally or separably to the non pneumatic rim and provides the connection between the non pneumatic rim and the vehicle or in the case of a non pneumatic tire assembly not incorporating a wheel a mechanical device which attaches either integrally or separably to the 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 2 6 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
96. or code Rim width This means the nominal distance between rim flanges Section width The linear distance between the exteriors of the sidewalls of an inflated tire excluding elevations due to labeling decoration or protective bands Sidewall That portion of a tire between the tread and bead Sidewall separation The parting of the rubber compound from the cord material in the sidewall Special Trailer ST Tire The ST is an indication the tire is for trailer use only Test rim The rim on which a tire is fitted for testing and may be any rim listed as appropriate for use with that tire Tread That portion of a tire that comes into contact with the road Tread rib A tread section running circumferentially around a tire Tread separation Pulling away of the tread from the tire carcass Treadwear indicators TWD The projections within the principal grooves designed to give a visual indication of the degrees of wear of the tread Vehicle capacity weight The rated cargo and luggage load plus 68 kilograms 150 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
97. ore carbon monoxide detectors in the trailer s accommodation spaces Carbon Monoxide is an odorless gas that can cause death Be certain exhaust from a running generator does not accumulate in or around your trailer by situations such as e Being drawn in by fans or ventilators operated in a trailer e Prevailing wind e Being trapped between your trailer and other trailers vehicles or buildings or e Being trapped between your trailer and or in a snow bank or other nearby objects Gasoline and diesel generators pose a risk of death from e Carbon Monoxide e Fire and Explosion e Electrocution Do not operate a generator without having a working carbon monoxide detector Do not refuel a running generator Do not refuel near ignition sources 1 2 17 Shore Power Shore Power is the name given to connecting your trailer to a source of electrical power using a cord specifically designed for that purpose Shore power poses a risk of death due to electrocution Always use a grounded connection Never connect to an ungrounded source of shore power Never remove the third prong from the shore power plug Section 1 Safety Information Risk of fire Connect only to source of correct voltage Risk of fire or explosion If LP gas is detected by smell or by the LP Do not overload electrical circuits gas detector e Do not touch electrical switches Extinguish flames and pilot lights
98. orn damaged or under inflated tires can cause loss of control injury and damage Check tires before each tow 8 2 11 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 i e being out of round and replace any damaged wheel Inspect the wheels for damage every year even if no obvious impact has occurred Never install aftermarket wheels or lug nuts on your trailer Use only original equipment wheels and lugs nuts Aftermarket wheels and lug nuts may not meet the Section 8 Inspection Service amp Maintenance load carrying requirements pressure capacity and offset as the original equipment 8 2 12 Wheel Liners Simulators Your trailer may be equipped with wheel liners simulators See figure 8 4 To remove the liners to access the wheel lugs 1 Locate the two removable jam nuts 1 These nuts will have a crimp mark on every other hex and are 180 degrees apart 2 Remove the jam nuts Do not use power tools on jam nuts 3 Remove the hub cover 2 wheel liner 3 spacers 4 and stud extenders 5 To install the liners 1 Install stud extenders 5 180 degrees apart and tighten to 30 Ib ft of torque 2 Install spacers 4 wheel liner 3 hub cover 2 and jam nuts 1 Tighten jam nuts to 30 Ib ft of torque Wheel Simulator Figure 8 4 8 2 13 Wheel Bearings A loose worn or damaged wheel be
99. ots from developing The main cause of tire failure 1s 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 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 dramatically affected Ifthe 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
100. ponents of trailer fastening systems may be referred to in terms of Class depending on their load rating The rating of hitch systems on tow vehicles also considers whether the hitch only carries the tongue weight for example a ball hitch which is also referred to as a Weight Carrying Hitch or if it distributes the tongue weight to all of the tow vehicle wheels also referred to as a Weight Distributing Hitch Your hitch or hitch ball may carry a class rating instead of a pound rating This chart may be used to cross reference hitch ball classification with trailer weight and tongue weight Hitch Classification Class Type of Hitch Maximum Maximum Towed Weight Tongue Weight Class 1 Weight Carrying Hitch up to 2 000 pounds up to 200 pounds Class 1 Weight Dist Hitch up to 2 000 pounds up to 300 pounds Class 2 Weight Carrying Hitch up to 3 500 pounds up to 300 pounds Class 2 Weight Dist Hitch up to 3 500 pounds up to 500 pounds Class 3 Weight Carrying Hitch up to 5 000 pounds 300 to 500 pounds Class 3 Weight Dist Hitch up to 7 500 pounds up to 750 pounds Class 4 Weight Dist Hitch up to 10 000 pounds up to 1 000 pounds 10 17 2008 Page 71 section 10 WARRANTY Haulmark Industries Inc provides you with a 3 year limited warranty which gives you specific legal rights Please be sure that you read and understand our Warranty THREE YEAR Limen WARRANTY Haulmark Industries Inc P O Box 281 Bristol IN 46507 Warrantor warr
101. r Trailers may be fitted with D ring hold downs and or a track system that can be used to secure the cargo Inspect the D rings and track system for looseness or signs of bending before loading the cargo onto the trailer Damaged or loose D rings can break allowing cargo to become loose inside the trailer Loose cargo can shift the center of gravity and result in loss of control of the trailer Inspect D rings and test them for looseness before loading cargo Do not use a damaged or loose D ring to secure cargo 4 2 2 Loading the Trailer Enclosed trailers may be fitted with a drop ramp door The weight of the drop ramp door may be partially held by a spring and cable counterbalance assembly If this assembly is out of adjustment or worn out it will not provide the expected assistance for slow and careful lowering and raising of ramp 10 17 2008 Page 52 A spring and cable counterbalance can inflict serious injury if it breaks or if incorrectly adjusted Stand to the side when opening the door Inspect the cable and cable ends each time the door is operated Do not attempt to service the counterbalance Take the trailer to your Haulmark dealer for service Carefully lower the drop ramp to the ground Load the cargo up the drop ramp and into the trailer with approximately 70 of the cargo in front of the axle of a goose neck trailer and 60 of the cargo in the front o
102. r broken parts e Connect the pullpin lanyard to the tow vehicle so that the pullpin will be pulled out before all of the slack in the safety chains is taken up see Breakaway Brake Connection figure 3 12 Do not connect the pullpin lanyard to a safety chain safety chain receiver or to the gooseneck ball or its support This would keep the breakaway brake system from operating when it is needed Contact the hitch manufacturer or installer if you are not certain of the hitch provisions for the breakaway brake connection e To test the breakaway brake battery pull out the pullpin 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 e Immediately replace the pullpin The breakaway brake system battery discharges rapidly when the pullpin is removed Section 3 Coupling To The Tow Vehicle 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 Connect the breakaway lanyard to the tow vehicle and NOT to the safety chain safety chain receiver gooseneck ball or gooseneck ball support Test the function of the breakaway brake system before towing the trailer Do not tow the trailer if the breakaway brake system is not working Have it serv
103. r Haulmark dealer The 2000 Ib capacity model is most commonly useful An unrestrained trailer can fall off its support resulting in serious injury or death Block trailer wheels front and rear before checking tongue weight For most trailers it is easier to go to a truck stop where there is a certified scale Pull the trailer onto the scale and decouple 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 second ticket which lists the trailer s axle weight Simple subtract the axle weight from the total weight to determine the hitch weight It is also desirable while you are at the scale to 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 10 17 2008 Page 51 they are in the same proportion as the tow vehicle alone and that the rear axle is not overloaded You are responsible to secure your cargo in such a way that it does not shift within the trailer while the trailer is being towed The ride inside a trailer can be very bumpy and rough A shifting load can re
104. r mirror requirements Section 3 Coupling To The Tow Vehicle Heavy Duty Flasher A Heavy Duty Flasher is an electrical component that may be required when your trailer turn signal lights are attached to the tow vehicle flasher circuit Electrical Connector An Electrical Connector connects the light and brake systems on the trailer to the light and brake controls on the towing vehicle Heavy Duty Engine Oil Cooling System The tow vehicle engine works harder when a trailer is being towed Depending on the size of the trailer you may need to install a separate engine oil cooler Inadequate cooling may result in sudden engine failure Ask the tow vehicle dealer if it is necessary to install a heavy duty cooling system Automatic Transmission Oil Cooler The automatic transmission of a towing vehicle handles more power when a trailer is being towed Inadequate cooling will shorten transmission life and may result in sudden transmission failure Ask the tow vehicle dealer if it is necessary to install a separate oil cooler for the automatic transmission Fire Extinguisher It is sensible to have a fire extinguisher in the tow vehicle Emergency Flares and Emergency Triangle Reflectors It is wise to carry these warning devices even if you are not towing a trailer It is particularly important to have these when towing a trailer because the hazard flashers of your towing vehicle will not operate for as long a period of time when the
105. railer tongue to the towing vehicle When the drop leg base is no longer resting on the ground the towing vehicle hitch is holding all of the weight of the trailer tongue Continue retracting the jack to its fully retracted position Return the drop legs to their upper positions The drop legs are held in the lowered position with a plunger pin Rotating the plunger pin while pulling it outward about 34 inch will cause it to come out of the engagement with the drop leg and the leg will rapidly raise See figure 3 17 e Raise the tailgate e Pick up the trailer wheel blocks Note Locks Extend i fs i men Window Ee H i e s cy To Open y A Locks Shown In Closed Position No Space Ye ny Y jokes Flush E 7 sw With Ends Y e Of Locks Ww Ee Shown In Open Position Correct Check 3 Space Incorrect Fifth Wheel Checks Figure 3 16 e Check 1 The adjustment nut must be seated against the fifth wheel e Check 2 The secondary lock must be behind the yoke e Check 3 The fifth wheel must be in contact with the kingpin plate with no space Drop Leg Jack Mechanism Figure 3 17 10 17 2008 Page 46 Section 3 Coupling To The Tow Vehicle The drop legs are heavily spring loaded in the lowered position They will rapidly return to the upper position when released and can inflict serious bruises scrapes or pinching Keep your feet shins and hands well clear of the drop legs and
106. re power Replace fuses with like rating 7 4 LP GAS FUEL SYSTEM When LP gas is used in a living quarters environment our living quarters meet ANSI 1 14 2 and NFPA 11 9 2 standards LP gas systems are installed to operate a variety of appliances such as stoves refrigerators heating units and electrical generators The exhaust fumes from burning LP gas contain carbon monoxide Carbon monoxide gas is odorless and can cause death or serious brain injury if inhaled The exhaust from LP appliances must be directed to the outdoors You must have an 10 17 2008 Page 57 operating carbon monoxide detector in the accommodation space of your trailer A DANGER You can die or be brain damaged by Carbon Monoxide Make certain the exhaust from LP appliances is directed to the outdoors Have a working carbon monoxide detector in the accommodation spaces of your trailer before operating any LP gas appliance Do not operate portable grills portable stoves portable lanterns or portable heaters inside the trailer When used for the first time or after a period of storage the LP gas lines will be full of air and must be purged of air before the appliances will stay lit Have the LP gas lines purged by your trailer dealer or an LP gas dealer An LP gas system is designed to operate with a supply of LP gas only NOT natural gas A natural gas supply is unsafe for the system s pressure regulation devices Risk of
107. rom speeds no greater than 10 m p h If your trailer is equipped with brakes try using different combinations of trailer electric brake and tow vehicle brake Note the effect that the trailer brakes have when they are the only brakes used When properly adjusted the trailer brakes will come on just before the tow vehicle brakes It will take practice to learn how to back up a tow vehicle with a trailer attached Take it slow Before backing up get out of the tow vehicle and look behind the trailer to make sure that there are no obstacles Some Section 1 Safety Information drivers place their hands at the bottom of the steering wheel and while the tow vehicle is in reverse think of the hands as being on the top of the wheel When the hands move to the right counter clockwise as you would do to turn the tow vehicle to the left when moving forward the rear of the trailer moves to the right Conversely rotating the steering wheel clockwise with your hands at the bottom of the wheel will move the rear of the trailer to the left while backing up If you are towing a bumper hitch rig be careful not to allow the trailer to turn too much because it will hit the rear of the tow vehicle To straighten the rig either pull forward or turn the steering wheel in the opposite direction 1 2 21 Safe Trailer Towing Guidelines e Recheck the load tiedowns to make sure the load will not shift during towing e Before towing check coupl
108. rops An improperly coupled fifth wheel can come loose resulting in death or serious injury Do not tow the trailer until all of the visual checks are met Adjust the height of the trailer using the jack so that the fifth wheel plate just touches the kingpin plate Slowly back up the tow vehicle keeping the e Adjustment nut against fifth wheel e Secondary lock behind yoke e Fifth wheel against kingpin plate kingpin centered in the slot of the fifth wheel Continue backing up until the fifth wheel locks firmly on the kingpin e Visually check to confirm that the fifth wheel locks are properly locked onto the kingpin by performing the three checks illustrated in the Fifth Wheel Checks figure 3 16 e Attempt to pull forward as an initial test of the closing of the fifth wheel locks Raise The Drop Leg Jack A trailer having a fifth wheel coupler will be outfitted with one or two drop leg jacks for raising and lowering the fifth wheel coupler Because we use several drop leg jack mechanisms the general instructions below may vary slightly from the jack manufacturer s instructions If the trailer jack on your trailer does not resemble the jack shown in the figures follow the jack instructions Laisa Y provided by the jack manufacturer From Fifth Wheel Note Secondary 5 amp Lock Away From e Rotate the jack handle counter clockwise This will slowly retract the jack and transfer the weight of the t
109. s 9 1 2 22 Safety Warning Labels on Your Trailer 10 1 2 23 Reporting Safety Defects ccccccccccccssesesceeseees 21 SECTION 2 TIRE SAFETY INFORMATION 22 2d TRAILER TIRE INFORMATION 22 22 STORING YOUR VEHICLE WITHOUT REMOVING THE TEES a e E E E E ie aeaesens 23 293 STEPS FOR DETERMINING CORRECT LOAD LIMIT TRAED open E A E 23 2 3 1 Trailers 10 000 Pounds GVWR or LeSS 24 2 3 2 Trailers Over 10 000 Pounds GVWR 24 2 4 STEPS FOR DETERMINING CORRECT LOAD LIMIT TOW VENICE ei sacazcarsseasecauavanaeansaaiaaansaagacapaassscarsaanerraceiners 24 2D GLOSSARY OF TIRE TERMINOLOGY 00000 24 2 6 TIRE SAFETY EVERYTHING RIDES ON IT 21 2 6 1 Safety First Basic Tire Maintenance ar 2 6 2 Finding Your Vehicle s Recommended Tire Pressure and Loga TIMMS ard ed ccasonencemneen Z 2 6 3 Understanding Tire Pressure and Load Limits 27 2 6 4 Checking Tire Pressure jossssesitinsccnssidtesinxesnsviss 28 2 6 5 Steps for Maintaining Proper Tire Pressure 28 200 TUCE E eirean e EEEE EEEREN 28 20 7 Twe Trend RE CoE ee Rene eee 28 2 6 8 Tire Balance and Wheel Alignment 28 2 6 9 Tire Repaif scsisccinesreisiresecesvsaeasaatieoseatncesniatisonts 28 2 6 10 Tire Fundamentals ccccccccccccssseeccecceeeeeneeees 29 2 6 10 a Information on Passenger Vehicle Tires 29 2610 0 UWlOGS Informatics ctcccscievesscssutsaveiecnceseacsees 29 2 6 10 c Information
110. s of driving and before each tow thereafter Metal creep between the wheel rim and lug nuts bolts will cause rim to loosen Death or injury can occur if wheel comes off Lug nuts are prone to loosen after being first assembled Death or serious injury can result Tighten lug nuts bolts before each tow Check lug nuts for tightness on a new trailer and after re mounting a wheel at 10 25 and 50 miles 10 17 2008 Page 68 Section 9 TECHNICAL REFERENCE 9 1 TRAILER LIGHTING ELECTRICAL CONNECTION The electrical wiring on your Haulmark trailer has been designed and built in accordance with all the Federal Motor Vehicle Safety Standards that were in effect when the trailer was produced Wiring Your tow vehicle must have the correct plug at the rear and must be connected to the correct tow vehicle circuits for the vehicle to correctly tow the trailer Trailers not equipped with brakes will have a 4 way fl at plug and all other trailers will have a larger 7 way round plug The figure below illustrates the wiring code that has been adopted for several types of electrical lighting connectors Recept WHITE 1 GROUND BLUE 2 BRAKES GREEN 3 RUNNING LIGHTS BLACK 4 HOTLINE RED 5 LEFT TURN SIG BROWN 6 RIGHT TURN SIG YELLOW 7 AUXILLARY RN RUNNING LIGHTS 7 WAY PLUG for tow vehicle It is very important that you have a ground wire running from the plug to the frame of your tow vehicle Hitches safety chains a
111. s the brake cylinders Like electrical brakes an electric hydraulic braking system is operated by an electrical signal from the tow vehicle 8 2 6 Trailer Connection to Tow Vehicle 8 2 6 a Coupler and Ball The coupler on the trailer connects to the ball attached to the hitch on the tow vehicle The coupler ball and hitch transfer the towing forces between the tow vehicle and the trailer 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 Section 8 Inspection Service amp Maintenance 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 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 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 8 2 6 b Gooseneck The gooseneck receiver on the trailer connects to a hitch
112. serious injury if the coupler or ball hitch fails Test the function of the breakaway brake system before towing the trailer Do not tow the trailer if the breakaway brake system is not working have it serviced or repaired Connect the breakaway lanyard to the tow vehicle NOT to the safety chain and NOT to the hitch ball 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 Failure to replace the pullpin 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 10 17 2008 Page 38 Replace the breakaway brake battery according to the intervals specified by the battery manufacturer 3 2 1 f Connect the Electrical Cables Connect the trailer lights to the tow vehicle s electrical system using the electrical connectors e Check all lights for proper operation e Clearance and Running Lights Turn on tow vehicle headlights e Brake Lights Step on tow vehicle brake pedal e Turn Signals Operate tow vehicle directional signal lever e Check electric brakes for proper operation using brake controller mounted in the cab If your trailer has electric brakes your tow vehicle will have an electric brake controller that sends
113. sult 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 ropes straps etc to prevent the load from shifting while trailering 4 2 LOADING CARGO Couple the trailer to the tow vehicle before loading The tongue of a bumper pull trailer can rise during loading before the cargo is properly distributed Depending on the exact model of your Haulmark trailer the cargo carrying portion may be designed for carrying such things as A car Snowmobiles All Terrain Vehicles ATVs Motorcycles Do not transport people containers of hazardous substances cans or containers of flammable substances However fuel in the tank of an off road vehicle or a car or motorcycle etc may be carried inside of your enclosed cargo trailer Never transport people inside your Haulmark trailer even if it has living quarters Besides putting their lives at risk the transport of people may be illegal Section 4 Loading The Trailer Do not transport flammable explosive poisonous or other dangerous materials in your trailer Exceptions Fuel in the tanks of vehicles that are being towed Fuel stored in proper containers used in trailer living quarters for cooking Fuel stored in the tank of an on board generator 4 2 1 Preparing the Trailer for Loading Before loading cargo into your trailer inspect the interior of the traile
114. t be in good condition and properly rigged to be effective 10 17 2008 Page 3 An ineffective breakaway brake system can result in a runaway trailer leading to death or serious injury if the coupler or ball hitch fails Test the function of the breakaway brake system before towing the trailer Do not tow the trailer if the breakaway brake system is not working have it serviced or repaired Connect the breakaway lanyard to the tow vehicle NOT to the safety chain and NOT to the hitch ball or support 1 2 8 Matching Trailer and Hitch A DANGER Use of an under rated hitch ball or tow vehicle can result in loss of control leading to death or serious injury Make certain your hitch and tow vehicle are rated for your trailer 1 2 9 Worn Tires Loose Wheels and Lug Nuts Just as with your tow vehicle the trailer tires and wheels are important safety items Therefore it is essential to inspect the trailer tires before each tow If a tire has a bald spot bulge cut cracks or is showing any cords replace the tire before towing If a tire has uneven tread wear take the trailer to a dealer service center for diagnosis Uneven tread wear can be caused by tire imbalance axle misalignment or incorrect inflation 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 incr
115. t in severe personal injury or death if the warning is ignored WARNING Hazards or unsafe practices which COULD result in severe personal injury or death if the warning is ignored CAUTION Hazards or unsafe practices which could result in minor or moderate injury if the warning is ignored 10 17 2008 Page 1 NOTICE NOTICE Practices that could result in damage to the trailer or other property 1 2 MAJOR HAZARDS Loss of control of the trailer or trailer tow vehicle combination can result in death or serious injury The most common causes for loss of control of the trailer are e Improper sizing the trailer for the tow vehicle or vice versa e Excessive Speed Driving too fast for the conditions e Failure to adjust driving behavior when towing a trailer e Overloading and or improper weight distribution e Improper or mis coupling of the trailer to the hitch e Improper braking and steering under sway conditions e No brakes on trailer if trailer is originally equipped with brakes e Not maintaining proper tire pressure e Not keeping lug nuts tight 1 2 1 Improper Sizing of the Trailer to the Tow Vehicle Trailers that weigh too much for the towing vehicle can cause stability problems which can lead to death or serious injury Furthermore the additional strain put on the engine and drive train may lead to serious tow vehicle maintenance problems For these reasons the maximum towing capaci
116. tanks inside the trailer 10 17 2008 Page 7 Section 1 Safety Information Gasoline and diesel generators pose a risk of death from e Carbon Monoxide e Fire and Explosion e Electrocution Do not operate a generator without having a working carbon monoxide detector Do not refuel a running generator Do not refuel near ignition sources Shore power poses a risk of death due to electrocution or fire Always use an electrical cord specifically designed for shore power connection Never use an ordinary extension cord Always connect the electrical cord to a grounded source of shore power Do not remove the third prong from the shore power plug Connect only to source of proper voltage Make certain polarity is correct Do not overload electrical circuits Always replace fuses or circuit breakers with correct rating Risk of fire or explosion Never use a flame heat lamp or hair dryer to thaw an LP gas regulator Use an incandescent light bulb Do not remove the regulator cover of attempt to service the LP gas regulator 10 17 2008 Page 8 Do not transport flammable explosive poisonous or other dangerous materials in your trailer Exceptions e Fuel in the tanks of vehicles that are being towed e Fuel stored in proper containers used in trailer living quarters for cooking Fuel stored in the tank of an on board generator 1 2 20 Trailer Towing Guide Driving a vehicle with a tr
117. tenowuinsters 6 8 2 3 C Manually Adjusting Brake Shoes 62 8 2 5 d Brakes PIC CHa sis swccsccraanawerdunevicnsedaviorsonnienuawas 63 8 2 9 6 Brakes Hydraulic Air or Electric Operated 63 8 2 6 Trailer Connection to Tow Vehicle 00060 63 8 2 6 a Coupler and Ball vicscs ctecvcasonwnisdisesenceseeeeiiess 63 8 2 6 b Gooseneck vsasisasviaeavssosisvsasiietassiessiansvacaexeon 64 8 20 Fifth Wheel Kingpin ssssssssseoeeeeneeeessesssssss 64 8 2 7 Landing Leg or SACK oisscscosnspodniriasiesseiareesaomins 64 S26 Lieh and SONGS ee ee nee One ee 64 SaF Accessory 1 oogen EERE 64 d DIVES E E E EE E 64 8 2L Wheel RiMScirsserisreiciscvissririeiiieisreinirnrnnaia 64 8 2 12 Wheel Liners Simulators 65 Sdo Wheel DEAT GS vieran etsn t ie r N 65 8 2 13 a Standard Bearings vec co desccctercconessnaded doteannensuadins 65 8 2 13 6 E Z Lube or Other Grease Fitting Lubricated CAM E E E 66 8 2 13 c Nev R Lube or Other Sealed Bearings 66 8 2 14 Lug Nuts Bolts sssisccsscchsetanssiantaricesvceriesssiseavenys 66 SECTION 9 TECHNICAL REFERENCE 69 TRAILER LIGHTING ELECTRICAL CONNECTION 69 9 2 HCH SYSTEMS gi ae scoe estesya rOn E i 71 SECTION 10 WARRANTY seesseesseosseosseoesseosseosse 72 il This Users Manual information and trailer contains safety Instructions for your You must read this manual before loading or towing your trailer You must follow all safety precaut
118. that the plunger pin is released from the drop leg See figure 3 19 e Push down on the drop leg base with your foot to place a drop leg to the desired lowered position 10 17 2008 Page 48 The drop legs are heavily spring loaded in the lowered position They will rapidly return to the upper position when released and can inflict serious bruises scrapes or pinching Keep your feet shins and hands well clear of the drop legs and drop leg bases when releasing the drop legs Rotate the plunger pin handle so that the plunger pin is attempting to engage the drop leg See figure 3 17 Slowly raise your foot permitting the drop leg to rise The plunger pin will engage a hole in the drop leg Be sure the plunger pin is fully engaged Push it in by hand if necessary The bent part of the plunger pin handle must be touching the plunger pin housing If your trailer has two drop leg jacks lower them both to the same level following the preceding instructions NOTICE If the drop legs are not set at the same level one of the drop leg jacks can be overloaded and can be damaged Release the handle or crank from its holder and engage it with the jack shaft Rotate the handle or crank clockwise to slowly extend the jack and transfer the weight of the trailer tongue to the jack On two speed jacks pushing the handle shaft toward the gearbox can perform rapid extension This shifts the gearbox into a high speed mode W
119. that they are positioned correctly relative to the vehicle s frame This adjustment maximizes the life of your tires These adjustments require special equipment and should be performed by a qualified technician 2 6 9 Tire Repair If a tire loses all or most of its air pressure it should be removed from the wheel for a complete inspection for possible internal damage Tires that are run even for short distances while flat are often damaged beyond repair Remember these important points on tire repair e Most punctures and nail holes in the tread area up to 1 4 can be repaired e Only trained personnel using industry approved methods and materials should repair a tire e Tires with sidewall punctures or a tread depth of less than 1 16 should be replaced and not repaired The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that surrounds the puncture hole Section 2 Tire Safety Information 2 6 10 Tire Fundamentals Federal law requires tire manufacturers to place standardized information on the sidewall of all tires This information identifies and describes the fundamental characteristics of the tire and also provides a tire identification number for safety standard certification and in case of a recall 2 6 10 a Information on Passenger Vehicle Tires Please refer to the diagram below Radial PUT ae Ratha of height to width aspect ratio Load index a
120. the wheel bearings e After removing the grease cap cotter pin spindle nut and spindle washer items 7 10 in Standard Wheel Bearing figure 8 5 remove the hub and drum to inspect the bearings for wear and damage e Replace bearings that have flat spots on rollers broken roller cages rust or pitting Always replace bearings and cups in sets The inner and outer bearings are to be replaced at the same time e Replace seals that have nicks tears or wear e Pack the bearings with a high quality EP 2 automotive wheel bearing grease Every time the wheel hub is removed and the bearings are reassembled follow the steps below to check the wheel bearings for free running and adjust e Turn the hub slowly by hand while tightening the spindle nut until you can no longer turn the hub by hand Section 8 Inspection Service amp Maintenance e Loosen the spindle nut just until you are able to turn it the spindle nut by hand Do not turn the hub while the spindle nut is loose e Put a new cotter pin through the spindle nut and axle e Check the adjustments Both the hub and the spindle nut should be able to move freely the spindle nut motion will be limited by the cotter pin Bearing Lubrication Oil If your trailer is equipped with oil lubricated bearings check the oil level every 6 months or 6 000 miles whichever occurs first The oil can be filled through the oil fill hole in the hub or cap Fill to the leve
121. the wheels 2 5 5 BOLT 2 4 BOLT 10 17 2008 Page 67 Remove all excess paint oil and grease from mounting surfaces Start all lug nuts by hand to prevent cross threading Tighten lug nuts in sequence shown in Lug Nut Sequence of Tightening figure 8 8 Never install aftermarket wheels or lug nuts on your trailer Use only original equipment wheels and lugs nuts Aftermarket wheels and lug nuts may not meet the load carrying requirements pressure capacity and offset as the original equipment Never install aluminum wheels on hubs studs that were designed for steel wheels The stud length required for aluminum wheels is greater than that required for steel wheels Aftermarket wheels may part from the trailer resulting in death or serious injury Never install aftermarket wheels or lug nuts on your Haulmark trailer Never install aluminum wheels on hubs studs that were designed for steel wheels Information or torque values stamped on lug nuts supersedes the information listed in this manual 2 6 BOLT 8 BOLT Section 8 Inspection Service amp Maintenance Lug Nut Sequence of Tightening Figure 8 8 Lug Nut Torque 2nd Stage 3rd Stage 1 2 Inch 35 Ib ft 65 Ib ft 100 Ib ft ee ee Lug Nut Torque Figure 8 9 Lug nuts 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 are tight after the first 10 25 and 50 mile
122. the electric brake controller in the tow vehicle cab You should feel the operation of the trailer brakes Failure to connect the tow vehicle lighting and braking to the trailer will result in inoperable lights and brakes and can lead to collision Check that all the trailer lights and brakes work before each tow 3 2 3 9 Rig the Safety Chains e Visually inspect the safety chains and hooks for wear or damage Replace worn or damaged safety chains and hooks before towing e Rig the safety chains so that they attach to the safety chain receivers on the tow vehicle If you are not certain of the hitch provisions for receiving safety chains contact the hitch manufacturer or installer Do NOT attach the safety chains to the fifth wheel or its support and e Rig the safety chains so they have sufficient slack to permit turning but not too much slack the safety chains must keep the gooseneck on the tow vehicle bed if the trailer uncouples 3 2 3 N Uncoupling the Fifth Wheel Trailer Follow these steps to uncouple your fifth wheel hitch trailer from your tow vehicle e Block trailer tires to prevent the trailer from rolling before jacking the trailer up e Disconnect the electrical connector e Disconnect the breakaway brake switch lanyard e If the tow vehicle has a tailgate lower it e Make certain that ground surface below jack base will support trailer tongue load e Rotate the drop leg plunger pin handle so
123. the trailer s Gross Vehicle Weight Rating GVWR If you do not know the empty weight of the trailer you must measure it at a commercial scale 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 The GVWR and GAWR s are listed on the Certification VIN label mounted on the front left side of the trailer An overloaded trailer can result in failure or in 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 Never exceed an axle Gross Axle Weight Rating GAWR 1 2 5 Trailer Not Properly Coupled to the 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 Uncoupling may result in death or serious injury to you and to others Coupler and hitch selection and condition are critical for safe towing Uncoupling can result in death or serious injury e Make sure the hitch and ball are rated for the trailer Make sure the hitch ball size matches the coupler e Check the hitch ball for wear corrosion and cracks before coupling Replace worn corroded or cracked hitch ball before coupling to the trailer Make sure the hitch ball is tight to the hitch before coupling the trailer
124. tie down all loads with proper sized fasteners ropes straps etc to prevent the load from shifting while trailering If the door latch is equipped with a catch that has a hole for a linchpin use a linchpin to prevent the door latch from opening Always secure the door latch after closing Place a linchpin in the catch If the door opens your cargo may be ejected onto the road resulting in death or serious injury to the animals or other drivers 10 17 2008 Page 5 1 2 12 Inappropriate Cargo Your trailer may be designed for specific cargo for example only for horses If your trailer is designed for specific cargo only carry that cargo in the trailer Your trailer must not be used to carry certain items such as people containers of hazardous substances or containers of flammable substances A trailer not designed with living quarters should only be used for transportation of its intended cargo A DANGER You can die or be brain damaged by Carbon Monoxide Do not operate a generator portable grills portable heaters portable lanterns or portable stoves inside the trailer Never transport people inside your Haulmark trailer even if it has living quarters Besides putting their lives at risk the transport of people may be illegal Do not sleep in a trailer not equipped with living quarters A trailer not designed with living quarters should only be used for transportation of its intended cargo Yo
125. 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 maintenance conditions Section 2 Tire Safety Information 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 2 2 STORING YOUR VEHICLE WITHOUT REMOVING THE TIRES Ideally a vehicle in storage should be placed on blocks to remove all weight from the tires If the vehicle cannot be put on blocks follow these steps for tire protection e Completely unload the vehicle so the minimum weight will be placed on the tires e Keep the tires inflated to recommended operating inflation pressure e Be sure the storage surface is firm clean well drained and reasonably level Move the vehicle at least every three months to prevent ozone cracking in the tire bulge
126. tion and Service Intervals Manual Service Interval Every 3 Every 6 Every Mo s Mo s Year Lights and Signals Check for proper operation Verify connection is ssa ama ca Gs and tight a T r Trailer body Wash as needed to remove salt and liquid de icer 822 FP Hinges doors and dividers Inspect Repair or replace damaged worn or broken parts ee ee ee Frame members Inspect all frame members bolts amp rivets 8 2 2 a Repair or replace damaged worn or broken parts Slide Out Clean dirt buildup Lubricate slides shafts and gears ee ee ee Roof Vents Clean dirt buildup Lubricate hinges ee eee fe S y S y Rotate tires tires EEN 5 000 miles __ Fosse treads amp sidewalls thoroughly Replace tire when 8 2 11 treads are worn or a sidewall has a bulge Standard Bearings Standard Bearings Disassemble inspect and re pack inspect and re Disassemble inspect and re pack 8218a 2 13 a Every 12 000 mi ort yr 12 000 mi or 1 yr E Z Lube or Other Grease Check for free running and lubricate 8 2 13 Every 12 000 mi or 1 yr Fitting Lubricated Bearings Nev R Lube Other Check for excessive wear replace if necessary Manufacturer Every 12 000 mi or 1 yr Sealed a Lug Bolts and Hub Check and tighten 8 2 15 Check for tightness before every use Check torque After first 10 25 amp 50 ltem Service Required Section Reference miles After any impact Annually amp At start of
127. 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 capability 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 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 standards The next two numbers or letters are the plant code where it was manufactured and the last four numbers represent the week and year the tire was built For example the numbers 3197 means the 31st week of 1997 The other numbers are marketing codes used at the manufacturer s discretion This information is used to contact consumers if a tire defect requires a recall Tire Ply Composition and Materials Used The number of plies indicates the number of layers of rubber coated fabric in the tire In general the greater the number of plies the more weight a tire can support Tire manufacturers also must indicate the materials in the tire which include steel nylon polyester and others Maximum Load Rating This number indicates the maximum load in kilograms and pounds that can be carried by the tire Maximum Permissible Inflation Pressure This number is the greatest amount of air pressure that shou
128. towing vehicle hitch If the receiver does not line up with the ball raise the receiver again and adjust the position of the tow vehicle Then lower the receiver over the ball When the drop leg base is no longer resting on the ground the towing vehicle hitch is holding all of the weight of the trailer tongue e Close the lock plate on the gooseneck ball receiver e Move the spring loaded lock plate locking pin to the CLOSED position Be sure the locking pin is holding the lock plate e Be sure the receiver is all the way on the gooseneck ball and the lock plate is engaged A properly engaged locking mechanism will allow the coupler to raise the rear of the tow vehicle Using the trailer Drop Leg Jack Mechanism Figure 3 10 3 2 2 f Rig the Safety Chains e Visually inspect the safety chains and hooks for wear or damage Replace worn or damaged safety chains and hooks before towing 10 17 2008 Page 41 Section 3 Coupling To The Tow Vehicle e Rig the safety chains so that they attach to the safety chain receivers on the tow vehicle If you are not certain of the hitch provisions for receiving safety chains contact the hitch manufacturer or installer Do NOT attach the safety chains to the gooseneck ball or its support and e Rig the safety chains so they have sufficient slack to permit turning but not too much slack the safety chains must keep the gooseneck on the tow vehicle bed if the trailer uncouples See
129. ty of your towing vehicle should not be exceeded The towing capacity of your tow vehicle in terms of maximum Gross Trailer Weight GTW and maximum Gross Combined Weight Rating GCWR can be found in the tow vehicles Owner s Manual A DANGER Use of an under rated hitch ball or tow vehicle can result in loss of control leading to death or serious injury Make certain your hitch and tow vehicle are rated for your trailer Section 1 Safety Information 1 2 2 Driving Too Fast With ideal road conditions the maximum recommended speed for safely towing a trailer is 60 mph If you drive too fast the trailer is more likely to sway thus increasing the possibility for loss of control Also your tires may overheat thus increasing the possibility of a blowout Driving too fast for conditions can result in loss of control and cause death or serious injury Adjust speed down when towing trailer 1 2 3 Failure to Adjust Driving Behavior When Towing a Trailer When towing a trailer you will have decreased acceleration increased stopping distance and increased turning radius which means you must make wider turns to keep from hitting curbs vehicles and anything else that is on the inside corner Furthermore the trailer will change the handling characteristics of your towing vehicle making it more sensitive to steering inputs and more likely to be pushed around in windy conditions or when being passed by large vehicles
130. ty that trailer owners and users need to be familiar with and practice Inadequate and or inappropriate wheel nut torque tightness is a major reason that lug nuts loosen in service Loose lug nuts can rapidly lead to a wheel separation with potentially serious safety consequences e Be certain you have a clear understanding of the specific wheel maintenance responsibilities your vehicle manufacturer requires recommends you as the owner must perform in order to insure your wheel equipment is safely maintained Check the lug nut tightness the first 10 25 and 50 miles of driving and before each tow thereafter Refer to the owner s manual and speak with your dealer if you have any questions about proper tightening practices e The only way to be certain you have checked the tightness or torqued the lug nuts to the proper value is with a torque wrench Four way wrenches ratchets and similar tools can be useful for short term emergency repairs but are not appropriate tools for accurately checking lug nut torque You must use a torque wrench to accurately indicate the torque that you are applying to the lug nut e Keep a record of the date and approximate mileage when you check the lug nut torque Note any lug nut that has lost torque Investigate the reason s if the lug nut torque is not maintained after more than one re torque application because this indicates there is something wrong with the lug nuts nut studs wheels and or hubs a
131. ult in death or serious injury Check the hitch ball for wear corrosion and cracks before coupling the trailer Replace worn corroded or cracked hitch ball before coupling the trailer Rock the ball to make sure it is tight to the hitch and visually check that the hitch ball nut is solid against the lock washer and hitch frame Wipe the inside and outside of the coupler clean and inspect it visually for cracks and deformations feel the inside of the coupler for worn spots and pits Be sure the coupler is tight to the tongue of the trailer All coupler fasteners must be visibly solid against the trailer frame A loose hitch ball nut can result in uncoupling leading to death or serious injury Make sure the hitch ball is tight to the hitch before coupling the trailer Prepare the Coupler and Hitch Lubricate the hitch ball and the inside of the coupler with a thin layer of automotive bearing grease Using the jack raise the coupler above the ball height Open the coupler locking mechanism Ball couplers have a locking mechanism with an external moving piece ball clamp and an outside handle or latch See figure 3 4 10 17 2008 Page 36 e Inthe open or released position the coupler is able to drop fully onto the hitch ball Slowly back up the tow vehicle so that the hitch ball is near or aligned under the coupler if the trailer jack has raised the coupler Engaged Released Ball Hitch Coupler Mechan
132. ur Haulmark trailer is not capable of safely transporting flammable explosive poisonous or other dangerous materials 1 2 13 Inoperable Brakes Lights or Mirrors Be sure that the brakes if equipped and all of the lights on your trailer are functioning properly before towing your trailer Electric brakes and lights on a trailer are controlled via a connection to the tow vehicle generally a multi pin electrical connector Check the trailer taillights by turning on your tow vehicle headlights Check the trailer brake lights by having someone step on the tow vehicle brake pedal while you look at trailer lights Check the turn signal lights by operating the turn signal lever in the tow vehicle Section 1 Safety Information If your trailer has electric brakes your tow vehicle will have an electric brake controller that sends power to the trailer brakes Before towing the trailer on the road you must operate the brake controller while trying to pull the trailer in order to confirm that the electric brakes operate While towing the trailer at less than 5 mph manually operate the electric brake controller in the tow vehicle cab You should feel the operation of the trailer brakes Failure to connect the tow vehicle lighting and braking to the trailer will result in inoperable lights and brakes and can lead to collision Check that all the trailer lights and brakes work before each tow If your trailer has hydraulic surg
133. use an accident that could lead to death or serious injury Tow vehicle and hitch manufacturers are the appropriate source of competent advice 10 17 2008 Page 32 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 an under rated hitch ball or tow vehicle can result in loss of control leading to death or serious injury Make certain your hitch and tow vehicle are rated for your trailer 3 1 1 Trailer Information The Trailer Certification VIN Tag 1 location figure shows the location of the Certification Vehicle Identification Number VIN tag on your trailer See figure 3 1 or 3 2 INNA L Gooseneck Certification VIN Tag Location Figure 3 1 Bumper Pull Certification VIN Tag Location Figure 3 2 Section 3 Coupling To The Tow Vehicle 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 Month and year the trailer was manufactured 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 GVWR The Gross Vehicle Weight Rati
134. used as a dual that is when four tires are put on each rear axle a total of six or more tires on the vehicle Max Load Single kg lbs at kPa psi Cold This information indicates the maximum load and tire pressure when the tire is used as a single Load Range This information identifies the tire s load carrying capabilities and its inflation limits 2 6 11 Tire Safety Tips Preventing Tire Damage e Slow down if you have to go over a pothole or other object in the road e Donotrun over curbs or other foreign objects in the roadway and try not to strike the curb when parking Tire Safety Checklist Section 2 Tire Safety Information 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 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 placard or owner s manual for the maximum recommended load for the vehicle 10 17 2008 Page 31 Section 3 COUPLING TO THE TOW VEHICLE This manual provides instructions for the operation and care of Haulmark trailers The instructions in the manual must be followed to ensure safety of persons and cargo and satisfactory life of the trailer Safety precautions to protect agai
135. wer 2 500 pound truck the towing capacity that a 300 horsepower 5 000 pound truck has Towing Hitch The towing hitch attached to your tow vehicle must have a capacity equal to or greater than the load rating of the trailer you intend to tow The hitch capacity must also be matched to the tow vehicle capacity Suspension System A tow vehicle equipped with a factory installed Towing Package likely comes equipped with heavy duty springs heavy duty tires and other suspension components which are able to serve the size and weight of the trailer that the vehicle is rated to tow However the addition of additional equipment may further improve the tow vehicle performance These may include adjustable air shocks helper springs etc Brake Controller The brake controller is part of the tow vehicle and is essential in the operation of the electric brakes on the trailer If your trailer has electric brakes it requires a brake controller be installed at the driver s position The brake controller is not the same as the safety breakaway brake system that is installed on the trailer Side View Mirrors The size of the trailer that 1s being towed and your state law regulations determine the size of the mirrors However some states prohibit extended mirrors on a tow vehicle except while a trailer is actually being towed In this situation detachable extended mirrors are necessary Check with your dealer or the appropriate state agency fo
136. y calculated in Step 4 12 If your vehicle will be towing a trailer load from your trailer will be transferred to your vehicle Consult the tow vehicle s manual to determine how this weight transfer reduces the available cargo and luggage capacity of your vehicle 2 5 GLOSSARY OF TIRE TERMINOLOGY Accessory weight The combined weight in excess of those standard items which may be replaced of automatic transmission power steering power brakes power windows power seats radio and heater to the extent that these items are available as factory installed equipment whether installed or not Bead The part of the tire that is made of steel wires wrapped or reinforced by ply cords and that is shaped to fit the rim Bead separation This is the breakdown of the bond between components in the bead Bias ply tire A pneumatic tire in which the ply cords that extend to the beads are laid at alternate angles substantially less than 90 degrees to the centerline of the tread Carcass The tire structure except tread and sidewall rubber which when inflated bears the load Chunking The breaking away of pieces of the tread or sidewall Cold inflation pressure The pressure in the tire before you drive Cord The strands forming the plies in the tire Cord separation The parting of cords from adjacent rubber compounds Cracking Any parting within the tread sidewall or inner liner of the tire extending to cord material
137. y provision of this Warranty is held to be illegal or unenforceable by any court of competent jurisdiction the remaining provisions shall remain effective Some states do not allow the exclusion or limitation of implied warranties or the limitation of incidental or consequential damages for certain products supplied to consumers or the limitation of liability for personal injury so the limitations and exclusions above may be limited in their application When the implied warranties cannot be excluded in their entirety they will be limited to the duration of the written express warranty DESIGN CHANGES Warrantor reserves the right to change the design of its Products from time to time without notice and with no obligation to make corresponding changes in its Products previously manufactured LEGAL REMEDIES OF PURCHASER This warranty gives you specific legal rights and you may have Other rights which may vary from state to state No action to enforce this Warranty shall be commenced later than six 6 months after the discovery of any defect or after expiration of the Warranty Period 10 17 2008 Page 73
138. y when the pullpin is removed An ineffective breakaway brake system can result in a runaway trailer if the fifth wheel hitch fails leading to death or serious injury Test the function of the breakaway brake system before towing the trailer Do not tow the trailer if the breakaway brake system is not working have it serviced or repaired Connect the breakaway lanyard to the tow vehicle NOT to the kingpin or its support Do not tow the trailer with the breakaway brake system ON because the brake will overheat which can result in permanent brake failure Failure to replace the pullpin 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 at intervals recommended by the battery manufacturer 3 2 3 1 Connect the Electrical Cables e Connect the trailer lights to the tow vehicle s electrical system using the electrical connectors Check all lights for proper operation e Clearance and Running Lights Turn on tow vehicle headlights e Brake Lights Step on Tow vehicle brake pedal e Turn Signals Operate tow vehicle directional signal lever Section 3 Coupling To The Tow Vehicle Check brakes for proper operation While towing the trailer at less than 5 m p h manually operate
139. your tow vehicle where the load rating of the hitch and ball is equal to or greater than that of your trailer Also 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 OF THE SAME SIZE AS THE COUPLER IF THE HITCH BALL IS TOO SMALL IS UNDERRATED IS LOOSE OR IS WORN THE TRAILER CAN COME LOOSE FROM THE TOW VEHICLE RESULTING IN DEATH OR SERIOUS INJURY The ball size and load rating capacity are marked on the ball hitch capacity is marked on the hitch 3 2 1 a Before Coupling the Trailer to the Tow Vehicle e 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 3 2 1 0 Section 3 Coupling To The Tow Vehicle Coupler to hitch mismatch can result in uncoupling leading to death or serious injury Make sure the hitch and ball are rated for the trailer coupling Make sure the hitch ball size matches the coupler Wipe the hitch ball clean and inspect it visually and by feel for flat spots cracks and pits A worn cracked or corroded hitch ball can fail while towing and may res

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