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Top Hat Industries, Inc.

1. een 86 6 3 SYNCHRONIZING THE BRAKE SYSTEMS e ee 86 ACGESSORIES 3 A E E cc aaddd ra RE 88 7 1 ACCESSORY BATTERY veivciiacatectesdecscactscoevesseavk codi Creado da e Eo Saee er ade a To n 88 7 2 ELECTRIC POWERED LANDING GEAR eeeeeeeeeenennnnnnnnnnnn 89 7 3 ELECTRIC POWERED HYDRAULIC PUMP eee 89 INSPECTION SERVICE amp MAINTENANCE eene 90 8 1 INSPECTION SERVICE amp MAINTENANCE SUMMARY CHARTS eene 90 8 2 INSPECTION AND SERVICE INSTRUCTIONS eere 92 8 2 1 Axle Bolts Frame Suspension amp Structure 92 8 2 2 Trailer SIUCIUFO S ioco eee e e Ee irre o 92 8 2 2 1 Fasteners and Frame Members eese 92 8 2 2 2 WeldS s ee ev eee eee ex a Dee ede 93 8 2 3 Drop Ramp Torsion Springs esses 93 8 2 4 Trailer BIak s ior nt ar er tb pe ea oae 94 8 2 4 4 Brake Shoes and Drums eemRR ene 94 8 2 4 2 Manually Adjusting Brake Shoes sesessess 94 8 2 4 3 Brakes Electri6 ios er eee t Y rer eee eer rev 94 8 2 4 4 Brakes Hydraulic vacuum air or electric operated 95 8 2 5 Trailer Connection to TOW V NICIC ccccccccccececeeeeeeeeeeseeeeeeeeees 96 8 25 14 Couplerand Ball eme 96 8 2 5 2 GOOSEMECK cccccccccccccececeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeneneneeenes 97 8 2 5 8 Fift
2. 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 System figure Do not connect the pullpin cable 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 To test the break away 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 Immediately replace the pullpin The breakaway brake system battery discharges rapidly when the pullpin is removed 43 Coupling to Tow Vehicle A WARNING An ineffective breakaway brake system can result in a runaway trailer leading to death or serious injury if the coupler or ball hitch fails Connect the breakaway cable to the tow vehicle and NOT to the hitch ball or support Before towing the trailer test the function of the breakaway brake system If the breakaway brake system is not working do not tow the trailer Have it serviced or repaired Do not tow the trailer with the breakaway brake system ON because the brakes will overheat which can result in permanent brake failure A WARNING Failure to replace the pullpin will prevent brakes from working leading
3. Safety Chain Arrangement Bumper Pull Trailer ALWAYS use safety chains Chains hold trailer if connection fails You must 1 CROSS chains underneath coupler 2 ALLOW slack for trailer to tum NA ww v 3 ATTACH chain hooks securely to tow i oun Dt vehicle frame 2002 NATM UT0020 Visually inspect the safety chains and hooks for wear or damage Replace worn or damaged safety chains and hooks before towing Rig the safety chains so that they Cris cross underneath the coupler so if the trailer uncouples the safety chains can hold the tongue up above the road Loop around a frame member of the tow vehicle or to holes provided in the hitch system but do not attach them to an interchangeable part of the hitch assembly Attach S hooks up from underneath the hole do not just drop into hole and Provide enough slack to permit tight turns but not be close to the road surface to drag A WARNING Improper rigging of the safety chains can result in loss of control of the trailer and tow vehicle leading to death or serious injury if the trailer uncouples from the tow vehicle e Fasten chains to frame of tow vehicle Do not fasten chains to any part of the hitch unless the hitch has holes or loops specifically for that purpose e Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up if the trailer comes loose 42 Coupling to Tow Vehicle 3 2 2 5 A
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5. If you do not use your trailer for three or more months or during winter months Store the battery indoors and Charge the battery every three months Replace the breakaway brake battery at intervals recommended by the battery manufacturer s instructions 3 2 3 5 Connect the electrical cables Connect the trailer lights to the tow vehicle s electrical system using the electrical connectors Check all lights for proper operation Clearance and Running Lights Turn on tow vehicle headlights Brake Lights Step on tow vehicle brake pedal Turn Signals Operate tow vehicle directional signal lever Check electric brakes for proper operation 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 m p h manually operate the electric brake controller in the tow vehicle cab You should feel the operation of the trailer brakes 54 Coupling to Tow Vehicle A WARNING Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes and can lead to collision Before each tow e Check that the taillights brake lights and turn signals work e Check that the electric brakes work by oper
6. Uncoupling the Ball Hitch Trailer with Tongue Jack 45 3 2 3 Trailer with Gooseneck Coupler and Drop leg Jack 45 3 2 8 1 Prepare the ball receiver and gooseneck ball 49 3 2 8 2 Couple the trailer to the tow vehicle 50 3 2 8 3 Rig the safety chains 52 3 2 8 4 Attach and test the breakaway brake system 52 3 2 8 5 Connect the electrical cables sssesesessesss 54 3 2 3 6 Uncoupling the Gooseneck Trailer with Drop leg Jack 55 3 2 4 Trailer with Fifth wheel Coupler and Drop leg Jack 57 3 2 4 1 Before attempting to tow the trailer sss 57 3 2 4 2 Raise the Drop Leg Jack see 60 3 2 4 3 Attach and test the breakaway brake system 61 3 2 4 4 Connect the electrical cables seeseseseses 63 3 2 4 5 Uncoupling the Fifth Wheel Trailer with Drop leg Jack 63 4 LOADING THE TRAILER eee ones 67 4 1 TONGUE WEIGHT 5 3 pre nectit ee EP E npe ee eee 67 4 2 CHECKING TONGUE WEIGHT ceseeeeeeeenennenne enne nennen 69 4 3 SECURING THE CARGO esten iege EE Eae HE in e RES ERE aE ESEA 71 4 3 1 Distributing the Cargo Open Trailer esessss 71 4 3 1 1 Preparing the Trailer for Loading ssssssss 72 4 3 1 2 Loading
7. 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 battery is running both the trailer lights and tow vehicle lights 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 36 Coupling to Tow Vehicle Hitch That part of the connecting mechanism including the ball support platform and ball and those components that extend and are attached to the towing vehicle including bumpers intended to serve as hitches e Weight Distributing Hitch or Equalizing Hitch A mechanical device that connects the trailer to the towing vehicle and by means of leverage applied on both the trailer and towing vehicle structures when properly adjusted distributes the imposed vertical load at the hitch an
8. e Recommended tire inflation pressure including a description and explanation of A Cold inflation pressure B Vehicle Placard and location on the vehicle C Adverse safety consequences of under inflation including tire failure D Measuring and adjusting air pressure for proper inflation e Tire Care including maintenance and safety practices e Vehicle load limits including a description and explanation of the following items A Locating and understanding the load limit information total load capacity and cargo capacity B Calculating total and cargo capacities with varying seating configurations including quantitative examples showing illustrating how the vehicles cargo and luggage capacity decreases as combined number and size of occupants increases This item is also discussed in Section 3 C Determining compatibility of tire and vehicle load capabilities D Adverse safety consequences of overloading on handling and stopping on tires 20 Tire Safety Information 2 1 TEPS FOR DETERMININ RRECT LOAD LIMIT TRAILER E TIRE AND LOADING INFORMATION The weight of cargo should never exceed 21241 kg or 4675 lbs COLD TIRE PRESSURE pron srzzszspisiRD 448 KPA 65 PS lum Dol OPARI MOD ID 4R7BU18278T085294 SEE OWNER S5 MANUAL FOR ADDITIONAL INFORMA TION Tire and Loading Information Placard Figure 1 1 2 1 1 TRAILERS 10 000 Pounps GVWR on LESS 1 Locate the statement T
9. General Safety Information WARNING Improper tire pressure can result in a blowout and loss of control which can lead to death or serious injury Be sure tires are inflated to pressure indicated on the Certification VIN label before towing trailer The tightness of the lug nuts is very important in keeping the wheels properly seated to the hub Before each tow check to make sure they are tight A WARNING Metal creep between the wheel rim and hub may cause lug nuts to loosen and could result in a wheel coming off leading to death or serious injury Tighten lug nuts before each tow The proper tightness torque for lug nuts is listed in Section 8 2 11 2 in the Inspection and Service Instructions chapter of this manual Use a torque wrench to tighten the lug nuts use the crisscross star pattern on page 101 If you do not have a torque wrench use a lug wrench from your tow vehicle and tighten the nuts as much as you can At the first opportunity have a service garage or trailer dealer tighten the lug nuts to the proper torque 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 tight after the first 10 25 and 50 miles of driving and before each tow thereafter Failure to perform this check can result in a wheel separating from the trailer and a crash leading to death or serious injury A WARNING
10. 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 Slowly back up the tow vehicle so that the gooseneck ball is aligned under the gooseneck ball receiver 49 Coupling to Tow Vehicle A WARNING If the trailer drops during coupling death or serious injury may result There must be no one under the trailer or coupler before or during the coupling operation 3 2 3 2 Couple the trailer to the tow vehicle 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 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 Close the lock plate on the gooseneck ball receiver Move the spring loaded lock plate locking pin to the CLOSED position Be sure the locking pin is holding the lock plate Be sure the receiver is all the way on the gooseneck ball and
11. Trailers are produced with a variety of coupler devices One of the sections below will pertain to your trailer Bumper pull Ball Hitch Coupler Pintle Coupler Gooseneck Hitch Coupler Fifth Wheel Coupler If the coupler on your trailer does not resemble one of the couplers shown in the figures see the separate coupler instructions If you do not have separate coupler instructions call Top Hat Industries Inc at 903 897 2813 for a free copy 3 2 2 TRAILER WITH BALL HITCH COUPLER A ball hitch coupler connects to a ball that is located on or under the rear bumper of tow vehicle This system of coupling a trailer to a tow vehicle is sometimes referred to as bumper pull 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 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 your tow vehicle where the load 38 Coupling to Tow Vehicle 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 tr
12. the body prop Modifying or altering hydraulic components Modifying or altering dump controls Not dumping from a solid and level foundation Not fully opening rear doors when dumping Jerking the trailer or hydraulics to loosen the load Operating near over head powerlines See Section 4 4 for more details on these hazards 1 2 17 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 1 2 18 SAFETY WARNING LABELS ON YOUR TRAILER The following decals are used on Top Hat Industries Inc Due to Difference in trailer models and equipment your trailer may or may not use all decals 12 General Safety Information WIN 2002 BujAyip jo saju os pue sz OL 184 34 38 sinu Bn ueuBn e sjoauM pejunouaJ pue Mau 4043 sseujuby 40 sjnu Bn1 eBewep 10 sjoauM pue seJ L z peasy pue ensseJd adj 423H2 1snui noA Huimo a10jagq ojjuoa JO SSO esnga uea aJnjiej 3nuBny 10 jesUM as _ NINHYMY_ Bupom you a48 S46 J MOL LON OG s 46 exe1q pue jeubys uan syyByy 123 S1051I e 423H2 Z 1012euuoo e21129Ja 9 9Iu8A MO pue 19j 8J LOANNOD L snw noA sa 2IuaA 43470 Aq Yy Bujeq woa 19jj81 quaAe1d ue sjubr1 EMO SIeauM pue SALL e By 001 WIWN 2002 Snina uod 9UJE4J 3JIYAA H9n
13. 2 TRAILER STRUCTURE Because the trailer floor receives the most abuse it will most likely corrode before any other part of the structure This is particularly true for horse and livestock trailers having floors subjected to urine and manure The urine and manure are corrosive to the metal flooring and other structural parts of the trailer Remove the rubber mats from the floor of the trailer and wash them at least every three months Using a power washer and a detergent solution wash both sides of the rubber mat as well as the floor and walls of the trailer Rinse the rubber mat and the trailer floor and walls Be sure the rubber mat and trailer floor are completely dry before replacing the rubber mat 8 2 2 1 Fasteners and Frame Members Inspect all of the fasteners and structural frame members for bending and other damage cracks or failure Repair or replace any damaged fastener and repair the frame member If you have any questions about the condition or method of repair of fasteners or frame members get the recommendation of or have the repair done by your dealer The various fastener types used on your trailer are 92 Inspection Service and Maintenance 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 and WARNING Broken or damaged fasteners or welds
14. 2 14 Hazards From Modifying Your Trailer esses 11 1 2 15 Hazards to Livestock Livestock Trailer sss 11 1 2 16 Hazards for Dump Trailers seen 12 1 2 17 Hazards from Accessories 12 1 2 18 Safety Warning Labels on Your Trailer sess 12 1 2 19 Trailer Towing Guide esses senses 17 1 2 20 Reporting Safety Defects sssssssseeenes 18 1 3 SAFE TRAILER TOWING GUIDELINES esee 18 2 TIRE SAFETY INFORMATION essere eene 20 2 1 STEPS FOR DETERMINING CORRECT LOAD LIMIT TRAILER 21 2 1 1 Trailers 10 000 Pounds GVWR or Less enne 21 2 1 2 Trailers Over 10 000 Pounds GVWR Note These trailers are not required to have a tire information placard on the vehicle 21 2 2 STEPS FOR DETERMINING CORRECT LOAD LIMIT TOW VEHICLE 21 2 3 GLOSSARY OF TIRE TERMINOLOGY 0 ceecceeeceeeeeeeeeeeeeneeeeaeeeneeeteaeeeeatens 22 2 4 TIRE SAFETY EVERYTHING RIDES ON IT sese 25 2 4 1 Safety First Basic Tire Maintenance sess 26 2 4 2 Finding Your Vehicle s Recommended Tire Pressure and Load Limits essen 26 2 4 8 Understanding Tire Pressure and Load Limits 26 2 4 4 Checking Tire Pressure ssssssssseseeene e
15. 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 is underinflated fill it to the recommended cold inflation pressure indicated on your vehicle s tire 27 Tire Safety Information information placard or certification label While your tire may still be slightly underinflated due to the extra pounds of pressure in the warm tire it is safer to drive with air pressure that is slightly lower than the vehicle manufacturer s recommended cold inflation pressure than to drive with a significantly underinflated tire Since this is a temporary fix don t forget to recheck and adjust the tire s pressure when you can obtain a cold reading 2 4 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 b
16. Adjustment figure shows the gooseneck height adjustment The gooseneck height adjustment bolts which have a cup that makes a gripping impression into the gooseneck tube must be tight so that the trailer does not drop to a lower position Do not over tighten because the tube can be deformed After tightening the bolts tighten the jam nuts on the bolts Gooseneck Ball Receiver and Height Adjustment 47 Coupling to Tow Vehicle A WARNING Improper gooseneck height adjustment can result in overloaded tires blowout and loss of control leading to death or serious injury Adjust the gooseneck receiver so that the loaded trailer is level 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 figures follow the jack instructions provided by the jack manufacturer If you do not have these instructions call Top Hat Industries Inc at 903 897 2813 for a free copy Drop leg Jack Arrangement Before attempting to tow the trailer 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 Wipe the gooseneck
17. Brake Shoes and Drums Properly functioning brake shoes and drums are essential to ensure safety You must have your dealer inspect these components at least once per year or each 12 000 miles The brake shoes must be adjusted after the first 200 miles of use and each 3 000 miles thereafter Most axles are fitted with a brake mechanism that will automatically adjust the brake shoes when the trailer is hard braked from a rearward direction Read your axle and brake manual to see how to adjust your brakes If you do not have this manual call Top Hat Industries Inc at 903 897 2813 for a free copy 8 2 4 2 Manually Adjusting Brake Shoes Some braking systems are not automatically adjusted by hard stopping These brakes require manual adjustment The following steps apply to adjust most manually adjustable brakes Read your axle and brake manual to see how to adjust your brakes If you do not have this manual call Top Hat Industries Inc at 903 897 2813 for a free copy e Jack up the trailer and secure 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 Note Your
18. Lug nuts are prone to loosen after initial installation which can lead to death or serious injury Check lug nuts for tightness on a new trailer or when wheel s have been remounted after the first 10 25 and 50 miles of driving General Safety Information WARNING Improper lug nut torque can cause a wheel separating from the trailer leading to death or serious injury Be sure lug nuts are tight before each tow 1 2 9 IMPROPER LOADIN The total weight of the load you put in or on the trailer plus the empty weight of the trailer itself must not exceed the trailer s Gross Vehicle Weight Rating GVWR If you do not know the empty weight of the trailer plus the cargo weight you must weigh the loaded trailer at a commercial 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 If your trailer is equipped with a Tire amp Loading Information Placard mounted next to the Certification VIN label the cargo capacity weight stated on that placard is only a close estimate The GVWR and GAWR s are listed on the Certification VIN label mounted on the front left side of the trailer A WARNING An overloaded trailer can result in loss of control of the trailer leading to death or serious injury Do not exceed the trailer Gross Vehicle Weight Rating GVWR or an axle Gross Axle Weight Rating GAWR Do not load a trailer so that the
19. a Rigid deck Trailer 72 4 3 1 3 Loading a Pivoting deck Tilt Bed Trailer 73 4 3 1 4 Preparing the Trailer for Loading sssssssss 75 4 3 2 Loading Livestock Livestock Trailer ssssusss 76 4 3 2 1 Preparing the Livestock Trailer for Loading 76 4 3 2 2 Loading the Livestock Trailer eeen 77 4 4 LOADING THE DUMP TRAILER 2 coetu ccr eei rc cete cte eue 78 4 4 1 Payload Capacity siet erg 78 4 4 2 Loading Cargo iia ned past aet ci ere 78 4 4 3 Loading Flowable material eene 79 4 4 4 Loading Fixed Loads including equipment such as skid steer loaders sse 79 4 4 5 Securing the Cargo soie iiie iei rei e trei 80 4 4 6 Unloading Flowable Loads from the Dump Trailer 80 4 4 7 Hydraulic Components essen 81 5 Table of Contents 4 4 8 Body Prop ieget ase eei e tei e ieee ee 81 4 4 9 Unload Bulk Material Using The Spreader Gate 82 CHECKING THE TRAILER BEFORE AND DURING EACH TOW 85 5 1 PREZ TOW CHECKEISTA eee eee ee E eere ed eet a 85 5 2 MAKE REGULAR STOPS 0s0seeeeeeeeeeeeeseeesseeeseeseesseeeseseseeeseeessseseeeeeees 85 BREAKING IN A NEW TRAILER eere 86 6 1 RETIGHTEN LUG NUTS AT FIRST 10 25 amp 50 MILES 86 6 2 ADJUST BRAKE SHOES AT FIRST 200 MILES
20. already have a tow vehicle know your vehicle tow rating and Gross Combination Weight Rating GCWR and make certain the trailer s rated capacity is less than or equal to the tow vehicle s rated towing capacity If you already have or plan to buy a trailer make certain that the tow rating of the tow vehicle is equal to or greater than the GVWR of the trailer and that the GCWR will be within limits Use of a hitch with a load rating less than the load rating of the trailer can result in loss of control and may lead to death or serious injury Use of a tow vehicle with a towing capacity less than the load rating of the trailer can result in loss of control and may lead to death or serious injury Be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer 3 1 1 TRAILER INFORMATION Certification VIN Label The location of the trailers Certification VIN Tag is shown on next page 33 Coupling to Tow Vehicle Certification VIN Tag Location DATE 42 2007 COLD INFLATION PRESSURE RIM KPA PSI SGL DUAL ST225 75D15LRD 15 X5 J 448 KPA 65 PSI SINGLE ST225 75D15 LRD 19 X 5 J 448 KPA 65 PSI SINGLE TIGHTEN LUG NUTS PERIODICALLY OOOO TYPE OF VEHICLE TRAILER BP18X7 7E D Certification VIN Tag Contents VIN Tag Location TOP Driver s Side Front WI The trailer Certification VIN tag contains the following critical safety information for the
21. 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 Always wear shoes or boots while performing this operation 3 2 4 3 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 The breakaway brake system includes a battery a switch with a pullpin anda breakaway brake lanyard Read and follow the instructions here as well as the instructions that have been prepared by the breakaway brake controller manufacturer If you do not have these instructions call Top Hat Industries Inc at 903 897 2813 for a free copy 61 Coupling to Tow Vehicle h 5 Wheel Coupler PIN PULLED OUT ONLY TO TEST BRAKES Breakaway Brake System Trailer can roll if it comes loose Electric safety brake applies when cable pulls pin out of switch box 1 PULL hard to get pin out of switch box SWITCH BOX i with tow vehicle 3 ATTACH pin CABLE to tow vehicle so RENAN pin will be pulled out if trailer separates ATTACH 4 Promptly REPLACE pin in switch box ur Yo Tow 2002 NATM VEHICLE STORAGE p PIN IN 2 CHECK brake by PULLING TRAILER t i SWITCH BOX FOR v 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
22. and deformations feel the inside of the coupler for worn spots and pits 39 Coupling to Tow Vehicle Be sure the coupler is tight to the tongue of the trailer All coupler fasteners must be visibly solid against the trailer frame A WARNING A loose hitch ball nut can result in uncoupling leading to death or serious injury Be sure the hitch ball is tight to the hitch before coupling the trailer Raise the bottom surface of the coupler to be above the top of the hitch ball Use the jack if one is provided otherwise use wood or concrete blocks to support the trailer tongue 3 2 2 2 Prepare the coupler and hitch Lubricate the hitch ball and the inside of the coupler with a thin layer of automotive bearing grease If your trailer is equipped with a jack raise the coupler above the ball height Open the coupler locking mechanism Ball couplers have a locking mechanism with an internal moving piece ball clamp and an outside handle wheel or latch In the open position the coupler is able to drop fully onto the hitch ball See the coupler instructions for details of placing the coupler in the open position Slowly back up the tow vehicle so that the hitch ball is near or aligned under the coupler if the trailer jack has raised the coupler Ball Hitch Coupler Mechanism Sleeve back re OPEN em CLOSED fall LATCH RET Kis p iw n c Pin in place Sieevi e forward 7 LEVER CLO
23. ball clean and inspect it visually and by feel for flat spots cracks and pits 48 Coupling to Tow Vehicle A WARNING A worn cracked or corroded gooseneck ball can fail while towing and may result in death or serious injury Before coupling the trailer inspect the gooseneck ball for wear corrosion and cracks and replace worn or damaged gooseneck ball 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 A WARNING A loose gooseneck ball can result in uncoupling leading to death or serious injury Be sure the gooseneck ball nut is tight before coupling the trailer 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 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 Make certain the ground beneath the jack foot is firm enough to support the tongue weight Rotate the handle crank clockwise to raise the bottom surface of the gooseneck to be above the top of the gooseneck ball 3 2 3 1
24. 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 3 1 2 Loading a Rigid deck Trailer Open trailers have either a rigid deck or a pivoting deck depending on the exact model This subsection describes loading a rigid deck trailer Before loading a rigid deck trailer couple the trailer to the tow vehicle and make sure the rigid deck is level Do not load or unload the trailer when the deck is not level Make sure the top of the ramp or ramps is secure to the trailer and the bottom is resting on firm ground Pockets may be provided to hold the ramp to the frame of the trailer 72 Loading the Trailer A WARNING Load can suddenly move or topple which can result in death or serious injury Do not load or unload your open trailer unless it is prevented from tipping and is on firm and level ground Load the cargo onto the trailer with approximately 60 of the cargo in the front half of the trailer Secure the cargo to the trailer using appropriate straps chains and tensioning devices 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 WARNING Shifting cargo can result in loss of control of th
25. 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 95 Inspection Service and Maintenance 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 8 2 4 4 A VACUUM OPERATED HYDRAULIC When towing a trailer the vacuum gauge which is located inside the cab of the tow vehicle must indicate 18 In Hg inches of mercury or more at all times A WARNING If the vacuum gauge in tow vehicle is not at or above 18 In Hg inches of mercury damage to the brake system will result and the brakes may become inoperable 8 2 4 4 B AIR PRESSURE OPERATED HYDRAULIC Air 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 8 2 4 4 C ELECTRICAL OPERATED HYDRAULIC E
26. cargo in the front half of the bed As the cargo is moved forward on the deck the deck will pivot down into the driving position Place the latch system into the driving position see Pivoting Deck Trailer figure Ensure that the locking leaver is in down position and insert pin A WARNING An unlocked pivoting deck can result in loss or cargo or loss of control of the trailer which can result in death or serious injury Before towing the trailer e Lock the pivoting deck in the driving position e Double check that the latch system is in the lock position Secure the cargo onto the trailer using appropriate straps and tensioning devices 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 74 Loading the Trailer A WARNING Shifting cargo can result in loss of control of the trailer and can lead to death or serious injury Tie down all loads with proper sized fasteners ropes straps etc Loading Cargo Enclosed Trailer 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 To measure the tongue weight you will have to uncouple the trailer after it is loaded 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 c
27. death or serious injury Make certain that tongue weight is within the allowable range Be sure to e Distribute the load front to rear to provide proper tongue weight see chart e Distribute the load evenly right and left to avoid tire overload and e Keep the center of gravity low 4 2 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 If a tongue weight scale is not available from your dealer call Top Hat Industries Inc at 903 897 2813 for assistance An alternate method of checking tongue weight involves the use of a bathroom scale The loaded trailer must be on a smooth and level surface and you must block the trailer wheels front and rear Checking Tongue Weight Using a lever and bathroom scale 69 Loading the Trailer A WARNING An unrestrained trailer can fall off its support resulting in serious injury or death Before checking tongue weight block trailer wheels front and rear Raise the tongue of the trailer with the jack Place a bathroom scale on the ground directly below the coupler Place a strong block support such as a cement block on the scale note the scale reading for the weight of the block support Lower the tongue until the co
28. fifth wheel plate just touches the kingpin plate Slowly back up the tow vehicle keeping the kingpin centered in the slot of the fifth wheel Continue backing up until the fifth wheel locks firmly on the kingpin 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 Coupler Operation figure Attempt to pull forward as an initial test of the closing of the fifth wheel locks Figure 3 2 Fifth Wheel Coupler Operation CHECK 1 The adjustment nut must be seated against the fifth wheel see Figure 6A CHECK 2 The secondary tock must be behind the yoke see Figure 6A CHECK 3 The fifth wheei must be fiush with the kingpin piate see Figure 7A FIGURE 6B j MOUNTING BOX FOR i BIRTH WHEEL TO MOUNTING BOX FOF i247 TRAILER FIFTH WHEEL TO r 7 TRAILER i CHECK NO 3 No Space Between Wheel and FRONT OF VEHICLE iha Kingpi Moy i i 1 me SPACE HA NO SPACE N CORRECT ENGAGEMENT INCORRECT ENGAGEMENT BED OF TRUCK BEO OF TRUCK FIGURE 7A FIGURE 7B 59 Coupling to Tow Vehicle A WARNING 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 have been performed e Adjustment nut against fifth wheel e Secondary lock behind yoke e Fifth wheel against kin
29. have your dealer inspect them to determine the proper action to prevent failure of the fifth wheel and kingpin system See the manual prepared by the manufacturer of the fifth wheel and kingpin for other inspection and maintenance activities If you do not have this manual call Top Hat Industries Inc at 903 897 2813 for a free copy 8 2 6 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 97 Inspection Service and Maintenance 8 2 7 LIGHTS AND SIGNALS Before each tow check the trailer taillights stoplights turn signals and any clearance lights for proper operation A WARNING Improper operating taillights stoplights and turn signals can cause collisions Check all lights before each tow 8 2 8 ACCESSORY BATTERY Your trailer may be outfitted with an accessory battery that operates electric landing gear hydraulic pump for dump bodies or other accessories An accessory battery may be kept charged either by the tow vehicle 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 bat
30. instructions for recharging the extinguisher after use 7 1 ACCESSORY BATTERY AVOID SERIOUS INJURY OR DEATH Battery must be connected before pump is operational Use CAUTION when opening battery case CAUTION Insure clamps are properly connected to posts on battery Positive Negative Improper connection will cause sparks and possible explosion Eye protection is required when working on battery No smoking or open flames near battery BATTERIES CAN HARM YOU THEY CAN BE DANGEROUS BECAUSE They contain ACID that can burn you They contain GAS that can expolde or ignite They contain enough ELECTRICITY to burn you Your trailer may be outfitted with an accessory battery that operates electric landing gear hydraulic pump for dump body or other accessories An accessory battery may be kept charged either by the tow vehicle 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 88 Accessories The accessory battery must be kept in a charged condition during storage The battery could freeze and break if it becomes discharged 7 2 ELECTRIC POWERED LANDIN EAR The landing gear also known as the jack on your trailer may be powered with an electric motor The landing gear is operated
31. n rear as COCE et ET DO NOT use the body prop to support a loaded dump DO NOT perform maintenance under a raised dump body without first blocking the empty dump bed up with the body prop 81 Loading the Trailer WARNING Risk of Death by crushing Dump body can drop unexpectedly Never go under a raised dump body Use body prop for maintenance A WARNING Risk of Death by crushing Make sure dump body is empty DO NOT manipulate the body prop if a person is near the control e Read and understand the hoist operating procedure before operating the dump body Clear the area around the dump trailer e Park the tow vehicle and trailer on a firm and level surface both left right and front rear Attempting to unload on a soft or uneven surface may cause the trailer to overturn which can result in death or serious injury e For spreading material the surface in which the tow vehicle and trailer will travel MUST be firm and level A WARNING A soft and or uneven surface may cause the tow vehicle and trailer to overturn when the dump body is raised or while spreading material Raise the dump body ONLY if the tow vehicle and trailer are both ona firm and level surface 82 Loading the Trailer A WARNING An overloaded trailer or improperly distributed load can result in death or serious injury An overloaded trailer can cause the hydraulic system to malfunction resulting in the dump body
32. not provide power to the breakaway brake battery you must periodically charge the battery to keep the breakaway brake system in working order Visually inspect the breakaway brake system for broken parts Connect the pullpin cable to the tow vehicle see Breakaway Brake System figure Do not connect to kingpin or its support To test the break away 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 lock up Immediately replace the pullpin The breakaway brake system battery discharges rapidly when the pullpin is removed A WARNING An ineffective breakaway brake system can result in a runaway trailer leading to death or serious injury if the coupler fails Connect the breakaway cable to the tow vehicle and NOT to the kingpin or its support Before towing the trailer test the function of the breakaway brake system If the breakaway brake system is not working do not tow the trailer have it serviced or repaired Do not tow the trailer with the breakaway brake system ON because the brake will overheat which can result in permanent brake failure 62 Coupling to Tow Vehicle A WARNING Failure to replace the pullpin will prevent brakes from working 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 Store t
33. 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 20 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 Top Hat Industries Inc If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Top Hat Industries Inc To contact NHTSA you may either call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go tohttp www safercar gov or write to Administrator NHTSA 1200 New Jersey Ave SE West Building Washington DC 20590 You can also obtain
34. risk is indicated by the following signal words DANGER Immediate hazards which WILL result in severe personal injury or death if the warning is ignored A WARNING 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 A 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 Excessive Speed Driving too fast for the conditions Failure to adjust driving behavior when towing a trailer Overloading and or improper weight distribution Improper or mis coupling of the trailer to the hitch Improper braking and steering under sway conditions Not maintaining proper tire pressure Not keeping lug nuts tight 1 2 1 IMPROPER SIZING OF THE TRAILER TO THE TOW VEHICLE Trailers that weigh too much for the towing vehicle can cause stability problems which can lead to death or serious injury Furthermore the additional strain put General Safety Information on the engine and drive train may lead to serious tow vehicle maintenance problems For these reasons the maxi
35. sape siy uo Sjaqe NOLLA VO Pue NINHVM H3ONVG Ie uim J esuno ezueqgiuej ISN NOA 434124 Si Buimo 380338 UIT 0j 4aj84 10 42efs MOTIV Z 19jdno2 ujeeuiepun suyo SSOH2 L asnu noA SIJE uogaeuuoo JI 134e pjou sujeyg suey dajes asn SAYMIY 16 General Safety Information I WARNING i Demectiag Ba homi ia a bydraaic spite with nore pracsare sul d ewigen Bani eesommamded ty ta botst mantactorer can cursus thn boit fo Wik during the Comping et atasa This casig lead ts damage serious mury or eath Aa re you have the carreri pestserm end Wow W yeu da ef know the recammended presura wn flow Comat the irsor masafactum Ades the bydrae prezsure is mare Gun ive recreated sedo mary came De baiiio ho rafter cuimmlactares Have caly qualified persse wt ha Oyomde pres Frisieg a visi irad during emping with the Dody raised by Jerking or cioci ng the balar may tem damage io Be trate veritas injury or death Movar drive forward ar rearward aed sing quicihy with iue land uy er other wise chock the ad 6a lca iz sue ia Da hody Bwer Be D GABE LOADED BON WI DE VECOS O Oh 18 PVT POLT Body len ires De bai T ENORA ie OA 5 008 A RESO SO TO LOCISEN A STUCK OAD y li J tng ander a roland hady cao renati in serine talary Or duai cid tho bec vewsyncdhvely denn Verr prtiios yourtei ot allow oer to pexffon Burmative gader 1 landed Voy A
36. 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 If you do not have these instructions call Top Hat Industries Inc at 903 897 2813 for a free copy TIRE PRESSURE Check tire pressures on both the trailer and tow vehicle Inflate to the maximum shown on the VIN Certification Label 87 Accessories 7 ACCESSORIES This chapter 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 Top Hat Industries Inc at 903 897 2813 before operating the accessory The following accessories are described in this section e Accessory Battery e Electric powered Landing Gear e Hydraulic Pump 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
37. the trailer tow vehicle combination will come to a controlled stop The breakaway brake system includes a battery a switch with a pullpin anda breakaway brake controller Read and follow the instructions here as well as the instructions that have been prepared by the breakaway brake controller manufacturer If you do not have these instructions call Top Hat Industries Inc at 903 897 2813 for a free copy 52 Coupling to Tow Vehicle Breakaway Brake System Gooseneck Coupler PIN PUL LED OUT ONLY TO TEST BRAKES Trailer can roll if it comes loose Electric safety brake applies when cable pulls pin out of switch box 1 PULL hard to get pin out of switch box with tow vehicle 3 ATTACH pin CABLE to tow vehicle so N pin will be pulled out if trailer separates ATTACH 4 Promptly REPLACE pin in switch box u Yo TOW 2002 NATM VEHICLE STORAGE gt PIN IN 2 CHECK brake by PULLING TRAILER SWITCH BOX FOR v 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 Visually inspect the breakaway brake system for broken parts Connect the pullpin cable to the tow vehicle so that the pullpin will be pulled out before all of the slack in the safety chains is taken up
38. the torque or torqued the lug nuts to the proper torque 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 adequately checking lug nut torque You must use a torque wrench to adequately indicate the torque that you are applying to the lug nut If you do not have a torque wrench tighten the fasteners with a lug wrench as much as you can then have a service garage or dealer tighten the lug nuts to the proper torque Over tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels 101 Inspection Service and Maintenance 5 LUG BOLT 6 LUG BOLT 8 LUG BOLT PATTERN PATTERN PATTERN 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 and should be corrected Contact your dealer or vehicle manufacturer immediately if you experience any persistent lug nut loosening or any other lug wheel or axle problems 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 stu
39. to loss of control serious injury or death If you do not use your trailer for three or more months or during winter months e Store the battery indoors and e Charge the battery every three months Replace the breakaway brake battery according to the intervals specified by battery manufacturer 3 2 2 6 Connect the electrical cables Connect the trailer lights to the tow vehicle s electrical system using the electrical connectors Check all lights for proper operation Clearance and Running Lights Turn on tow vehicle headlights Brake Lights Step on tow vehicle brake pedal Turn Signals Operate tow vehicle directional signal lever 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 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 44 Coupling to Tow Vehicle A WARNING Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes and can lead to collision Before each tow e Check that the taillights br
40. trailer for an extended period make sure the tires are fully inflated to the maximum rated pressure and that you store them in a cool dry place such as a garage Use tire covers to protect the trailer tires from the harsh effects of the sun A WARNING Worn damaged or under inflated tires can cause loss of control resulting in damage serious injury and possibly death Inspect tires before each tow 8 2 10 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 8 2 11 WHEELS BEARINGS AND LuG NuTS A loose worn or damaged wheel bearing 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 99 Inspection Service and Maintenance Most trailer axles are built with sealed bearings that are not serviceable Sealed bearings must be replaced as complete units 8 2 11 1 Unsealed Bearings Hubs If your trailer has unsealed axle bearings they must be inspected and lubricated once a year or 12 000 miles to insure safe operation of your trailer If a trailer wheel bearing is immersed in water it must be replaced If your trailer ha
41. use of your trailer e MANUFACTURER Name of trailer manufacturer e DATE OF MANUFACTURE Month and year the trailer was manufactured e GVWR The Gross Vehicle Weight Rating is the maximum allowable gross weight of the trailer and its contents The gross weight of the trailer includes the weight of the trailer and all of the items within it such as cargo water food and other supplies e 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 34 Coupling to Tow Vehicle the tire or wheel rating is lower than the axle manufacturers rating and will then determine GAWR The sum total of the GAWR for all trailer axles may be less than the GVWR for the trailer because some of the trailer load is carried by the tow vehicle rather than by the trailer axle s The total weight of the cargo and trailer must not exceed the GVWR and the load on an axle must not exceed its GAWR TIRE SIZE The tire size recommended for your trailer and load range PSIC The pounds per square inch cold is the tire pressure Kilopascals Pounds per Square Inch measured when Cold VIN The Vehicle Identification Number VEHICLE TYPE Generally the word trailer is used However after this you may put a Model or additional descriptor Tow Vehicle When equipping a new vehicle or an older vehicle to tow your trailer ask the vehicle dealer for adv
42. you must pull the pin from the switch and confirm that the brakes apply to each wheel You can do this by trying to pull the trailer with the tow vehicle after pulling the pin The trailer brakes may not lock but you will notice that a greater force is needed to pull the trailer A WARNING If electric breakaway brakes do not operate when trailer is uncoupled from the tow vehicle death or serious injury can occur Check emergency breakaway brake system BEFORE each tow 8 2 4 3 B 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 If you do not have these instructions call Top Hat Industries Inc at 903 897 2813 for a free copy 8 2 4 3 C MAGNETS FOR ALL ELECTRIC BRAKES To make certain an electrically operated braking system will function properly you must have your dealer inspect the magnets at least once a year or each 12 000 miles See the brake manual for wear and current inspection instructions 8 2 4 4 Brakes Hydraulic vacuum 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
43. 0 S8 Swess 9NLLVH QVOT IIEq 1801 423H2 E 318nui NO ej2Iu8A MO WO 9 00 WOd 0j 13 184 esneo jjj Bupdnoouf 14 General Safety Information ADANGER AWARNING AVOID SERIOUS INJU DEATH Uncoupling will cause Traller can roll if it comes loose ff ALWAYS use safety chains trailer to come loose from f Safety brake applies when chain Chains hold trailer If H E AVY tow vehicle pte Casha ene connection fails 1 ATTACH brake CHAIN securaly lo tow vehicle so lever will R A M P You MUST be pulled if trailer separates You MUST 2 CHECK brake fluid level 3 DO NOT TOW trailer I brake fluid is NOT FULL 1 CROSS chains underneath ND CLEAR 1 CHECK that ball LOAD RATING is same or greater than coupler LOAD RATING coupler 2 CHECK that ball SIZE is same Breakaway Chock as coupler fotow Brake Chain Pie Ra ALLOW slack for traller to tum 3 CLOSE COUPLER CLAMP Venicle 3 ATTACH chain hooks secruely on ball to tow vehicle frame 4 LIFT coupler upwards to test that It will not separate from ball cr Criss crass chains under coupler Tire wheel or lugnut failure can cause loss of An control Before towing you must CHECK Lug Nuts 1 Tire pressure and tread TIGHT 2 Tires and wheels for damage 5 Lug nuts for tightness For new and remounted wheels re tighten lug nuts at the first 10 25 and 50 miles of driving Tires and Wheels OK 2002 NATM A WARNING UNCOUPLING WILL CAU
44. 3 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 TO LIVESTOCK LIVESTOCK TRAILER A livestock trailer is designed for the safe transport of livestock other than horses It is not equipped for hauling horses Before loading your livestock inspect the interior of the livestock trailer to insure that no hazards are present Read section 4 3 2 Loading Livestock Livestock Trailer for specific instructions regarding trailering of livestock other than horses 11 General Safety Information WARNING Large animals are capable of inflicting serious injury or death to a human handler Know your animals temperament before attempting to trailer them Hauling a horse in a livestock trailer may result in its serious injury or death Do not carry a horse in a livestock trailer Use a trailer designed to carry horses 1 2 16 HAZARDS FOR DUMP TRAILERS A dump trailer is specifically designed for hauling cargo that is to be dumped not for transporting equipment or livestock The major hazards associated with dump trailers are Overloading Improper weight distribution both side to side and front to back Getting under a raised dump bed Not using or improperly using
45. 4 3 Section 8 2 4 4 Sections 3 2 2 5 3 2 3 4 amp 3 2 4 3 Section 8 2 4 3 A i Brakes all types Check operation Section 6 3 Shoes and Drums Adjust Section 6 2 8 2 4 2 Brakes Hydraulic Vacuum Actuated Check gauge for proper vacuum of 18 In Hg inches of mercury Section 8 2 4 4 A Coupler and Hitch Ball Check for cracks pits and flats Replace w ball amp coupler having trailer GVW Rating Grease Check locking device amp replace Section 8 2 5 1 Gooseneck Ball Check for cracks pits and flats Replace w ball amp coupler having trailer GVW Rating Grease Check locking device amp replace when worn Section 3 2 3 1 Section 3 2 3 1 Section amp 8 2 5 2 Fifth Wheel amp Kingpin Check for cracks Grease Check locking device amp replace when worn Section 3 2 4 1 Section 3 2 4 1 Section 3 2 4 1 amp 8 2 5 3 Safety Chain s amp Hooks Check for wear and damage Sections 3 2 2 4 amp 3 2 3 3 Tires Check tire pressure when cold Inflate as needed Sections 5 1 amp 8 2 9 Wheels Lug Nuts Bolts amp Hub Check for tightness Tighten For new and remounted wheels check torque after first 10 25 amp 50 miles of driving and after any impact Section 5 1 Sections 6 1 amp 8 2 11 2 90 Inspection Service and Maintenance Inspection and Service each 3 Months or 3 000 Miles It
46. CAPACITY Check if the trailer has payload decals on the sides If not then determine the payload or Cargo Capacity by subtracting the empty weight of the trailer from the GVWR given on the Certification VIN tag Determine the density of the material to be loaded and dumped so that you will know approximately how many cubic yards of material may be safely loaded carried and dumped WARNING Trailer hitch or dump body can fail You or others can die or be seriously injured Load in trailer must not exceed the payload capacity It must be evenly distributed 4 4 2 LOADING CARGO Couple the trailer to the towing vehicle before loading This is essential for bumper pull trailers because the tongue can raise during loading To measure the tongue weight you will have to de couple the trailer after it is loaded Be sure the trailer is located on level ground Attempting to load on uneven ground may cause the trailer to overturn which can result in serious injury or death 78 Loading the Trailer A WARNING RAISED DUMP BODY CAN DROP OR TIP OVER SUDDENLY YOU AND OTHERS CAN DIE OR BE SERIOUSLY INJURED YOU MUST Have trailer on level firm ground before dumping Keep others away while dumping Stay at controls until dump body is down NEVER LEAVE THE SCENE WHEN DUMP BODY IS LIFTED Lock hoist controls after use Have dump body down before moving trailer Use body prop and have dump body empty
47. ER NOT PROPERLY COUPLED TO THE HITCH It is critical that the trailer be securely coupled to the hitch ball and that the safety chains and emergency break away brake cable are correctly attached Uncoupling may result in death or serious injury to you and to others A WARNING Proper selection and condition of the coupler and hitch are essential to safely towing your trailer A loss of coupling may result in death or serious injury e Be sure the maximum load rating of the hitch on the tow vehicle is equal to or greater than the maximum load rating of the coupler on the trailer e Be sure the hitch ball size matches the coupler size e Observe the hitch for wear corrosion and cracks before coupling Replace worn corroded or cracked hitch components before coupling the trailer to the tow vehicle e Be sure the hitch components are tight before coupling the trailer to the tow vehicle General Safety Information WARNING An improperly coupled trailer can result in death or serious injury Do not move the trailer until e The coupler is secured and locked to hitch ball e The safety chains are secured to the tow vehicle and e The trailer jack s are fully retracted Do not tow the trailer on the road until Tires and wheels are checked The trailer brakes are checked if so equipped The breakaway switch is connected to the tow vehicle if so equipped The load is secured to the trailer and The trailer lights are
48. G THE CARGO OPEN TRAILER Couple the trailer to the tow vehicle before loading This is essential for the bumper pull trailer because the tongue of a bumper pull trailer can rise during loading before the cargo is properly distributed To measure the tongue weight you will have to uncouple the trailer after it is loaded Do not transport people containers of hazardous substances cans or containers of flammable substances such as gasoline kerosene paint etc However fuel in the tank of an off road vehicle or a car or motorcycle etc may be carried on your open trailer 71 Loading the Trailer A WARNING 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 3 1 1 Preparing the Trailer for Loading Before loading cargo onto the trailer e Inspect the deck of the trailer for corrosion or damage and e Inspect the hold down openings and or D rings Hold down openings must be sturdy with no visible cracks or kinks D rings must be tight to the deck and must not be bent If the deck or any required hold down is damaged do not load the cargo Bring the trailer to your dealer or a competent repair service before using it to carry cargo A WARNING Damaged or loose D rings can
49. SE TRAILER TO COME LOOSE FROM THE TOW VEHICLE YOU MUST 1 CHECK that ball LOAD RATING is the same or greater than coupler LOAD RATING 2 CHECK thal bail SIZE is the same as coupler SIZE 3 Make sure ball is fully seated into ball socket 4 SECURE COUPLER CLAMP on ball 5 LIFT coupler upwards to test that it will not separate from ball 6 CHECK that all latches or pins are in proper place UNCOUPLING WILL CAUSE TRAILER TO COME LOOSE FROM TOW VEHICLE 1 To open lift the latch and pull back ward raising the yoke and resting it on the nose of the coupler Fig 1 2 Place coupler on ball of same diameter as coupler and of same or greater capacity 3 When ball is completely nested In ball socket push handie forward until yoke drops over nose of coupler and the latch handle locking tips freely enter slots on top of coupler Fig 2 4 Lift coupler upwards to test that fa it will not separate from ball 5 insert padiock or boltthrough D US lock hole in yoke for theft protection UNCOUPLING WILL CAUSE TRAILER TO COME LOOSE FROM TOW VEHICLE YOU MUST 1 CHECK that bali LOAD RATING is the same or greater than PNIS IR couiertoao rane ose pm 2 CHECK that ball SIZE is the same as coupler SIZE nannies Pinch Point 3 CLOSE COUPLER CLAMP on ball Always use handles provided when folding the ramp gate to 4 LIFT coupler upwards to test that it the forward position will not separate from bail Failure to follo
50. SED HITCHAALL SEATED Lift Coupler to check 40 Coupling to Tow Vehicle Pintle Hitch Coupler Mechanism Closed clamp 3 2 2 3 Couple the trailer to the tow vehicle If your trailer does not have a jack you will have to lift the coupler and place it over the ball If you have a jack lower the trailer tongue until the coupler fully engages the hitch ball If the coupler does not line up with the hitch ball adjust the position of the tow vehicle Engage the coupler locking mechanism In the engaged position the locking mechanism securely holds the coupler to the hitch ball Insert a pin or lock through the hole in the locking mechanism Be sure the coupler is all the way on the hitch ball and the locking mechanism is engaged A properly engaged locking mechanism will allow the coupler to raise the rear of the tow vehicle Using the trailer jack test to see that you can raise the rear of the tow vehicle by 1 inch after the coupler is locked to the hitch Overloading can damage the tongue jack 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 Top Hat Industries Inc at 903 897 2813 or your dealer for assistance Lower the trailer so that its entire tongue weight is held by the hitch and continue retracting the jack to its fully retraced position 41 Coupling to Tow Vehicle 3 2 2 4 Rig the safety chains
51. Top Hat Industries Inc ALL MODELS A WARNING This Users Manual contains safety information and instructions for your trailer You must read this manual before loading or towing your trailer You must follow all safety precautions and instructions Top Hat Industries Inc P O Box 40 Naples TX 75568 903 897 2813 Phone 903 897 2815 Facsimile Table of Contents 1 GENERAL SAFETY INFORMATION eese 1 1 1 SAFETY ALERT SYMBOLS AND SIGNAL WORDS eee 1 1 2 MAJOR HAZARDS 2 LEE Deere cie rte evi teed tn ay iota 2 1 2 1 Improper Sizing of the Trailer to the Tow Vehicle 2 1 2 2 Driving ToOo Fasti unen ao eme eie eee 3 1 2 3 Failure to Adjust Driving Behavior When Towing a Trailer 3 1 2 4 Trailer Not Properly Coupled to the Hitch ssus 4 1 2 5 Proper Use of Safety Chains sse 5 1 2 6 Proper Connection of Breakaway Brake ssssssss 5 1 2 7 Matching Trailer and Hitch senes 6 1 2 8 Worn Tires Loose Wheels and Lug Nuts ss 6 1 2 9 Improper Loading iate triste teet nre haue eniin nn 8 1 2 10 Unsafe Load Distribution essen 8 1 2 11 Shifling Cargo ot tee e etes 9 1 2 12 Inappropriate Cargo sssesssseseeee nennen 10 1 2 13 Inoperable Brakes Lights or Mirrors seessssss 10 1
52. ace below jack base will support trailer tongue load 63 Coupling to Tow Vehicle 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 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 Always wear shoes or boots while performing this operation e Rotate the plunger pin handle so that the plunger pin is attempting to engage the drop leg see Releasing Drop Leg Mechanism figure e Slowly raise your foot permitting the drop leg to raise The plunger pin will engage a hole in the drop leg 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 f your trailer has two drop leg jacks lower them both to the same level following the above instructions 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 e Rotate the handle or crank clockwise to slo
53. ad 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 A WARNING An overloaded trailer can result in loss of control of the trailer leading to death or serious injury Do not load a trailer so that the weight on any tire exceeds its rating Do not exceed the trailer Gross Vehicle Weight Rating GVWR or the Gross Axle Weight Rating GAWR 4 1 TONGUE WEIGHT It is critical to have a portion of the trailer load carried by the tow vehicle That is the trailer tongue must exert a downward force on the hitch This is necessary for two reasons First the proper amount of tongue weight is necessary for the tow 67 Loading the Trailer 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 ton
54. ailer 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 The ball size and load rating capacity are marked on the ball hitch capacity is marked on the hitch 3 2 2 1 Before coupling the trailer to the tow vehicle Be sure the size and rating of hitch ball match the size and rating of the coupler Hitch balls and couplers are marked with their size and rating A WARNING Coupler to hitch mismatch can result in uncoupling leading to death or serious injury Be sure the LOAD RATING of the hitch ball is equal or greater than the load rating of the coupler Be sure the SIZE of the hitch ball matches the size of the coupler Wipe the hitch ball clean and inspect it visually and by feeling for flat spots cracks and pits A WARNING A worn cracked or corroded hitch ball can fail while towing and may result in death or serious injury Before coupling trailer inspect the hitch ball for wear corrosion and cracks Replace worn or damaged hitch ball 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
55. ake 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 10 General Safety Information mph manually operate the electric brake controller in the tow vehicle cab You should feel the operation of the trailer brakes A WARNING Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes and can lead to collision Before each tow e Check that the taillights brake lights and turn signals work e Check that the electric brakes work by operating the brake controller inside the tow vehicle If your trailer has hydraulic surge brakes pull the emergency break away 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 HazAnps From MODIFYING YOUR TRAILER Essential safety items can be damaged by altering your trailer Even simply driving a nail or screw to hang something 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 Top Hat Industries Inc at 903 897 281
56. ake lights and turn signals work e Check that the electric brakes work by operating the brake controller inside the tow vehicle 3 2 2 7 Uncoupling the Ball Hitch Trailer with Tongue Jack 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 3 2 3 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 coupling 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 Trailer with Gooseneck Hitch Coupler figure shows a trailer with a gooseneck coupler 45 Coupling to Tow Vehicle Trailer with Gooseneck Coupler We have installed a Gooseneck ball receiver that is suitable for the size and weight of the t
57. ar or motorcycle etc may be carried inside of your enclosed cargo trailer A WARNING Do not transport people inside the trailer even if it has living quarters The transport of people puts their lives at risk and may be illegal A WARNING 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 3 1 4 Preparing the Trailer for Loading Before loading cargo into your enclosed trailer inspect the interior of the trailer Enclosed 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 75 Loading the Trailer A WARNING 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 3 2 LOADING LIVESTOCK LIVESTOCK TRAILER Couple the trailer to the tow vehicle before loading This is essential for the bumper pull trailer because the tongue of a bumper pull t
58. at the ground is providing stable and level support for the trailer 56 Coupling to Tow Vehicle e After the jack s are extended and the gooseneck ball receiver is well clear of the gooseneck ball to permit driving the tow vehicle away disengage the handle from its shaft and return to its holder 3 2 4 TRAILER WITH FIFTH WHEEL PLER AND DROP LEG JACK A fifth wheel coupler on the trailer see Trailer with a Kingpin Coupler figure 3 1 and Fifth Wheel Coupler figure 3 2 connects to a kingpin that is installed on the tow vehicle A Fifth Wheel Coupler on the tow vehicle Figure 3 2 connects to a Kingpin that is installed on a trailer A fifth wheel coupler includes a flat load bearing plate with a slot and a mechanism inside the slot that grips the kingpin We have installed a kingpin that is suitable for the size and weight of the trailer You must provide a fifth wheel coupler that matches the kingpin and that is rated for the Gross Vehicle Weight Rating GVWR of your trailer Figure 3 1 Trailer with Kingpin Coupler 3 2 4 1 Before attempting to tow the trailer Be sure the size and rating of the fifth wheel and kingpin match 57 Coupling to Tow Vehicle Wipe the kingpin clean and inspect it visually and by feel for flat spots cracks and pits Check the condition of the kingpin and king pin plate and its attachment to the trailer A WARNING A worn bent cracked or corroded kingpin
59. ating the brake controller inside the tow vehicle 3 2 3 6 Uncoupling the Gooseneck Trailer with Drop leg Jack Follow these steps to uncouple your gooseneck hitch trailer from the tow vehicle 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 Move the spring loaded gooseneck receiver lock plate locking pin to the OPEN position see Gooseneck Ball Receiver and Height Adjustment figure Rotate the lock plate to a position that permits the gooseneck ball to exit the receiver Before releasing dropleg jack make certain ground surface below jack base will support the trailer tongue load Rotate the drop leg plunger pin handle so that the plunger pin is released from the drop leg see Releasing Drop Leg Mechanism figure Push down on the drop leg base with your foot to place a drop leg to the desired lowered position Rotate the plunger pin handle so that the plunger pin is attempting to engage the drop leg see Releasing Drop Leg Mechanism figure Slowly raise your foot permitting the drop leg to raise The plunger pin will engage a hole in the drop leg 55 Coupling to 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 bru
60. before getting under raised dump body If the hoist does not lift the load Manually reduce the load obtain service from a qualified hydraulics technician NEVER ASSIST THE HOIST i e with a jack crane heavy equipment etc If the load does not leave the dump body Lower the dump body and manually free the load Never attempt to free a load from a raised dump body Do not transport people containers of hazardous substances or cans of flammable liquids However fuel in the tank of a tractor skid steer loader generator etc may be carried in the dump trailer 4 4 3 LOADING FLOWABLE MATERIAL Flowable loads will assume an even weight distribution within the trailer Couple the trailer to the tow vehicle Check the bed for damage Close and fasten doors Level evenly distribute the load within the trailer from front to back and from side to side 444 LOADING FIXED LOADS INCLUDING EQUIPMENT SUCH AS SKID STEEH LOADERS Fixed loads that are to be carried or dumped should be loaded evenly throughout the trailer Too much load in the front portion will strain and possibly overload the hydraulic hoist Too much load in the rear will lead to reduced trailer sway stability at hignway speeds Inspect the hold down openings or D rings for any cracks or kinks 79 4 4 5 Loading the Trailer Clear the area around the dump trailer Load the equipment or material Secure the equipment Close and fasten door
61. can cause injury or damage to trailer and contents Inspect for and repair all damaged parts at least once a year 8 2 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 A WARNING Improper weld repair will lead to early failure of the trailer structure and can cause serious injury or death Do not repair cracked or broken welds unless you have the skills and equipment to make a proper repair If not have the welds repaired by your dealer 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 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 93 Inspection Service and Maintenance 8 2 4 TRAILER BRAKES 8 2 4 1
62. can fail while towing and may result in death or serious injury Before coupling the trailer inspect the kingpin and kingpin plate for wear bending cracks or corrosion and replace worn or damaged kingpin Be sure the fifth wheel mechanism operates freely and is property mounted to the tow vehicle Lubricate the fifth wheel plate surface with a light coat of Lithium base waterproof grease Be sure the fifth wheel and kingpin fasteners are tight and any welds are solid WARNING A loose fifth wheel or kingpin can result in uncoupling leading to death or serious injury Be sure the fifth wheel and kingpin are tight before coupling the trailer Be sure the brake line electrical line and any other lines are clear of the coupling area Be sure the locks are open see Fifth Wheel Coupler Operation figure If the tow vehicle is equipped with a tailgate lower it Block the trailer wheels front and rear Make certain that trailer kingpin plate is slightly above the fifth wheel plate on the tow vehicle Back tow vehicle up close to the trailer centering the kingpin in the slot of the fifth wheel STOP before engaging the coupling 58 Coupling to Tow Vehicle A WARNING If the trailer drops during coupling death or serious injury may result There must be no one under the trailer or coupler before or during the coupling operation Adjust the height of the trailer using the jack so that the
63. chnique 6 2 ADJUST BRAKE SHOES AT FIRST 200 MILES Brake shoes and drums experience a rapid initial wear The brakes must be adjusted after the first 200 miles of use and each 3 000 miles thereafter Some axles are fitted with a mechanism that will automatically adjust the brake shoes when the trailer is hard braked from a rearward direction Read your axle and brake manual to see if your brakes adjust automatically If you do not have the axle and brake manual call Top Hat Industries Inc at 903 897 2813 for a free copy A hard stop is used to e Confirm that the brakes work e Confirm that the trailer brakes are properly synchronized with the tow vehicle brakes using the brake controller in the tow vehicle e Adjust the brake shoes as necessary e For surge brakes check the Master cylinder reservoir for fluid If your trailer is not fitted with automatically adjusting brakes the brakes will need to be manually adjusted See section 8 2 4 2 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 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 86 Breaking in a New Trailer A WARNING If trailer and tow vehicle brakes do not work properly together death or
64. connected and checked 1 2 5 Proper USE OF SAFETY CHAINS If your trailer comes loose from the hitch for any reason we have provided safety chains so that control of the trailer can still be maintained WARNING Improper rigging of the safety chains can result in loss of control of the trailer and tow vehicle leading to death or serious injury if the trailer uncouples from the tow vehicle e Fasten chains to frame of tow vehicle Do not fasten chains to any part of the hitch unless the hitch has holes or loops specifically for that purpose e Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up if the trailer comes loose 1 2 6 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 ball 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 must be in good condition and properly rigged to be effective General Safety Information WARNING An ineffective or inoperative breakaway brake system can result in a runaway trailer leading to death or serious injury if the coupler or hitch fails The breakaway cable must be connected to the tow vehicle and NOT to any part of the hitch Before towing the trailer test the
65. d coupling connection between structures of the towing vehicle and trailer e Weight Carrying Hitch A mechanical and or structural device that connects the trailer to the towing vehicle and that does not employ features designed to redistruibute the load imposed at the hitch and carrying connection Safety chains or cables Chains or cables permanently attached to the trailer such that if the coupler connection comes loose the safety chains or cables can keep the trailer attached to the tow vehicle With properly rigged safety chains or cables it is possible to keep the tongue of the trailer from digging into the road pavement even if the coupler to hitch connection comes apart Some states do not allow safety cables e g Pennsylvania therefore it may be wise to check with the State Police to see if your state has any restrictions on the use of safety cables if your trailer is so equipped Trailer lighting and braking connector A device that connects electrical power from the tow vehicle to the trailer Electricity is used to turn on brake lights running lights and turn signals as required In addition if your trailer has a separate braking system the electrical connector will also supply power to the trailer brakes from the tow vehicle Breakaway switch If the trailer becomes de coupled from the towing vehicle the breakaway switch lanyard attached independently to the tow vehicle hitch will pull a pin in the emergency electrica
66. ding 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 4 TiRE SAFETY EVERYTHING HIDE NIT The National Traffic Safety Administration NHTSA has published a brochure DOT HS 809 361 that discusses all aspects of Tire Safety as required by CFR 575 6 This brochure is reproduced in part below It can be obtained and downloaded from NHTSA free of charge from the following web site http www nhtsa dot gov cars rules TireSafety ridesonit tires index html Studies of tire safety show that maintaining proper tire pressure observing tire and vehicle load limits not carrying more weight in your vehicle than your tires or vehicle can safely handle avoiding road hazards and inspecting tires for cuts slashes and other irregularities are the most important things you can do to avoid tire failure such as tread separation or b
67. ds Don t repair or service the trailer yourself Call a trained technician Lug Nut Torque Steel Wheels Axle Rating Dry Torque 3 500 to 7 000 Ye inch 80 to 95 8 000 9 16 inch 120 to 140 9 000 5 8 inch 175 to 225 10 000 5 8 inch flanged 275 to 325 12 000 34 inch flanged 375 to 425 Lug Nut Torque Aluminum Wheels Dry Torque 15 inch 5 or 6 hole 65 to 75 16 inch 8 hole 65 to 75 Dry Torque Foot pounds is determined by manufacturer 102 9 TOP HAT WARRANTY 9 1 1 Top HATINDUSTRIES NC 12 MONTH WARRANTY TOP HAT INDUSTRIES INC hereinafter referred to as Manufacturer warrants each new product to be free from defects in material and workmanship under normal use and service for a period of ONE YEAR 12 months normal wear of parts excepted This warranty period begins from the date of delivery of the new TOP HAT INDUSTRIES INC product to its original purchaser Manufacturer s liability and obligation is limited to at manufacturer s option to repair or replace free of charge to the original purchaser any defective part or parts The part or parts must be returned to manufacturer within thirty 30 days from the date of failure through the dealer from whom purchase was made with transportation charges being prepaid Manufacturer will then examine defective part or parts and determine if the product is defective This warranty does not cover any TOP HAT INDUSTRIES INC product which has been r
68. e trailer and can lead to death or serious injury Tie down all loads with proper sized fasteners ropes straps etc Return the ramp s to their stowed position s and secure them so that they will not move during transit 4 3 1 3 Loading a Pivoting deck Tilt Bed Trailer Some open trailers are equipped with a pivoting deck instead of with ramps The pivoting feature allows for easier loading and unloading Pivoting Deck Trailer Tilt Bed 73 Loading the Trailer The pivoting deck trailer is fitted with a latch system that keeps the trailer in the driving position After the trailer is loaded and the cargo is secured with hold downs be sure the latch system is in the driving position Couple the trailer securely to the tow vehicle before attempting to unlock the deck and load the trailer Unlock the deck and pivot it to the Loading position see Pivoting Deck Trailer figure Before loading the cargo be certain the latch system is retracted A WARNING Loading a pivoting deck trailer before retracting the latch system can cause damage to the latch system which can cause loss of cargo or loss of control of the trailer Death or serious injury may result Before loading the trailer retract the latch system If the deck latch system becomes bent do not straighten it Replace the deck latch system before towing the load Load the cargo onto the trailer with approximately 60 of the
69. e loaded dump body may result in the tow vehicle rear wheels loosing traction Do not fully raise a loaded dump body or place the entire load at the rear of trailer Watch for and avoid obstructions such as tree limbs overhead lines potholes etc and SLOWLY drive the tow vehicle and trailer ahead to spread the material DO NOT drive forward and stop quickly to shock the load out of the body DO NOT jerk the control button up and down to dislodge the load The proper procedure for a stuck load is to fully lower the dump and dislodge the material by hand You may need to raise the dump body higher after a portion of the load has been spread to place the remaining material at the rear of the dump body Stop tow vehicle after all material has exited the dump body Press and hold button to lower the dump body Release button when the dump body is fully lowered Close and latch rear gate 84 5 CHECKING THE TRAILER BEFORE AND DURING EACH Tow 5 1 PRE TOW CHECKLIST Before towing double check all of these items See section 8 1 Inspection Service amp Maintenance Summary Charts for more information e Tires wheels and lug nuts see the Major Hazards of this manual e Tire Pressure Inflate tire on trailer and tow vehicle to the pressure stated on the VIN Certification label e Coupler secured and locked see the Coupling and Uncoupling the Trailer section of this manual e Safety chains pro
70. ed by the cotter pin 100 Inspection Service and Maintenance 8 2 11 2 Lug Nuts Bolts Being sure wheel mounting nuts lug nuts on trailer wheels are tight and properly torqued is an important responsibility 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 Lug nuts are prone to loosen right after a wheel is mounted to a hub When driving on a new or remounted wheel check the lug nut tightness often during the first few hundred miles of the trailer s use especially after the first 10 25 and 50 miles of driving before each tow and at least twice per year thereafter WARNING Lug nuts are prone to loosen after initial installation which can lead to death or serious injury Check lug nuts for tightness on a new trailer or when wheel s have been remounted after the first 10 25 and 50 miles of driving WARNING Metal creep between the wheel rim and lug nuts will cause rim to loosen and could result in a wheel coming off leading to death or serious injury Tighten lug nuts before each tow Tighten the lug nuts to the proper torque for the axle size on your trailer to prevent wheels from coming loose Use a torque wrench to tighten the fasteners The only way to be certain you have checked
71. ed weight of the driver and passengers who will be riding in your vehicle 21 Tire Safety Information 9 Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds 10 The resulting figure equals the vailable amount of cargo and luggage capacity For example if the XXX amount equals 1400 Ibs and there will be five 150 Ib passengers in your vehicle the amount of available cargo and luggage capacity is 650 Ibs 1400 750 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 capacity 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 3 L ARY OF TIRE TERMINOL Y 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 com
72. ehicle s GVWR 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 70 Loading the Trailer Simple subtract the axle weight from the total weight to determine the hitch weight While you are at the scale you should weigh the entire combination vehicle This result should be less than the Gross Combined Weight Rating GCWR for your towing vehicle Some scales allow you to get individual axle weights also If this is possible get the tow vehicles front and rear axle weights to make sure they are in the same proportion as the tow vehicle alone and that the rear axle is not overloaded This is the best way to check that a weight distribution or load leveling hitch is adjusted properly i e you have the proper number of chain links attached to the snap up brackets 4 3 SECURING THE 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 WARNING Shifting cargo can result in loss of control of the trailer and can lead to death or serious injury Tie down all loads with proper sized fasteners ropes straps etc 4 3 1 DISTRIBUTIN
73. em Inspection Service Manual Section Reference Structure gt Rubber mats and floor gt Hinges Doors and Remove mats Wash both sides Wash floor Inspect Repair or replace Section 8 2 2 Sections 4 3 2 1 dividers damaged worn or broken parts amp 8 2 2 Inspection and Service each 6 Months or 6 000 Miles Item Inspection Service Manual Section Reference Tires Rotate 5 000 miles Section 8 2 9 Brakes electric gt Magnets Check wear and current draw Section 8 2 4 3 C gt Controller in tow vehicle Check power output amperage and modulation Section 8 2 4 3 B See Controller Mfr s Manual Structure gt Roof Vents Clean dirt buildup lubricate Section 8 2 2 gt Windows hinges and slides Inspect tread and sidewalls Section 8 2 9 Tires thoroughly Replace tire when treads are Section 8 2 9 worn when sidewall has a bulge or sidewall is worn Inspection and Service Each Year or 12 000 Miles Item Inspection Service Manual Section Reference Brakes all types gt Shoes and Check for scoring and wear Replace per manufacturer s Section 8 2 4 1 See Brake Mfr s drums specifications Manual Jack Drop leg Grease gears at top See Jack Mfr s Manual Structure Inspect all frame members bolts Section 8 2 1 gt Frame members gt Welds amp rivets Repair or replace damaged worn or broken parts Ins
74. epaired or altered outside of the factory of Manufacturer in any way so as to in the judgment of the Manufacturer affect the stability reliability or performance of the product This warranty does not cover damage or product failure caused by accident misuse negligence tampering overloading improper attachment or improper maintenance TOP HAT INDUSTRIES INC makes no warranty with respect to tires wheels brake systems axle assemblies hitches jacks couplers lumber paint or any other product not produced by Manufacturer These items are usually warranted through their respective manufacturer and their network of dealers This warranty is subject to any existing conditions of supply which may directly affect Manufacturer s ability to obtain materials or manufacture replacement parts This warranty is in lieu of all other warranties and representations whether oral express or implied and all other express or implied obligations or liabilities on the part of the Manufacturer This warranty excludes any and all liability for consequential or incidental damages No one is authorized to alter modify or enlarge this warranty nor its exclusions limitations and reservation 103 Service Record Serial Date Service Performed Mileage Service Performed
75. es Pneumatic tire A mechanical device made of rubber chemicals fabric and steel or other materials that when mounted on an automotive wheel provides the traction and contains the gas or fluid that sustains the load Production options weight The combined weight of those installed regular production options weighing over 2 3 kilograms 5 lbs in excess of those standard items which they replace not previously considered in curb weight or accessory weight including heavy duty brakes ride levelers roof rack heavy duty battery and special trim Radial ply tire A pneumatic tire in which the ply cords that extend to the beads are laid at substantially 90 degrees to the centerline of the tread Recommended inflation pressure This is the inflation pressure provided by the vehicle manufacturer on the Tire Information label and on the Certification VIN tag 24 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 Rim size designation This means the rim diameter and width Rim type designation This means the industry of manufacturer s designation for a rim by style or code Rim width This means the nominal distance between rim flanges Section width The linear distance be
76. falling A load that is improperly distributed in the trailer can result in the trailer overturning when the dump body is raised Loaded materials can exert pressure against the spreader gate This may cause the spreader gate to swing out with force when unlatched causing serious injury Stand away from the trailer to unlatch spreader gate Unlatch spreader gate While using the dump body controller position yourself in a safe location clear of the dump body Check for overhead power lines and other obstructions before raising dump body A WARNING Risk of electrocution Dump body coming near or contacting power lines may result in electrocution Electrocution can occur without contact Be sure there are no overhead power lines over or near the trailer before raising dump body A lowering or falling dump body can result in death or serious injury NEVER enter the area under the dump body unless the empty dump body is supported by the body props 83 Loading the Trailer The body props are designed to support an empty dump body only NEVER support a loaded dump body by the body props Unload the dump body before using body props Press and hold button to raise the dump body Release the button when the body has reached approximately the halfway point of its dumping angle or if the load begins to shift rearward Never leave the dump body control when operating the dump body A WARNING Fully raising th
77. function of the breakaway brake system If the breakaway brake system is not working do not tow the trailer have it serviced or repaired 1 2 7 MATCHING TRAILER AND HITCH Use of a hitch with a load rating less than the load rating of the trailer can result in loss of control and may lead to death or serious injury 1 2 8 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 increased tire wear and may reduce trailer stability which can result in a tire blowout or possible loss of control Therefore before each tow you must also check the tire pressure Remember the proper tire pressure is listed on the Certification VIN label normally mounted on front left side of the trailer and should be checked when tires are cold Allow 3 hours cool down after driving as much as 1 mile at 40 mph before checking tire pressure
78. gpin plate 3 2 4 2 Raise the Drop Leg Jack A trailer having a kingpin will be outfitted with one or two drop leg jacks for raising and lowering the kingpin 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 provided by the jack manufacturer If you do not have these instructions call Top Hat Industries Inc at 903 897 2813 for a free copy Rotate the jack handle counter clockwise This will slowly retract the jack and transfer the weight of the trailer 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 the Releasing Drop Leg Mechanism figure Raise the Tailgate Pick up the trailer wheel blocks 60 Coupling to Tow Vehicle Drop Leg Mechanism The drop legs are heavily spring loaded in the lowered position They will rapidly return to the upper position when released
79. gue 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 Axle Weight Rating GAWR The table below has rules of thumb for proper tongue weight In the table below 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 Tongue Weight as a Percentage of Loaded Trailer Weight Type of Hitch 10 15 for large trailers 6 10 for smaller utility and cargo trailers 4 6 for boat trailers Gooseneck Hitch 20 25 Fifth Wheel Hitch 20 25 The numbers quoted above are for example purposes only and should be tailored to the specific trailer For questions regarding the actual percent of tongue weight for the trailer check with the manufacturer for specifics Ball Hitch or Bumper Hitch 68 Loading the Trailer A WARNING Improper tongue weight load distribution can result in loss of control of the trailer leading to
80. h Wheel Kingpin ccccccceesesceeeeeeeeeeeeneeeeesseeessnenees 97 8 2 6 Landing Leg or Jack sti asainne ente te renes 97 8 2 7 Lights and Signals idi te rine 98 8 2 8 Accessory Ballery iieri tit regni 98 8 2 9 I EEA EAE IE ES E E E NEE EE AAE 98 8 2 10 Whee R E eat ee as 99 8 2 11 Wheels Bearings and Lug Nuts seeeeeee 99 8 2 11 1 Unsealed Bearings Hubs 100 8 2 11 2 Lug N ts Bolts ente 101 TOP HAT WARRANTUY ceeeeeeeea nena nna numum anna uana sana naar aa 103 9 1 1 Top Hat Industries Inc 12 Month Warranty 103 1 GENERAL SAFETY INFORMATION 1 1 SAFETY ALERT SYMBOLS AND SIGNAL WORDS An Owner s Manual that provides general trailer information cannot cover all of the specific details necessary for the proper combination of every trailer tow vehicle and hitch 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 Top Hat Industries Inc at 903 897 2813 for a free copy General Safety Information The safety information in this manual is denoted by the safety alert symbol 4 The level of
81. he battery indoors and Charge the battery every three months Replace the breakaway brake battery at intervals recommended by the battery manufacturer 3 2 4 4 Connect the electrical cables Connect the trailer lights to the tow vehicle s electrical system using the electrical connectors Check all lights for proper operation Clearance and Running Lights Turn on tow vehicle headlights Brake Lights Step on Tow vehicle brake pedal Turn Signals Operate tow vehicle directional signal lever Check brakes for proper operation 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 A WARNING Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes and can lead to collision Before each tow e Check that the taillights brake lights and turn signals work e Check that the electric brakes work by operating the brake controller inside the tow vehicle 3 2 4 5 Uncoupling the Fifth Wheel Trailer with Drop leg Jack 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 Disconnect the electrical connector Disconnect the breakaway brake switch lanyard If the tow vehicle has a tailgate lower it Make certain that ground surf
82. he weight of cargo should never exceed XXX kg or XXX Ibs on your vehicle s placard See figure 1 1 2 This figure equals the available amount of cargo and luggage load capacity 3 Determine the combined weight of luggage and cargo being loaded on the vehicle That weight may not safely exceed the available cargo and luggage load capacity The trailer s placard refers to the Tire Information Placard attached adjacent to or near the trailers VIN Certification label at the left front of the trailer Note The following calculations in Sections 2 1 2 and 2 2 are not required by the government For the purpose of completeness NATM has included these statements 2 1 2 IBAILERS OVER 10 000 Pounps GVWR NOTE THESE TRAILERS ARE NOT REQUIRED TO HAVE A TIRE INFORMATION PLACARD ON THE VEHICLE 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 2 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 combin
83. ice 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 horsepower 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 35 Coupling to Tow Vehicle Side V
84. iew Mirrors The size of the trailer that is 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 for mirror requirements 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
85. imum dump angle Stop the lift and walk to the rear to check to see if there is enough space for continued dumping Repeat the process until the load has been completely dumped If the load has not completely dumped DO NOT drive forward and stop quickly to shock the load out of the bed Also DO NOT jerk the control button up and down to dislodge the load The proper procedure for a stuck load is to lower the dump and dislodge the material by hand Secure the rear doors prior to moving forward Keep Control Box disconnected from trailer and in a secure place when not in use or during transportation 80 Loading the Trailer Risk of Death by crushing Empty dump body before using body prop 4 4 7 HYDRAULIC COMPONENTS Do not alter or substitute and hydraulic components on the dump trailer The hoist system is designed with each component being compatible with the safe and reliable operation of the hoist system Under no circumstances should you alter the hydraulic pressure or flow rate to the hoist system Always have the hoist system repaired or maintained by a qualified technician 4 4 8 Bopy Prop The body prop supplied as part of the trailer is to be used only when the dump body is empty The purpose of the body prop is a back up to the hydraulic system and will hold the empty dump body in a raised position while performing maintenance on the hoist trailer body or the trailer itself DANGER AWARNINGA
86. ises scrapes or pinching Keep your feet shins and hands well clear of the drop legs and drop leg bases when releasing the drop legs Always wear shoes or boots while performing this operation 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 f your trailer has two drop leg jacks lower them both to the same level following the above instructions 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 figure e Rotate the handle or crank from its hold and engage it with the jack shaft see Drop Leg Jack figure 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 gear mode by pulling or pushing on the handle shaft until it locks into low gear Do not use high gear to lift the trailer the drop leg jack mechanism can be damaged High gear is used only to rapidly move the drop leg base into contact with the ground e Continue to extend the jack s making sure th
87. l break away switch on the trailer The breakaway switch is activated by a separate battery supply in the trailer such as to energize the trailer brakes independently of the towing vehicle It is important to check the state of charge of the emergency break away battery before each trip Simply pull the pin out of the switch by hand and then try to pull the trailer If you feel a significant drag force the brakes are activated Be sure to re insert the pin in the break away switch Also be sure to allow enough slack in the break away brake lanyard such that the switch will only activate pin pulls out if the coupler connection comes loose For additional details refer to Section 3 2 2 5 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 37 Coupling to Tow Vehicle A WARNING An improperly coupled trailer can result in death or serious injury Do not move the trailer until e The coupler is secured and locked to hitch e The safety chains are secured to the tow vehicle and e The trailer jack s are fully retracted Do not tow the trailer on the road until Tires and wheels are checked The trailer brakes are checked The breakaway switch is connected to the tow vehicle and the break away battery is checked The load is secured to the trailer and The trailer lights are connected and checked 3 2 1 VABIQUS COUPLER DESIGNS
88. lation pressure on the tire sidewall This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions 2 4 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 4 5 STEPS FOR MAINTAINING PROPER TIRE PRESSURE e Step 1 Locate the recommended tire pressure on the vehicle s tire information placard certification label or in the owner s manual e Step 2 Record the tire pressure of all tires e Step
89. lectric hydraulic braking systems which are mounted on the trailer use a small electrically driven pump to generate hydraulic pressure which operates the brake cylinders Like electrical brakes an electric hydraulic braking system is operated by an electrical signal from the tow vehicle 8 2 5 TRAILER CONNECTION TO TOW VEHICLE 8 2 5 1 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 See the coupler manufacturer s manual for other inspection and maintenance activities If you do not have this manual call Top Hat Industries Inc at 903 897 2813 for a free copy 96 Inspection Service and 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 spri
90. linchpin in the catch 1 2 12 INAPPROPRIATE CARGO Your trailer may be designed for specific cargo for example only for cattle If your trailer is designed for specific cargo only carry that cargo in the trailer A utility trailer must not be used to carry certain items such as people containers of hazardous substances or containers of flammable substances A WARNING Do not transport people inside the trailer even if it has living quarters The transport of people puts their lives at risk and may be illegal A WARNING 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 1 2 13 INOPERABLE BRAKES LIGHTS OR MIRRORS Be sure that the electric brakes and all of the lights on your trailer are functioning properly before towing your trailer Electric brakes and lights on a trailer are controlled via a connection to the tow vehicle generally a multi pin electrical connector Check the trailer tail lights by turning on your tow vehicle headlights Check the trailer brake lights by having someone step on the tow vehicle brake pedal while you look at trailer lights Do the same thing to check the turn signal lights If your trailer has electric brakes your tow vehicle will have an electric br
91. lmas prep the unload tuf ap using Gs doy prap ar Dody rape supp Remember tady preps are is be used only en an aefuadet body Miwergriog ta droga kand on vuniewnl ground qury curse Da trailer to ever ru ami con emn damage serions injury or dsam Adwayy Gray Me lead om ground bat is level fre In rear as CLECE 2i WARNING To protect you and others against death or serious injury you must familiarize yourself with these labels If any of these labels are missing or cannot be read call Top Hat Industries Inc at 903 897 2813 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 19 TBAILER TOWING GUIDE Driving a vehicle with a trailer in tow is vastly different from driving the same vehicle without a trailer in tow Acceleration maneuverability and braking are all diminished with a trailer in tow It takes longer to get up to speed you need more room to turn and pass and more distance to stop when towing a trailer You will need to spend time adjusting to the different feel and maneuverability of the tow vehicle with a loaded trailer Because of the significant differences in all aspects of maneuverability when towing a trailer the hazards and risks of injury are also much greater than when driving without a trailer You are responsible for keeping your vehicle and trailer in control a
92. lowout 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 Tire Safety Information e Increase the life of your tires This booklet presents a comprehensive overview of tire safety including information on the following topics e Basic tire maintenance e Uniform Tire Quality Grading System e Fundamental characteristics of tires e Tire safety tips Use this information to make tire safety a regular part of your vehicle maintenance routine Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure 2 4 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 4 2 FINDING YOUR VEHICLE S RECOMMENDED TIRE PRESSURE AND LOAD Limits Tire information placards and vehicle certification labels contain information on tires and load limits These labels indicate the vehicle manufacturer s information including e Reco
93. m within the tire Innerliner separation The parting of the innerliner from cord material in the carcass Intended outboard sidewall The sidewall that contains a white wall bears white lettering or bears manufacturer brand and or model name molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle Light truck LT tire A tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose passenger vehicles Load rating The maximum load that a tire is rated to carry for a given inflation pressure Maximum load rating The load rating for a tire at the maximum permissible inflation pressure for that tire Maximum permissible inflation pressure The maximum cold inflation pressure to which a tire may be inflated Maximum loaded vehicle weight The sum of curb weight accessory weight vehicle capacity weight and production options weight 23 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 pneuma
94. mmended 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 4 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 26 Tire Safety Information will read below it is difficult to obtain the recommended tire pressure if your tires are not cold Because tires are designed to be used on more than one type of vehicle tire manufacturers list the maximum permissible inf
95. mum towing capacity of your towing vehicle should not be exceeded The towing capacity of your tow vehicle in terms of maximum Gross Trailer Weight GTW and maximum Gross Combined Weight Rating GCWR can be found in the tow vehicles Owner s Manual Use of atow vehicle with a towing capacity less than the Gross Vehicle Weight Rating of the trailer can result in loss of control and may lead to death or serious injury Be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer 1 2 2 Devine 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 A WARNING Driving too fast for conditions can result in loss of control and cause death or serious injury Decrease your speed when going downhill or as road weather and lighting conditions deteriorate 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 sen
96. nd for all the damage that is caused if you lose control of your vehicle and trailer As you did when learning to drive an automobile find an open area with little or no traffic for your first practice trailering Of course before you start towing the trailer you must follow all of the instructions for inspection testing loading and coupling Also before you start towing adjust the mirrors so you can see the trailer as well as the area to the rear of it Drive slowly at first 5 mph or so and turn the wheel to get the feel of how the tow vehicle and trailer combination responds Next make some right and left hand 17 General Safety Information turns Watch in your side mirrors to see how the trailer follows the tow vehicle Turning with a trailer attached requires more room Stop the rig a few times from speeds no greater than 10 mph If your trailer is equipped with brakes try using different combinations of trailer electric brake and tow vehicle brake Note the effect that the trailer brakes have when they are the only brakes used When properly adjusted the trailer brakes will come on just before the tow vehicle brakes It will take practice to learn how to back up a tow vehicle with a trailer attached Take it slow Before backing up get out of the tow vehicle and look behind the trailer to make sure that there are no obstacles Some drivers place their hands at the bottom of the steering wheel and while the tow vehicle is in
97. ng 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 5 2 Gooseneck The gooseneck receiver on the trailer connects to a hitch 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 See the gooseneck ball receiver manufacturer s manual for other inspection and maintenance activities If you do not have a manual for the receiver call Top Hat Industries Inc at 903 897 2813 for a free copy 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 5 3 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
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99. op leg bases when releasing the drop legs Always wear shoes or boots while performing this operation 51 Coupling to Tow Vehicle 3 2 3 3 Rig the safety chains Visually inspect the safety chains and hooks for wear or damage Replace worn or damaged safety chains and hooks before towing Rig the safety chains so that they attach to the safety chain receivers in the bed of the truck 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 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 A WARNING Improper rigging of the safety chains can result in loss of control of the trailer and tow vehicle leading to death or serious injury if the trailer uncouples from the tow vehicle 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 3 4 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
100. other information about motor vehicle safety from http www nhtsa gov Call 903 897 2813 to reach Top Hat Industries Inc 1 3 SAFE TRAILER TOWING GUIDELINES e Recheck the load tiedowns to make sure the load will not shift during towing e Before towing check coupling 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 18 General Safety Information Adjust the brake controller to engage the trailer brakes before the tow vehicle brakes Follow the instructions given with the brake controller manufacturer s literature Use your mirrors to verify that you have room to change lanes or pull into traffic Use your turn signals well in advance Allow plenty of stopping space for your trailer and tow vehicle Do not drive so fast that the trailer begins to sway due to speed Generally never drive faster than 60 m p h Allow plenty of room for passing A rule of thumb is that the passing distance with a trailer is 4 times the passing distance without a trailer Shift your automatic transmission into a lower gear for city driving Use lower gears for climbing and descending grades Do not ride the brakes while descending grades they may get so hot that they stop working Then you will potentially have a runaway tow vehicle and trailer To conserve fuel don t use full throttle to climb a hill Instead build speed on the approach Slow do
101. ould 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 98 Inspection Service and Maintenance Tires can lose air over a period of time In fact tires can lose 1 to 3 PSI per month This is because molecules of air under pressure weave their way from the inside of the tire through the rubber to the outside A drop in tire pressure could cause the tire to become overloaded leading to excessive heat build up If a trailer tire is under inflated even for a short period of time the tire could suffer internal damage High speed towing in hot conditions degrades trailer tires significantly As heat builds up during driving the tire s internal structure starts to breakdown compromising the strength of the tire It is recommended to drive at moderate speeds Statistics indicate the average life of a trailer tire is about five years under normal use and maintenance conditions After three years replacing the trailer tires with new ones should be considered even if the tires have adequate tread depth Some experts claim that after five years trailer tires are considered worn out and should be replaced even if they have had minimal or no use This is such a general statement that it may not apply in all cases It is best to have your tires inspected by a tire supplier to determine if your tires need to be replaced If you are storing your
102. pect all welds Repair as needed Section 8 2 2 2 Wheels gt Sealed Bearings Hubs gt UNSEALED Bearings Hubs gt Rims Check and confirm free running Replace if not sealed bearings are not serviceable Disassemble inspect assemble and repack Replace promptly if immersed in water Inspect for cracks amp dents Replace as needed Section 8 2 11 Section 8 2 11 1 See Axle Mfr s Manual Section 8 2 10 Structure gt Axle Attachment Bolts Check BY DEALER Section 8 2 1 91 Inspection Service and Maintenance 8 2 INSPECTION AND SERVICE INSTRUCTIONS 8 2 1 AxLE BoLrs FRAME SUSPENSION amp STRUCTURE A WARNING Worn or broken suspension parts can cause loss of control and injury may result Have trailer professionally inspected annually and after any impact To perform many of the inspection and maintenance activities you must jack up the trailer Jacking Points for All Trailers figure 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 A WARNING Never crawl under your trailer unless it is on firm and level ground and resting on properly placed and secured jack stands 8 2
103. peration and Opening Fifth Wheel Locks figures Slowly drive the tow vehicle away from the trailer Raise the tow vehicle tailgate 66 Loading the Trailer 4 LOADING THE TRAILER Improper trailer loading causes many accidents and deaths To safely load a trailer you must consider Overall load weight Load weight distribution Proper tongue weight and Securing the load properly To determine that you have loaded the trailer within its rating you must consider the distribution of weight as well as the total weight of the trailer and its contents The trailer axles carry most of the total weight of the trailer and its contents Gross Vehicle Weight or GVW The remainder of the total weight is carried by the tow vehicle hitch It is essential for safe towing that the trailer tongue and tow vehicle hitch carry the proper amount of the loaded trailer weight otherwise the trailer can develop an undesirable sway at towing speeds or the rear of the towing vehicle can be overloaded Read the Tongue Weight section below 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 Lo
104. perly rigged to tow vehicle not to hitch or ball see the Coupling to the Tow Vehicle chapter of this manual e Testof lights Tail Stop and Turn Lights e Testtrailer brakes e Safety breakaway switch cable fastened to tow vehicle not to safety chains see the Coupling to the Tow Vehicle chapter of this manual e Cargo properly loaded balanced and tied down see the Loading the Trailer chapter of this manual Tongue weight and weight distribution set up Doors and gates latched and secured Fire extinguisher Flares and reflectors 5 2 MAKE REGULAR STOPS After each 50 miles or one hour of towing stop and check the following items Coupler secured Safety chains are fastened and not dragging Cargo secured Cargo door latched and secured 85 Breaking in a New Trailer 6 BREAKING IN A NEW TRAILER 6 1 RETIGHTEN LUG NUTS AT FIRST 10 2 MILE 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 A WARNING Lug nuts are prone to loosen after initial installation which can lead to death or serious injury Check lug nuts for tightness on a new trailer or when wheel s have been remounted after the first 10 25 and 50 miles of driving See Section 8 2 11 2 page 101 on Proper Tourqing Te
105. ponents 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 22 Cord separation The parting of cords from adjacent rubber compounds Cracking Any parting within the tread sidewall or inner liner of the tire extending to cord material CT A pneumatic tire with an inverted flange tire and rim system in which the rim is designed with rim flanges pointed radially inward and the tire is designed to fit on the underside of the rim in a manner that encloses the rim flanges inside the air cavity of the tire Curb weight The weight of a motor vehicle with standard equipment including the maximum capacity of fuel oil and coolant and if so equipped air conditioning and additional weight optional engine Extra load tire A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire Tire Safety Information Groove The space between two adjacent tread ribs Innerliner The layer s forming the inside surface of a tubeless tire that contains the inflating mediu
106. railer 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 GVWR 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 The ball size and load rating capacity are marked on the ball hitch capacity is marked on the hitch 46 Coupling to Tow Vehicle A WARNING Coupler to hitch mismatch can result in uncoupling leading to death or serious injury Be sure the LOAD RATING of the hitch ball is equal or greater than the load rating of the coupler Be sure the SIZE of the hitch ball matches the size of the coupler The height of the ball receiver on the trailer must be adjusted to match the height of the gooseneck ball on your tow vehicle so that There is clearance between the bottom of the trailer and the sides of the tow vehicle bed and The trailer is level and allows equal weight distribution on tandem axles The Gooseneck Ball Receiver and Height
107. railer can rise during loading before the cargo is properly distributed The cargo carrying portion of a livestock trailer is for carrying livestock other than horses only The livestock trailer does not have the equipment required for the safe transport of horses e g stall dividers tie rings and a rubber floor mat Do not transport people containers of hazardous substances or containers of flammable substances A WARNING Do not transport people inside the trailer even if it has living quarters The transport of people puts their lives at risk and may be illegal A WARNING Do not transport flammable explosive poisonous or other dangerous materials in your trailer Hauling a horse in a livestock trailer may result in its serious injury or death Do not carry a horse in a livestock trailer Use a trailer designed to carry horses 4 3 2 1 Preparing the Livestock Trailer for Loading Before loading livestock in your livestock trailer inspect the interior of the trailer The interior of the trailer must be smooth and have no protruding objects such 76 Loading the Trailer as bolts broken parts of trailer interior etc A protruding object can injure your livestock Tighten any loose or protruding bolts in the walls Remove or secure loose objects so no items will move during towing The interior space of a trailer may contain hazards that result in serious injury or death to trailered livestock Inspec
108. ratio of height to width Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement R The R stands for radial Radial ply construction of tires has been the industry standard for the past 20 years Next number This two digit number is the wheel or rim diameter in inches If you change your wheel size you will have to purchase new tires to match the new wheel diameter Next number This two or three digit number is the tire s load index It is a measurement of how much weight each tire can support You may find this information in your owner s manual If not contact a local tire dealer Note You may not find this information on all tires because it is not required by law 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 29 Tire Safety Information Speed Rating The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time The ratings range from 99 miles per hour mph to 186 mph These ratings are listed below Note You may not find this information on all tires because it is not required by law Letter Rating Speed Rating 99 mph 106 mph 112 mph 118 mph 124 mph 130 mph 149 mph 168 mph 186 mph For tires with a maximum speed capability over 149 mph tire manufacturers sometimes use the le
109. re graded 200 Traction Letter This letter indicates a tire s ability to stop on wet pavement A higher graded tire should allow you to stop your car on wet roads in a shorter distance than a tire with a lower grade Traction is graded from highest to lowest as AA A B and ON 30 Tire Safety Information Temperature Letter This letter indicates a tire s resistance to heat The temperature grade is for a tire that is inflated properly and not overloaded Excessive speed underinflation or excessive loading either separately or in combination can cause heat build up and possible tire failure From highest to lowest a tire s resistance to heat is graded as A B or C Additional Information on Light Truck Tires Please refer to the following diagram Maximum load Load amp inflation when used as a dual Severe snow Light conditions truck tiro Maximum load amp inflation when Load inflation used as a single limits Tires for light trucks have other markings besides those found on the sidewalls of passenger tires LT The LT indicates the tire is for light trucks or trailers ST An ST is an indication the tire is for trailer use only Max Load Dual kg Ibs at kPa psi Cold This information indicates the maximum load and tire pressure when the tire is used as a dual that is when four tires are put on each rear axle a total of six or more tires on the vehicle Max Load Single kg Ibs a
110. rformed by a qualified technician 2 4 9 TIRE REPAIR The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that surrounds the puncture hole Punctures through the tread can be repaired if they are not too large but punctures to the sidewall should not be repaired Tires must be removed from the rim to be properly inspected before being plugged and patched 2 4 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 28 Tire Safety Information 2 4 10 1 Information on Passenger Vehicle Tires Please refer to the diagram below Radiat Rim diameter pode Ratio of height fo width aspect ratio Nominal widih of Vire in millimeters _ U S DOT lire g uientification number Severe snow conditions composition and materials used Trisadiwear traction and temperature grades Max load rating P The P indicates the tire is for passenger vehicles Next number This three digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge In general the larger the number the wider the tire Next number This two digit number known as the aspect ratio gives the tire s
111. s If loading ramps are used the operator must be experienced and skilled to perform the loading SECURING THE CARGO Since the trailer cargo is subjected to longitudinal front back and lateral side side forces you must secure all cargo that is not flowable so that it does not shift while the trailer is being towed 4 4 6 UNLOADING FLOWABLE LOADS FROM THE DUMP TRAILER Read and understand the hoist operating procedure before dumping the load Be sure the trailer is on level ground both left right and front back Attempting to unload on uneven ground may cause the trailer to overturn which can result in serious injury or death Clear the area around the dump trailer Check for powerlines Open the rear doors and make sure they are securely hooked to the sides of the trailer using the hold back door chains Standing well clear of the dump bed push the UP button on the control device until the dump bed reaches approximately the halfway point of its dumping angle Never leave the control device when operating the dump bed Discontinue pushing the UP button and walk to the rear of the trailer so you can estimate if there is enough space for the remainder of the load to be safely dumped If not then you need to lower the dump bed by depressing the DOWN button and pull the trailer forward and then repeat the previous step Standing well clear of the dump bed raise the dump bed to the three quarter point of the max
112. s 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 Exploded view of Wheel Bearing aya Hub amp Drum Assembly Hub Assembly 00 0 Required with AG Spindle Follow the steps below to disassemble and service the UNSEALED wheel bearings e After removing the grease cap cotter pin spindle nut and spindle washer items 7 10 in Exploded Wheel Bearing figure 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 Lubricate 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 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 Putanew 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 limit
113. see Safety Chains figure Do not connect the pullpin cable to a safety chain or a 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 breakaway brake connection To check the break away brake battery pull out the pullpin from the switch and attampt to pull the trailer forward You should feel the trailer resisting being towed but the wheels will not necessarily lock up Immediately replace the pullpin The breakaway brake system battery discharges rapidly when the pullpin is removed 53 Coupling to Tow Vehicle WARNING An ineffective or inoperative breakaway brake system can result in a runaway trailer leading to death or serious injury if the coupler or hitch fails Connect the breakaway cable 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 serviced 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 A WARNING Failure to replace the pullpin will prevent brakes from working leading to loss of control serious injury or death
114. sitive to steering inputs and more likely to be pushed around in windy conditions or when being passed by large vehicles In addition you will need a longer distance to pass due to slower acceleration and increased length With these caveats in mind 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 General Safety Information e When encountering trailer sway take your foot off the gas and steer as little as possible in order to stay on the road Use small trim like steering adjustments Do not attempt to steer out of the sway you ll only make it worse Also do not apply the tow vehicle brakes to correct trailer swaying On the other hand application of the trailer brakes alone will tend to straighten out the combination especially when going downhill 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 1 2 4 TRAIL
115. t of tongue weight for the trailer check with the manufacturer for specifics 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 A WARNING Improper tongue weight load distribution can result in loss of control of the trailer leading to death or serious injury Make certain that tongue weight is within the allowable range Be sure to Distribute the load front to rear to provide proper tongue weight see chart For dump trailers a flowable load should be evenly distributed throughout the bed Distribute the load evenly right and left Keep the center of gravity low 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 WARNING Shifting cargo can result in loss of control of the trailer and can lead to death or serious injury Tie down all loads with proper sized fasteners ropes straps etc If the gate latch is equipped with a catch that has a hole for a linchpin use a linchpin to prevent the gate latch from opening General Safety Information WARNING If the gate opens your cargo may be ejected onto the road resulting in death or serious injury to other drivers Always secure the gate latch after closing Place a
116. t 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 31 Tire Safety Information 2 4 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 Do not run over curbs or other foreign objects in the roadway and try not to strike the curb when parking Tire Safety Checklist e Check tire pressure regularly at least once a month including the spare e Inspect tires for uneven wear patterns on the tread cracks foreign objects or other signs of wear or trauma Remove bits of glass and foreign objects wedged in the tread Make sure your tire valves have valve caps Check tire pressure before going on a long trip Do not overload your vehicle Check the Tire Information and Loading Placard or User s Manual for the maximum recommended load for the vehicle 32 Coupling to Tow Vehicle 3 COUPLING TO THE TOW VEHICLE Follow all of the safety precautions and instructions in this manual to ensure safety of persons cargo and satisfactory life of the trailer 3 1 USE AN ADEQUATE TOW VEHICLE AND HITCH If the vehicle or hitch is not properly selected and matched to the Gross Vehicle Weight Rating GVWR of your trailer you can cause an accident that could lead to death or serious injury If you
117. t the interior of the trailer before loading livestock e Adjust or repair all loose and protruding features e All cargo and equipment besides the livestock must be prevented from being thrown about before towing trailer 4 3 2 2 Loading the Livestock Trailer The trailering of livestock introduces many variables that are not present in the trailering of non living cargo Livestock may resist being loaded into a trailer A WARNING Large animals are capable of inflicting serious injury or death to a human handler Know your animals temperament before attempting to trailer them If the trailer is fitted with a drop ramp carefully lower it to the ground With the trailer in position open and secure the loading door either swinging or roll up Open and secure the interior gates as necessary Guide the livestock into the trailer Gate the livestock tightly to keep them from moving or falling during transportation Close the loading doors either swinging or roll up and raise the drop ramp Secure the trailer door catch with a linchpin or similar device so that the catch and door cannot open while the trailer is being towed 77 Loading the Trailer A WARNING If the door opens your cargo may be ejected onto the road resulting in death or serious injury to other drivers Always secure the door latch after closing Place a linchpin in the catch 4 4 LOADING THE DUMP TRAILER 4 4 1 PAYLOAD
118. ter 27 2 4 5 Steps for Maintaining Proper Tire Pressure ss 27 2 4 6 TIfeSIZO A E o Hte nim iai tus 28 2 4 7 TWO Tread eid eee Sia ead dle eisdem 28 2 4 8 Tire Balance and Wheel Alignment sess 28 2 4 9 Tire Repair x2 Itt tatto pe eae eee 28 2 4 10 Tire Fundamerntals eee titer ipee rne 28 2 4 10 1 Information on Passenger Vehicle Tires 29 2 4 10 2 UTQGS Information sese 30 2 4 11 Tire Safety Tips be c EU be EGER ee ds 32 Table of Contents 3 COUPLING TO THE TOW VEHICLE eere 33 3 1 USE AN ADEQUATE TOW VEHICLE AND HITCH essceeeeseeeeeeneeeesenetereeaes 33 3 1 1 Trailer Information 2 itae e teer eee res 33 3 2 COUPLING AND UNCOUPLING THE TRAILER eene 36 3 2 1 Various Coupler Designs sese 38 3 2 2 Trailer with Ball Hitch Coupler sese 38 3 2 2 1 Before coupling the trailer to the tow vehicle 39 3 2 2 2 Prepare the coupler and hitch eeeesssessss 40 3 2 2 8 Couple the trailer to the tow vehicle 41 3 2 2 4 Rig the safety chains sssssssseeeeeeene 42 3 2 2 5 Attach and test electric breakaway brake system 43 3 2 2 0 Connect the electrical cables sseseesesss 44 3 2 2 7
119. tery 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 9 TIRES 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 spots from developing The main cause of tire failure is improper inflation Check the cold tire inflation pressures at least once a week for proper inflation levels Cold means that the tires are at the same temperature as the surrounding air such as when the vehicle has been parked overnight Wheel and tire manufacturers recommend adjusting the air pressure to the trailer manufacturer s 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 If the tires are inflated more than the recommended inflation level handling characteristics of the tow vehicle trailer combination c
120. 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 jack test to see that you can raise the rear of the tow vehicle by 1 inch oe Locking Pin Closed S l Locking Pin Housing closed _ Y ECP _ Open ce A X KE 3 Locking Plate Closed 3 Hitch Locking Pin Extends Ball Through Hole 50 Coupling to Tow Vehicle Overloading can damage the drop leg jack 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 Top Hat Industries Inc at 903 897 2813 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 Drop Leg Mechanism figure Drop Leg Mechanism 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 dr
121. tic tire assembly intended for temporary use in place of one of the pneumatic tires and rims that are fitted to a passenger car in compliance with the requirements of this standard Non pneumatic tire A mechanical device which transmits either directly or through a wheel or wheel center member the vertical load and tractive forces from the roadway to the vehicle generates the tractive forces that provide the directional control of the vehicle and does not rely on the containment of any gas or fluid for providing those functions Non pneumatic tire assembly A non pneumatic tire alone or in combination with a wheel or wheel center member which can be mounted on a vehicle Normal occupant weight This means 68 kilograms 150 Ibs times the number of occupants specified in the second column of Table of 49 CFR 571 110 Occupant distribution The distribution of occupants in a vehicle as specified in the third column of Table of 49 CFR 571 110 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 Ply A layer of rubber coated parallel cords Ply separation A parting of rubber compound between adjacent pli
122. 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 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 4 3 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 8 2 4 3 A BREAKAWAY BRAKE 94 Inspection Service and Maintenance 8 2 4 3 A i BREAKAWAY BATTERY This battery supplies the power to operate the trailer brakes if the trailer uncouples from the tow vehicle Be sure to check maintain and replace the battery according to the battery manufacturer instructions 8 2 4 3 A ii BREAKAWAY SWITCH This switch causes the breakaway battery to operate the electric brakes if the trailer uncouples from the tow vehicle The pull cable 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
123. ttach and test electric breakaway brake system If the coupler or hitch fails a properly connected and working breakaway brake system will apply electric brakes on the trailer The safety chains will keep the tow vehicle attached and as the 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 battery a switch with a pullpin anda lanyard Read and follow the instructions here as well as the instructions that have been prepared by the breakaway brake manufacturer If you do not have these instructions call Top Hat Industries Inc at 903 897 2813 for a free copy 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 Bumper Pull Trailer PIN PULLED OUT ONLY TO TEST BRAKES Trailer can roll if it comes loose Electric safety brake applies when cable pulls pin out of switch box 1 PULL hard to get pin out of switch box 2 CHECK brake by PULLING TRAILER with tow vehicle 3 ATTACH pin CABLE to tow vehicle so ATTACH pin will be pulled out if trailer separates a x AU MN 4 Promptly REPLACE pin in switch box VEHICLE TOWING AND 2002 NATM STORAGE UT0014
124. tters ZR For those with a maximum speed capability over 186 mph tire manufacturers always use the letters ZR rcaomo U S DOT Tire Identification Number This begins with the letters DOT and indicates that the tire meets all federal standards The next two numbers or letters are the plant code where it was manufactured and the last four numbers represent the week and year the tire was built For example the numbers 3197 means the 31st week of 1997 The other numbers are marketing codes used at the manufacturer s discretion This information is used to contact consumers if a tire defect requires a recall Tire Ply Composition and Materials Used The number of plies indicates the number of layers of rubber coated fabric in the tire In general the greater the number of plies the more weight a tire can support Tire manufacturers also must indicate the materials in the tire which include steel nylon polyester and others Maximum Load Rating This number indicates the maximum load in kilograms and pounds that can be carried by the tire Maximum Permissible Inflation Pressure This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions 2 4 10 2 UTQGS Information Treadwear Number This number indicates the tire s wear rate The higher the treadwear number is the longer it should take for the tread to wear down For example a tire graded 400 should last twice as long as a ti
125. tween 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 Testrim 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 Tire Safety Information Tread rib A tread section running circumferentially around a tire Tread separation Pulling away of the tread from the tire carcass Treadwear indicators TWI The projections within the principal grooves designed to give a visual indication of the degrees of wear of the tread Vehicle capacity weight The rated cargo and luggage load plus 68 kilograms 150 Ibs times the vehicle s designated seating capacity Vehicle maximum load on the tire The load on an individual tire that is determined by distributing to each axle its share of the maximum loaded vehicle weight and dividing by two Vehicle normal load on the tire The load on an individual tire that is determined by distributing to each axle its share of the curb weight accessory weight and normal occupant weight distributed in accordance with Table of CRF 49 571 110 and divi
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127. 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 7 3 ELECTRIC POWERED HYDRAULIC PUMP The dump body on your dump trailer is powered by an electric hydraulic pump the dump body is operated up or down by using controls located at the front of the trailer The battery and pump are located in box at the front of trailer Use oil recommended by pump manufacturer Check decal located on or near pump Additional safety and operating instructions are located in box If you do not have these instructions call Top Hat Industries Inc at 903 897 2813 for a free copy 89 Inspection Service and Maintenance 8 INSPECTION SERVICE amp MAINTENANCE 8 1 INSPECTI N SERVICE amp MAINTENANCE MMARY CHART 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 Inspection and Service before Each Use Item Inspection Service Manual Section Reference Breakaway Brakes Electric Hydraulic Breakaway Battery Check operation Check fluid level Fully charged connections clean Sections 3 2 2 5 3 2 3 4 amp 3 2
128. upler rests on the block support and the jack is Ye inch above the ground The scale reading minus the weight of the block support is the tongue weight If the tongue weight exceeds the capacity of a bathroom scale you can use leverage to divide the tongue weight between the bathroom scale and another support see Checking Tongue Weight figure e Raise the tongue of the trailer with the jack e Arrange a brick 2 x 4 or 4 x 4 board bathroom scale and pipes as shown in Checking Tongue Weight figure The brick should be about the same thickness as the bathroom scale e Leave a3 foot distance between the pipes and place the coupler about 2 feet from the pipe on the bathroom scale e Place a strong block support such as a cement block on the board Note the weight indicated on the scale e Lower the tongue until the coupler rests on the block support and the jack is V2 inch above the ground e Subtract the scale reading with the block and board alone from the scale reading with the trailer on the block Multiply the result by 3 to get the actual tongue weight Example Scale reading with block and board alone 10 lbs Scale reading with trailer coupler resting on board 50 lbs Actual tongue weight 50 10 x 3 120 Ibs For heavier trailers it is easier to go to a truck stop where there is a certified scale Pull only the tow vehicle onto the scale and get the weight This weight must be less than your tow v
129. w this WARNING 5 LOCK sleeve with pin or padlock can result in serious injury 15 General Safety Information Papoenas sj peddinbe os jj xoef en amp uo 483J 8 4 01 PEO 38235 apis OL apis puaAa peo Sj3auM JO JUG ur SWJ JajAESu PEOT Burm 1461844 apua 36245 H MAS Ajjoedea 5 491181 paa2xe jou saop 44jam sajes snid p amp 0j 4o juBje uje1192 yew SMW noA 10J1u02 Jo SSO Usppns pue Kems Jajen asnes uea Bujpeo 1adoaduu 49 1 0 peo 3H 1235 epis o1 epis jusAa peog s sS aauM JO PUOI UJ SWAY 43JAEGU PLOT Burey Bam aguan B8C1D H MA A119 6dea S 18 I amp J paaoxo jou soop 1uBia sapeu snjd peo jo 45jam ujea ayey 3jsnui noA j0Jjuo2 jo sso ueppns pue agen Bupwos oi 0 poyorye sj eomap Kew Xeoxq pug paysnipe Apodosd ouo paddinba os p sayesq ajed Buppow eue syubr sanen mmy ajoaan Gumo 0 poyseye au uo pue anBuo JEPUN posso eue suley gt J JEG pejeoipur aunssaud oj poyayLy cue pouope s Jajdnog peuejuBg Apedoud ee synu nj 994M ezis ouies ouz oe jjeq pue yoy iepdno e WIYN 2002 9 Xoq YOYMS ui utd 393WId3Y Andwoid gt sejeredes sae jj 3no paynd eq jw uid OS a 3Iu8 MO 0 31HV Vid HOV LLV SIJDA AO YAS WanivHL SNrTina Aq exe 333H9 Z xog uaijs Jo yno ujd 195 0j puey Tid L XO yams Jo 1no wd sind agea uaym sejdde exexq Kjojes 3443373 8 00 SAWOD 4 JI HOI UBI Jojf9 IVNNVW S H3NMO 4 ur SuononJjsul pue
130. weight on any tire exceeds its rating 1 2 10 UNSAFE LOAD DISTRIBUTION 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 Refer to Chapter heading Loading the Trailer for more information In the table below the second column shows the rule of thumb percentage of total weight of the trailer plus its cargo Gross Trailer Weight or GTW that should appear on the tongue of the trailer For example a trailer with a gooseneck hitch with a loaded weight of 12 000 pounds should have 20 25 of 12 000 pounds 2400 3000 lbs on the gooseneck A dump trailer will have the proper weight distribution if the load is evenly distributed in the dump bed For non flowable discrete loads locate the load such as to provide the proper tongue weight After loading be sure to check that none of the axles are overloaded General Safety Information Tongue Weight as a Percentage of Loaded Trailer Weight Type of Hitch 10 15 for large trailers 6 10 for smaller utility and cargo Ball Hitch or Bumper Hitch trailers 4 6 for boat trailers Gooseneck Hitch 20 25 Fifth Wheel Hitch 20 25 The numbers quoted above are for example purposes only and should be tailored to the specific trailer For questions regarding the actual percen
131. wly 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 64 Coupling to Tow Vehicle 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 e Continue to extend the jack s making sure that the ground is providing stable and level support for the trailer e Turn the crank two or three turns to take some of the weight of the coupling Do not raise the kingpin plate off the fifth wheel 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 Figure 3 3 Opening Fifth wheel Locks TYPE B LOCKING MECHANISM AS VIEWED THRU THE TOP PLATE LOCK Li a ADJUSTMENT 360 DEGREE KINGPIN AND NOTE 1 PIPE FRONT RELEASE HANDLE NOT SUPPLIED FRONT RELEASE CAM 65 Coupling to Tow Vehicle 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 Fifth Wheel Coupler O
132. wn for bumps in the road Take your foot off the brake when crossing the bump Do not brake while in a curve unless absolutely necessary Instead slow down before you enter the curve Do not apply the tow vehicle brakes to correct extreme trailer swaying Instead lightly apply the trailer brakes with the hand controller Make regular stops about once each hour Confirm that The coupler is secure to the hitch and is locked Electrical connectors are made There is appropriate slack in the safety chains There is appropriate slack in the breakaway switch pullpin cable The tires are not visibly low on pressure and The cargo is secure and in good condition 19 2 TIRE SAFETY INFORMATION This portion of the User s Manual contains tire safety information as required by 49 CFR 575 6 Section 2 1 contains Steps for Determining Correct Load Limit Trailer Section 2 2 contains Steps for Determining Correct Load Limit Tow Vehicle Section 2 3 contains a Glossary of Tire Terminology including cold inflation pressure maximum inflation pressure recommended inflation pressure and other non technical terms Section 2 4 contains information from the NHTSA brochure entitled Tire Safety Everything Rides On It This brochure describes the following items e Tire labeling including a description and explanation of each marking on the tires and information about the DOT Tire Identification Number TIN
133. y 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 4 7 JURE 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 4 8 TIRE BALANCE AND WHEEL ALIGNMENT To avoid vibration or shaking of the vehicle when a tire rotates the tire must be properly balanced This balance is achieved by positioning weights on the wheel to counterbalance heavy spots on the wheel and tire assembly A wheel alignment adjusts the angles of the wheels so that they are positioned correctly relative to the vehicle s frame This adjustment maximizes the life of your tires These adjustments require special equipment and should be pe

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