This operations manual will review safety, inspection requirements, loadings, unloading, electrical, suspensions, breaks, and more.
DRY BULK
OPERATIONS MANUAL PNEUMATIC TANK TRAILERS
For more information, visit us at www.beallmfg.com or email us information@beallmfg.com
PREFACE Congratulations on your purchase of a Beall Dry Bulk Trailer! This manual is provided to help you in the operation of your new tank equipment. It is meant to be a guide, and may not cover all aspects of the safe operation of your equipment. This equipment will require regular scheduled and unscheduled professional maintenance and care, but this manual is not intended as a maintenance manual. This manual includes the latest information at the time it was printed. Beall reserves the right to make changes after that time without notice. The manual describes features that are available for this model, but your trailer may or may not be equipped with them. Because it is impossible to foresee all possible hazards and include them in this manual, operators and mechanics must always be alert to potential hazards that could result in personal injury or equipment damage. Beall parts and products are specialized pieces of equipment presumed to be purchased by or for knowledgeable industry professionals. The ownership, operation, repairs, and maintenance/service of this equipment is also presumed to be carried out by industry professionals capable of safe and proper care. It is solely the Buyer’s responsibility to use personnel trained and informed on proper parts installation, maintenance, and operation of the purchased product. Keep this manual with the unit, so it will be there if it is needed while you are on the road. If the unit is sold, leave this manual with the unit. At Beall, we are dedicated to customer satisfaction. If you have any comments, suggestions, or questions about our products or any material covered in this manual, please let us know by calling Beall at: 1-855-219-5686. Privileged/confidential information is contained in this manual/drawing and is subject to legal privilege. Use by anyone without expressed written consent from Beall is unauthorized. If you are not the authorized user of this material, you may not use, copy, distribute or deliver to anyone this manual/drawing. This material has been exempt from disclosure under s.43 (trade secrets) of the Freedom of Information Act. DISCLAIMER : The information here does not include nor supersede any of the labeling and marking requirements of the Department of Transportation, Federal, State, or local government codes, regulations, standards or guidelines for truck trailer equipment. This Beall equipment includes components manufactured by OEM suppliers. Because component manufacturer’s products, procedures and recommended maintenance practices can change over time Beall directs all Beall equipment owners and operators to consult the original component manufacturers’ websites and technical resources for updated information prior to operating, or performing maintenance involving, these components. REFERENCES: This manual and the subsequent truck trailer labeling scheme follows the ANSI Standard Z535.6 – “American National Standard for Product Manuals, Instructions, and Other Collateral Materials”, ANSI Standard Z535.1 – “American National Standard for Safety Colors”, ANSI Standard Z535.3 – “American National Standard for Safety Symbols”, ANSI Standard Z535.4 – “American National Standard for Product Safety Signs and Labels”.
2
3 TABLE OF CONTENTS
DESCRIPTION
PAGE
Preface
2 4
T erms & Definitions
OPERATIONS
Safety Summary
5-9
General Safety Notice
5 5 6 6 6
Safety T erms Safety Decals
Safety Instructions
Pr eparation
Nomenclatu re
10-21 22-23 24-38
Pre-T rip Inspection
Safe Coupling Procedu re
Crank-Operated Landing Gear T r oubleshooting
39 40
Pintle Hitch
Drawbar & Tu r ntable
41-43 44-45 46-48
Access
Pr e-loading Instructions
Loading Unloading
49
50-53
V ibrator (Optional)
54
Electrical
55 & 65
Axles
56-57
Wheels
58
Air & Spring Suspension
59-60 61-62 64-66 68-70 63
Hubs
Brakes Nomenclatur e
Brakes
General Maintenance
Pr eventative Maintenance Schedule
71
Gr ease Points
72-73
Reporting
74
W arranty & Support
75-79
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TERMS & DEFINITIONS
4
TERM
DEFINITION
AIR DISCHARGE SYSTEM
Dry bulk trailers are discharged using air pressure and are referred to as pneumatics. The discharge, aeration, top air, and blow down piping are described in a dedicated section of this manual. This refers or the intended use of the trailer, valves, seats and seals of a trailer that is intended to be used in the transportation of food products.
FOOD GRADE
HOPPER
Load carrying cavity of trailer.
LINE PRESSURE
Measured by a pressure gauge located in the hopper area street side. Line pressure is generated by the air supply from a blower introduced into the discharge system. This pressure should be lower than the tank pressure. essure relief device that protects the trailer from being over pressured. The pressure relief device must always be in proper working order. Often referred to as full trailer. It is a trailer with wheels at the front and rear. The front axle can rotate because there is a roller bearing (turntable) between the axles and the tank as Landing legs that are not adjustable or carried on the trailer. They are used to support an empty trailer. Measured by a pressure gauge located in the hopper area street side. Tank pressure is generated by the air supply from a blower introduced into the hopper. This pressure should exceed the line pressure for product to discharge.
PRESSURE RELIEF DEVICE
PULL TRAILER
STIFF LEG SUPPORT
TANK PRESSURE
TURNTABLE OR ROLLER BEARING
The turntable is located on the front of a pull trailer and is designed with roller bearings so that the lower frame and axles can rotate when the trailer is turning.
UNDERCARRIAGE
Support structure for kingpin plate and running gear.
WORKING PRESSURE
Pneumatic trailers are discharged by air pressure and the serial plate will display the working pressure of the vessel. Do not exceed this pressure.
SAFETY SUMMARY
5
GENERAL SAFETY NOTICES
cautions appearing elsewhere in this manual. The notices are recommended precautions that must be understood before and during the operation or maintenance of the equipment covered herein. This equipment can be considered dangerous if operated or maintained incorrectly. The equipment must be operated and maintained by experienced and trained personnel. Read the entire manual before operating the equipment.
SAFETY TERMS
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
SAFETY ALERT SYMBOL
DESCRIPTION
Indicate[s] a hazardous situation which, if not avoided, will result in death or serious injury. The signal word “DANGER” is to be limited to the most extreme situations. DANGER [signs] should not be used for property damage hazards unless personal injury risk appropriate to these levels is also involved. Indicate[s] a hazardous situation which, if not avoided, could result in death or serious injury. WARNING [signs] should not be used for property damage hazards unless personal injury risk appropriate to this level is also involved. Indicate[s] a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION [signs] without a safety alert symbol may be used to alert against unsafe practices that can result in property damage only. [this header is] preferred to address practices not related to personal injury. The safety alert symbol shall not be used with this signal word. As an alternative to “NOTICE” the word “CAUTION” without the safety alert symbol may be used to indicate a message not related to personal injury.
NOTICE
T
value. This does not limit the need or use of torque settings to
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SAFETY SUMMARY
6
SAFETY DECALS All possible hazards cannot be foreseen as to be included in this manual or on equipment-mounted decals; therefore the operator must always be alert to possible hazards that endanger personnel and/or equipment. Replace all worn safety decals. SAFETY INSTRUCTIONS The equipment provided by Beall comprise only a portion of a total unit. Operators must be able to blend seamlessly the skills necessary to operate the equipment as a whole. It is an integral part of the equipment’s operation that use often requires a variety of highway and off-road situations. With safety as a primary concern, these instructions and notices, are provided to help avoid mistakes, hazards, and potential accidents. To help insure safe and dependable operation of this vehicle, proper maintenance is required. Maintain tire air pressure, wheel bolt torque, wheel bearings and brake components.
Lubricate as required.
PREPARATION 1. The equipment should be kept well maintained, used carefully, and applied properly as to assure a safe work environment. This environment may include any combination of:
ways to and from the maintenance shop and/or work site(s).
2. This operator manual should stay with the equipment at all times.
3. Any potential operator must be fully trained and capable of accomplishing the tasks and activities required to safely operate this equipment.
Do not allow anyone operate this equipment without
SAFETY SUMMARY
7
4. Before operating this equipment, every operator must read and understand this manual and the safety signs, and instructions contained therein.
is to obtain a translation of these instructions prior to allowing the person to operate the equipment.
Operators should become familiar with all the equipment functions and
practice the operation on an unladen unit. This familiarization should be performed with proper supervision in an approved site or yard. 5. Any persons who are to perform service or repair functions on the equipment covered by this manual, should be properly instructed and warned prior to beginning work. Each person must read and understand this manual and understand all notices, warnings, and general safety practices prior to maintenance or operation. 6. Maintenance should be performed within the guidelines set forth by the manufacture of that parts, assembly, or equipment. 7. Decals, signs, and operator manuals should be maintained so they can be read and understood by any person(s) that may be around or operating equipment. If a replacement needs to be obtained please call the Beall factory of origin, found on the Beall VIN or Serial Plate.
Do not remove or modify any of the original equipment without prior authorization from Beall. Doing so may void the warranty and endanger lives.
Before performing any maintenance or repair work requiring raising of vehicle, ensure vehicle is properly
not rely on jacks alone for support of vehicle.
Safety glasses and necessary personal protective equipment (PPE) should be used at all times when maintaining this equipment.
space that should not be entered without proper training and
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SAFETY SUMMARY
8
A serious or fatal injury can occur if you... • Lack proper training. • Fail to follow proper procedures. • Do not use proper tools and safety equipment. • Assemble components improperly. • Use incompatible equipment components. • Use equipment components in a non-approved application. This manual contains detailed safety instructions. Read, understand and follow this manual. • Get proper training. • Learn and follow safe operating procedures. • Use proper tools and safety equipment. • Use proper components that are in good condition. Like any other vehicle, trailers can tip or slide out of control if turns are negotiated at too high of speed or when making violent maneuvers such as abrupt lane changes.
Long combination vehicles and pull trailers can off- track, to the inside of a corner reducing turn clearance.
Beall cannot predict the lifetime of products, cleaning methods and materials, effluent discharge, or safety practices that a certain tank will see and cannot be held responsible for any cleaning related or tank entry problems. Be aware that this new tank has been entered and work my have been performed. Operator must determine that this tank is suitable to load. Beall assumes no responsibility for any potential product contamination.
NOTICE
NOTICE
SAFETY SUMMARY
9
BEALL PRODUCT CAUTION DECAL
CAUTION
THIS EQUIPMENT MUST ONLY BE OPERATED AND MAINTAINED BY TRAINED INDUSTRY PROFESSIONALS. DO NOT ATTEMPT TO OPERATE, MAINTAIN, OR ACCESS ANY PART OF THIS EQUIPMENT WITHOUT PROPER QUALIFICATIONS. AN OPERATIONS MANUAL IS SUPPLIED WITH THIS EQUIPMENT. STUDY THE OPERATIONS MANUAL FOR DANGER, WARNING, AND CAUTION SAFETY ALERTS ALONG WITH NOTICE ADVISORIES AND OTHER CRITICAL INFORMATION. CONTACT THE BEALL FACTORY OF ORIGIN (FOUND ON THE VIN OR SERIAL PLATE) IF YOU ARE IN NEED OF AN OPERATIONS MANUAL.
C002
This decal is installed on all new Beall equipment. If your Beall product is missing this Caution decal, contact Beall at 1-855-219-5686 or the Beall factory of origin, found on the Beall VIN or serial plate. This manual may be accompanied by vendor supplied decals. Install these vendor decals where you believe they will be the most effective for your operation. Contact the vendor or the Beall factory of origin found on the Beall VIN or serial plate if you need more of these vendor decals.
NOTICE
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10 NOMENCLATURE
550 SEMI - SINGLE HOPPER
11 NOMENCLATURE
550 PULL - SINGLE HOPPER
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12 NOMENCLATURE
710 SEMI - SINGLE HOPPER
13 NOMENCLATURE
710 PULL - SINGLE HOPPER
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14 NOMENCLATURE
775 SEMI - SINGLE HOPPER
15 NOMENCLATURE
775 PULL - SINGLE HOPPER
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16 NOMENCLATURE
1050 R - 3-HOPPER
17 NOMENCLATURE
1680 R - 4-HOPPER
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18 NOMENCLATURE
LOWER HOPPER
CONE STYLE AERATION
AERATION SUPPLY
SWING-AWAY LID
SWING AWAY DISCHARGE
AERATION SUPPLY
DISCHARGE VALVE
DISCHARGE PIPING
DISCHARGE OUTLET
DISCHARGE VALVE HANDLE EXTENSION
INDEXING HANDLE
GRAVITY DISCHARGE
19 NOMENCLATURE
DISCHARGE AIR CONTROL VALVE
DISCHARGE VALVE
DISCHARGE OUTLET
Y - DISCHARGE
FABRIC AERATION BOTTOM
CHECK VALVE
Y-DISCHARGE
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NOMENCLATURE
20
TRAILER DISCHARGE AIR SYSTEM AERATION: Aeration can come in several forms but they all are designed to introduce air into the load
of the hopper above the outlet. These cones can also be mounted in a plate or plenum arrangement adjacent the outlet. Another aeration design is fabric installed in the bottom of the hopper that allows air to pass through it to aerate the product. This design can also
AERATION VALVE:
used to supply air to the individual hopper. In some applications there may be only one aeration valve that supplies air to manifold feeding all the hoppers. AIR SUPPLY: The air supply line originates at the front of the trailer and transports “hot air” from the blower to the trailer. It is then diverted on demand to the aeration line and the discharge line. The air supply is coupled by a hose to the tractor, lead trailer, or stationary blower and transports all the air required to operate the trailer(s). This air supply line will have a one-way check valve at the front of the trailer to protect against air reversing back towards the blower. Pull trailers will have an air supply line under the drawbar that supplies air to the pull trailer.
Do not allow the tank or line pressure to exceed the air supply line pressure causing the product to potentially reverse toward the blower.
NOTICE
BLOW DOWN: The blow down line is plumbed into the air space at the top of the trailer and run down to the ground level where excess tank pressure can be exhausted. At the bottom of the unloading. This line can exhaust product dust and operators and personnel should stand clear of the exhaust outlet. The blow down piping assembly will also typically include a pressure relief device set to protect the tank from being over pressured.
Do not transport product under pressure.
21 NOMENCLATURE
TOP AIR: The top air line is an added feature to the standard blow down line. Using the same plumbing to the top of the tank as the blow down, it is used to add air pressure to the tank on top of the product. Some products need top air pressure to optimally discharge. The top air supply is
valve. Not all trailers have a top air line.
CHECK VALVES: Check valves are installed upstream of the discharge to protect against air reversing in the lines. installation technique and orientation is important for a check valve to work properly. These valves can contain springs and gaskets that require maintenance. Keep these valves in proper working order so they can properly protect the air system.
DISCHARGE VALVES:
the handles are extended for easier access. The disc, stems, seats, and seals of these discharge valves are in contact with the product should be properly matched for the product to prevent contamination. GRAVITY DISCHARGE: Sometimes products are discharged by gravity and provision may be provided such as a drop tee at the bottom of the hoper allowing product to empty straight out the bottom of the trailer. Other designs might use a gravity discharge valve with a dust cover to do this same operation. DISCHARGE: Discharge lines may run the length of the trailer connected to all the hoppers or it might be a single discharge in the case of single hopper trailers. The discharge outlet is typically a cam and grove outlet that the operator attaches the discharge hose to and also connects to a silo or some other form of product storage Y-BRANCH DISCHARGE: This design can typically be found on a single hopper trailer. It allows air to be introduced to the product down stream of the discharge valve. This design includes a check valve at the y-branch. SILENCER: Silencers are optional devices installed in the air system to help quiet the noise of the air movement upstream of the product introduction points. These can be mounted on the truck or trailer and can be inlet or outlet silencers. Typically silencers are mounted on the trailer down stream of the blower. PRESSURE RELIEF DEVICE: A pressure relief device is part of the air system and protects the tank from being over pressurized.
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22 PRE-TRIP INSPECTION
DRIVER’S VEHICLE INSPECTION REPORTS At minimum, the following items must be checked while performing the post- trip and pre-trip inspections. Review the last driver vehicle inspection report to verify action items are
are in safe operational condition. It is also up to the operator to make sure that
Vehicle safety check should be performed daily prior to operation.
PERIMETER OF TRAILER 1. Air and electrical lines: Look for signs of leakage or abrasion. 2. Glad hands: Make sure they are clean and positively seal when charged. 3. Coupler/drawbar eye: Check for loose fasteners, wear, and then consult the manufacture’s information if needed. 4. Drawbar hinges: Check for loose fasteners, wear, and then consult the manufacture’s information if needed. 5. Tires: Look closely for visible damage and uneven tread wear. Make sure 6. Rims/wheel nuts: Check for cracks, rust, or damage to rims. Look for loose, missing, or corroded fasteners. 7. Lights and reflectors: visible, and that all lighting devices are working properly. Clean or clear as required. 8. Warning labels/signage: Make sure they are in place and legible. Use the proper signage for product being transported. 9. Clean or replace all safety decals if they cannot be read. 10.Verify that all accessories are secure such as doors, safety items, etc.
23 PRE-TRIP INSPECTION
UNDERCARRIAGE
1. Spring suspension: Look for cracked or broken springs and loose fasteners.
2. Air-ride suspension: Look for frayed or leaking air springs and loose fasteners.
3. Air-brake system: Inspect the brake system for proper adjustment, leaks, broken, missing, or worn components.
4. Fasteners: Look for signs of movement at fasteners and replace any that are missing.
5. King pin/turntable: Check for proper lubrication, loose fasteners, wear, and then consult the manufacture’s information if needed. 6. Landing gear: Make certain that all bracing and fasteners are in tact, secure and that the gear is operational.
OVERALL
1. Check to make sure all your emergency equipment is in place and secure.
2. Check the entir
3. Look for signs of movement at fasteners and replace any that are missing.
For more information, review the Code of Federal Regulations (www.gpo.gov) or visit any of the compliance-related web-sites on the internet. The operator should also check local and state regulations for compliance. This information should compliment your Company inspection requirements and those mandated by your loading and unloading facilities.
A vehicle safety check should be performed daily prior to operation.
NOTICE
Make sure all safety decals are legible. If not, clean or replace them as needed.
NOTICE
Make sure Conspicuity is well maintained and clean for maximum performance
NOTICE
Conspicuity should be maintained as originally installed.
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SAFE COUPLING PROCEDURE
24
1. COUPLING PROCEDURE When coupling your trailer to the tow vehicle, be sure to use the correct procedure for
1.1 TRACTOR OR SEMI TRAILER TO SEMI TRAILER. 1.
fth wheel for loose fasteners and verify that no fasteners are
make sure both plungers are fully engaged.
2.
V
3.
fth wheel where it contacts the trailer’s upper coupler and tilt the ramps down. Also lubricate contact area between locking jaws and kingpin.
25 SAFE COUPLING PROCEDURE
4. Make sure that the locks (or jaws) are open. If they are not open, pull the release handle all the way out. If the locks are controlled by
open the locks.
5.
fth wheel of the tow vehicle with the kingpin of the trailer.
6.
Back the tow vehicle close to the trailer and STOP.
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SAFE COUPLING PROCEDURE
26
7.
exhausting the tractor’s air ride suspension.
8. Slowly back the tow vehicle into the trailer until the king pin is
DO NOT aggressively strike the front of the
trailer in an attempt to lift it.
9. Chock the trailer wheels, connect the brake lines and light cord. Be sure to support all brake lines and power connections securely out
you will not be able to set the lead trailer brakes.
Chock trailer wheels. Connect brake lines and light cord.
Support slack in lines to prevent interference.
Set trailer brakes.
10. With the trailer wheels still chocked, do a pull test to verify that the trailer is coupled to the tow vehicle.
The coupling procedure is not complete without a visual inspection. You must get out of wheel is properly coupled to the kingpin as shown in the next step.
27 SAFE COUPLING PROCEDURE
11. Get out of the tractor and visually inspect that the locks are closed.
If you do not obtain a proper couple, repeat
wheel that fails to operate properly.
12. Raise the landing gear, stiff legs, or other trailer support. 13. Re-check the brake lines and power cord. 14. Remove wheel chocks and continue with pre-trip inspection.
1.2 TRUCK TO PULL TRAILER -OR- SEMI TRAILER TO PULL TRAILER. When coupling your truck or semi trailer to a pull trailer, refer to the diagram below for information on operating the coupler.
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SAFE COUPLING PROCEDURE
28
1.
V obstacles. Do not exceed the rated capacity of the hitch or assembly.
2.
. Center the tow vehicle with drawbar of the trailer
3. Open the coupling latch. a. While facing the mounted coupling, push the latch lock toward the mounting plate (away from you) until full rotational travel is reached. While holding the latch lock in this position, grasp the top of the latch and pull out toward the pintle, rotating the latch until full rotational travel is reached. b. Hold the latch in place and slowly release the latch lock until it has rotated into the latch. c. Release the latch and the coupling is now open and ready to couple. d. If your latch mechanism is of a dif operation method. 4. Chock the trailer wheels and back the tow vehicle up to the drawbar of the pull trailer. 5. Connect the brake lines and light cord. Be sure to support all brake lines and power connections securely out of the way. 6. Verify that the drawbar eye is inside the coupler on the tow vehicle. 7. Close the coupling latch. a. Rotate the top of the latch toward the pintle until full rotational travel is reached and hold in place. Push the latch lock toward the mounting plate as far as it will go. b. While holding the latch lock in this position, slowly release the latch. Next, release the latch lock making sure it seats fully down in the slot on top of the latch. The coupling is now closed. c. Test for proper latching by applying a force toward the coupling body to the front of the latch. The latch should not open. If the latch does not stay closed, do not use until it has been repaired or replaced.
29 SAFE COUPLING PROCEDURE
8.
Raise and secure the drawbar jack.
9. Re-check the brake lines and power cord and connect safety cables. Remove wheel chocks and continue with pre-trip inspection.
Improper drawbar connections could lead to serious injury.
Do not attempt to lift drawbar by hand.
IN EXCESS OF 100 LBS.
IN EXCESS OF 100 LBS.
1.3 LANDING GEAR/DRAWBAR JACKS Your Beall trailer is/could be equipped with either a set of landing gear, stiff equipment is there to assist the operator in coupling and uncoupling their trailer and to hold the trailer or drawbar up while not in use. 1. Semi trailers with 2 speed crank style gear. a. Raising the landing gear. • Remove the crank handle from its transport position.
• Using low gear, raise the landing gear until the pads come off of the ground.
• Switch to high gear, fully retract landing gear and secure the handle in its transport position.
b. To lower the landing gear, reverse the steps shown for raising the landing gear.
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SAFE COUPLING PROCEDURE
30
• Always grip crank handle securely. • Always grip crank handle securely with both hands before shifting. • Never shift landing gear under load. • Never leave the crank unsecured. • Never raise or lower a loaded trailer in high gear.
2. Semi trailers with aluminum drop tube or adjustable stiff-leg landing gear. To raise or lower a trailer with drop tube or adjustable stiff-leg landing gear, the trailer must be properly supported, then simply pull the pin and slide the tube to the desired position and reinstall the pin. The following rules should be followed when using drop tube style landing gear. a. Always make sure that the curbside and drivers side pins are in the same holes. This will ensure that the trailer will sit equally on both sides. b. Do not allow a loaded trailer to rest solely on the drop tube style, stiff- leg, or adjustable stiff leg landing gear.
DROP TUBE OR ADJUSTABLE STIFF-LEG LANDING GEAR
These support legs are not intended for use with a loaded trailer. Do not place loaded trailer on legs or damage will result. Contact the Beall factory of origin for consultation.
31 SAFE COUPLING PROCEDURE
1.4 COUPLING PULL TRAILER 1. Have a spotter outside to help align the pintle hook to the drawbar eye and back under the eye. 2. Lower the drawbar eye down over the pintle hook and close the hitch latch. 3. Make sure the latch on the pintle hook is secure and the plunger is functioning correctly. 4. Connect air and electrical connections between equipment
Keep air and electrical cables off the ground, secure, and protected to prevent damage.
Always properly connect air and electrical lines and hoses between equipment.
5. Properly connect safety cables. a. There are a variety of cable connection devices and designs, but all must be appropriately rated and must be maintained.
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SAFE COUPLING PROCEDURE
32
Safety cables that are warn, frayed, cut, kinked, missing clamps, or otherwise abused are a safety hazard.
components, and connections.
Safety cables, connection components, and their installation
components, fasteners, and connections are rated and follow
and components with inferior un-rated, or under-rated parts.
Keep safety cables off the ground, secure, and protected to prevent damage.
6. Raise the drawbar jack and rotate to its stored position.
7. Check that all lights are functioning correctly. 8. Charge trailer with air and check brakes. 9. Release the brakes and slowly drive away only after all systems are working correctly and required pre-trip inspections are complete.
connecting components. Properly replace a damaged drawbar, hitch, or any other connecting parts including safety cables and air/electrical lines and hoses.
33 SAFE COUPLING PROCEDURE
1.5 AIR AND ELECTRIC CONNECTIONS Air and electrical connects can vary greatly due to variations in trailer equipment making the correct air and electric connections on your trailer. 1. Connect air for service and emergency. These are typically color coded. 2. Connect the 7 way plug to the 7 way receptacle. This is typically the primary electrical connection. 3. Connect all other electrical and hydraulic connections required. All connections should positively lock into place.
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SAFE COUPLING PROCEDURE
34
2. UNCOUPLING PROCEDURE 2.1 SEMI TRAILERS 1.
ound that is clear of people and obstacles.
2. 3. 4.
Chock the trailer wheels and set the trailer brakes.
Slowly back the tow vehicle tightly against the trailer.
Set the tractor brakes.
5. Lower the landing gear to eliminate any gap between the ground and the landing gear foot. Do not drop the trailer on the landing gear legs of any design. See Section 2.1.1 before lowering the landing gear if you trailer is equipped with air ride. 6. Landing gear and landing gear frames are not all designed for the same loads. 7. Emergency support of a loaded trailer. If there are any questions please contact the Beall factory of origin found on the VIN plate.
Not all landing gear or landing gear frames can support a loaded trailer even in an emergency situation. EVEN IN AN EMERGENCY SITUATION, only landing gear equipment with LOAD RATING that equals or exceeds the loads the operator plans to place on the equipment, may be deemed eligible by the operator to be lowered onto the landing gear loaded.
NOTICE
CAUTION
SUPPORTING A LOADED TRAILER ON THESE LEGS MUST BE AVOIDED. ANY DAMAGE OR LOSS CAUSED BY UNCOUPLING A LOADED TRAILER ON THESE LANDING LEGS IS NOT THE RESPONSIBILITY OF BEALL. TAKE EVERY PRECAUTION POSSIBLE IF AN EMERGENCY SITUATION REQUIRES UNCOUPLING A LOADED TRAILER. PRECAUTIONS: 1. The landing gea,r frame, and support braces must be in proper repair. 2. The trailer must be on level ground and all personnel must stand cl.ear 3. The landing surface must a solid, rigid base, not subject to settling (i.e. concrete). 4. Evacuate all air from the air bags on air ride suspensions prior uncoupling. 5. The landing gear feet must be under load prior to uncoupling. 6. DO NOT ALLOW TRAILER TO DROP FROM ANYADNISCTE WHEN UNCOUPLING. 7. Install support under the kingpin immediately after uncoupling. 8. Multi-compartment trailers CANNOT be uncoupled with only the forward compartment loaded or on trailers with their load biased to the front in any manner. 9. Do not exceed the rated load of the trai,leorr any trailer components.
THIS IS A TRAILER- SPECIFIC DECAL AND DOES NOT APPLY TO ALL LANDING LEGS OR LANDING GEAR FRAMES.
C003
35 SAFE COUPLING PROCEDURE
8.
Disconnect the brake lines and power cords.
9.
If equipped, pull and secure the secondary lock handle.
10. Pull the primary r
11. Release the tow vehicle brakes and slowly drive away from the trailer.
Do not assume that the landing gear or landing gear frame on your trailer can support a loaded trailer.
2.1.1TRAILERS EQUIPPED WITH AIR RIDE. If your semi trailer is equipped with air ride, you should evacuate the air from the air bags on the suspension before lowering the landing gear. This will ensure that the landing gear does not get damaged due to releasing the air in the suspension after the trailer is uncoupled from the tow vehicle. To release the air from the suspension air bags, locate the suspension dump valve. This valve can be located in various positions such as landing gear frame, the front of the rear subframe or at the rear of the trailer. Pull the dump valve to release the air from the suspension.
gear or damage to the equipment may result. Towed vehicle brakes must be set for this valve to operate. If the vehicle is equipped with an air spring suspension.
TYPICAL AIR RIDE EXHAUST VALVE
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SAFE COUPLING PROCEDURE
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UNCOUPLING PULL TRAILER 2.2 PULL TRAILER 1. people and obstacles. 2. Chock the trailer wheels and set the tow vehicle and trailer brakes. Disconnect the brake lines, power cords, and safety cables. 3. Open the coupling latch. a. While facing the mounted coupling, push the latch lock toward the mounting plate (away from you) until full rotational travel is reached. While holding the latch lock in this position, grasp the top of the latch and pull out toward the pintle, rotating the latch until full rotational travel is reached. b. Hold the latch in place and slowly release the latch lock until it has rotated into the latch. c. Release the latch and the coupling is now open and ready to uncouple.
37 SAFE COUPLING PROCEDURE
4. Lower the drawbar jack and raise the drawbar eye up and clear of the hitch.
5. Release the tow vehicle brakes and slowly drive away from the trailer.
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SAFE COUPLING PROCEDURE
38
3.1 B-TRAIN FIFTH WHEELS 1. B-T trailer. Typically this is a Holland “Kompensator” design with unique features. 2. fth wheel with the same care as described in 1.1 and 2.1. 3. Consult the manufactures’ care and maintenance procedures for
wheel could result in tractor/trailer or trailer/trailer separation causing death or serious injury.
39 CRANK-OPERATED LANDING GEAR TROUBLESHOOTING
PROBLEM: The crank is difficult to turn. POSSIBLE CAUSES:
• The unit may require lubrication. • The unit may be out of alignment. • The shaft bushing may have failed. • The cross shaft may be binding.
RECOMMENDED ACTION: • Lubricate the unit. • Check for proper operation. • If necessary, inspect additional components and repair or replace as needed.
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40 PINTLE HITCH
OUT-OF-SERVICE CRITERIA
(Installation may vary based on model)
• Follow manufacturer’s acceptance/rejection criteria using factory-
• There can be no fasteners missing (there cannot be corresponding holes in both the frame and hitch). • There cannot be cracks on the mounting surface extending from the point of attachment or cracks on the frame member providing attachment. • The pintle hook assembly itself cannot have any cracks on it. • Welded repairs to the assembly are not permissible. • Build up on worn parts is not permissible. • There cannot be signs of physical abuse (deformations, twisting) and the locking mechanism must function properly without excessive play. • Safety cable loop on the lead unit must be secure and free of defects.
Properly check the hitch for wear according to the
HITCH FASTENERS MUST BE KEPT TIGHT. Use properly torqued Grade-8 bolts and nuts with hardened washers. Contact the Beall factory of origin for the correct replacement fasteners. Do not reuse fasteners once removed.
T
41 DRAWBAR & TURNTABLE
OUT-OF-SERVICE CRITERIA
(For a complete listing of Out-of-Service Criteria, see 49 CFR 393)
• The turntable can have no more than 5/64” of play in the lateral direction and 1/8” of play in the vertical direction. • The connecting hinges cannot have mor
Properly check the turntable, hinges, and drawbar eye for
TURNTABLE
TURNTABLE FASTENERS MUST BE KEPT TIGHT. Use properly torqued 5/8” diameter, Grade-8 bolts and nuts with hardened washers. Contact the Beall factory of origin for the correct replacement fasteners. Do not reuse fasteners once removed.
T
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DRAWBAR & TURNTABLE
42
ADJUSTABLE DRAWBAR HOUSING:
Some drawbars have an optional adjustable drawbar housing. This allows the drawbar reach to be extended and retracted. The adjustable drawbar clamp housing must be kept tight when the trailer is in operation. All safety cables, air, and electrical lines must also be properly connected no matter the drawbar reach location.
Before sliding the adjustable drawbar, set the
stop bolt is secure at the end of the slider tube. All air & electrical lines and safety cables must be disconnected and clear. Stand clear of the drawbar when adjusting the drawbar reach. After sliding the adjustable drawbar, reconnect the air & electrical lines and secure the safety cable.
Periodically check and always maintain a tight drawbar slide mechanism.
43 DRAWBAR & TURNTABLE
EXTENDING OR RETRACTING THE DRAWBAR:
The adjustable drawbar housing has three grip nuts and two separation bolts. Back off the three grip nuts to release pressure on the slider tube, then further open the housing using the two separation bolts. These actions will allow the housing to open up so the reach tube can slide in the housing. Stand clear of this area during this operation and extend or retract the drawbar in a safe and secure manner. Once the drawbar is appropriately sized, tighten the the housing to come together. Next tighten the three grip nuts going from one to another, two or three time until the housing is evenly tightened. Finally, cinch the two separation bolt down so they do not back out. Reinstall the air/ electrical connections and secure the safety cable.
NOTICE
Do not lubricate the reach tube or slider housing.
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ACCESS
44
LADDERS, WALKWAYS, STEPS AND DRAWBARS Beall equipment can have a variety of ladders, steps, walkway, and drawbar designs and their locations are not limited to those discussed below. These items are meant for your safety and their surface texture, width, height, angle, and overall design can vary. Care needs to be taken when using all of these surfaces. LADDERS can be at the front, side or back of a Beall product depending on the design demands. Access can be from the ground via steps, drawbar, or from truck or tractor frame. Some ladders can have dual rails and can be used to access drawbars, platforms or other walkways and surfaces. Ladders can also be mounted at a slope or angle.
LARGE AND SMALL CUBE LADDER INSTALLATIONS
STEPS can be installed at front, side, back or on a slope of a Beall product depending on the design demands. Steps can also access drawbars, platforms, ladders, or other walkways and surfaces.
WALKWAYS can be located on the top, side, front, or rear of a Beall product depending on the design demands. Some walkways may contain hazards and extreme care must be taken when navigating any surface with known or unpredictable hazards.
DRAWBARS with a walkway surface are typically found on a pull trailer design. Do not attempt to walk on a drawbar without a surface intended to be used as a walkway. Treat drawbar walkways with the same care as any other walkway.
45 ACCESS
Watch your step when using access devices.
Use both hands when climbing on or off equipment.
Surface could be slippery.
CAUTION
WATCH YOUR STEP TANK ACCESS EQUIPMENT MUST BE PROPERLY MAINTAINED BY TANK OWNER.
No part of this equipment including the top walkway is intended as a heavy work area. Areas other than ladders, steps, and walkways are not intended as access.
Ladders, steps, and walkways are intended to provide access only when other external facilities are not provided.
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46 PRE-LOADING INSTRUCTIONS
Do not remove or modify any original equipment on this unit without the manufacturer's authorization. Doing so may void the warranty.
NOTICE
IN EXCESS OF 100 LBS.
(Example Only)
Your vehicle complies with the D.O.T. regulations. Improper removal or replacement of components could void stated compliance and endanger lives; maintain all components in good working condition.
Product volume is customer controlled. Since operation
NOTICE
precautions be taken to assure that the driver is familiar with the vehicle's handling characteristics. This will help assure safe operation.
Consult the data plate located near the front street-side for
temperature range ratings, along with other pertinent data.
Know what commodity was previously carried to avoid the mixing of incompatible materials.
Check the compatibility between the tank gasket material and the product being carried in the tank.
47 PRE-LOADING INSTRUCTIONS
Check all valves and controls for damage and make sure that they are in proper working condition before loading.
Make sure that all valves are functioning properly and not damaged.
Make sure all gaskets and seals are in good condition. Check all the plumbing for bolt tightness to avoid spillage.
closed and secure prior to loading and while in transit.
Replace any missing or otherwise impaired dome gasket before loading.
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48 PRE-LOADING INSTRUCTIONS
Before opening the blowdown line, make sure everyone is clear of the exhaust stream. Open blowdown valve before loading. Excess product in the blowdown line can plug the pressure relief valve. Be aware of any product spill out of blowdown line. Some load facilities require this valve to be closed when loading.
NOTICE
NOTICE
PRESSURE RELIEF DEVICE
TOP AIR/ BLOW DOWN HOSE
TOP AIR VALVE
BLOWDOWN VALVE
Make sure that the correct placards are in place, if required, before loading.
NOTICE
If the trailer is loaded by volume make sure the trailer is empty before loading.
49 LOADING
Set the trailer parking brakes in the cab before loading.
Be aware of the maximum loading temperature rating and do not load a product above that temperature. Loading of a product at a higher temperature can cause structural damage to the tank. Be aware of the maximum product density and the maximum product load. Do not exceed the Gross Vehicle Weight Rating. If loaded past this point, structural damage may result. If your trailer is equipped with an air suspension system, load the trailer with the tractor attached in order to maintain air pressure in the suspension system. If you must disconnect the tractor, support the trailer at the kingpin plate and exhaust the air from the suspension. Do not load a trailer that is being supported by non-load bearing landing legs. When top loading, make sure that the loading pipe is properly secured to prevent spillage. Make sure that the manholes and blowdown valves are properly sealed before moving the trailer. Overtightening the covers can cause damage to the gaskets.
Loading facility requirements can vary. Follow all loading facility instructions for safe loading.
NOTICE
Materials and dust are potentially harmful. Avoid contact with them by keeping clear of open manholes and vent outlets. DO NOT attempt to load this equipment by vacuum unless it is vacuum-capable by design, as indicated on the serial plate.
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50 UNLOADING
Check to make sure that the pressure relief device is in proper working condition. Make sure that the valve body and exhaust vents are kept clear of buildup and other obstructions. Periodically check to ensure thread tightness. Blower vibration may loosen them over time. Ensure that all the gauges are in proper working order. If the gauges are unresponsive during working conditions, check for clogs. (1) Tank air pressure gauge (1) Line air pressure gauge
Start the blower and pressurize the tank through the aerator(s) to normal
the product as well. The line pressure should read 0 during this process. Make sure the blow down valve is closed. (see TTMA RP No. 83,84)
All product valves must be closed before removing the discharge cap. Beware of possible product retention under the cap when it is being removed. Make sure that you have a good connection of the discharge hose before opening the product valves.
51 UNLOADING
Open the discharge line control valve part way. Gradually open one of the product valves. Adjust the line control valves to maintain a steady tank pressure. As tank pressure decreases, close the line control valve a little bit to increase the tank pressure. If the tank pressure is increasing, open the line control valve wider to reduce the tank pressure.
The top of the hopper is not intended as a heavy work area. The ladder and walk surface are intended to provide access only when other facilities are not provided. Personnel should never be on top of the hopper while it is pressurized. The working line pressure of the unit is 14.5 psi. If there is a discrepancy between the gauges, check the system for clogs.
As the product level reaches within a few feet of the product valve on the hopper being unloaded, the pressure will begin to fall off. Close this product valve and open and adjust another one. Cycle through the hoppers in this manner in order to have the smoothest possible unloading.
All of the check valves must be operational to prevent product backup into the supply lines. Do not exceed the working pressure of the system. Check and maintain the vacuum and pressure relief devices regularly. Do not close the domes after cleaning until the hopper has cooled. (see TTMA RP No. 84) Opening the product discharge valve too fast may cause line plugging. When unloading, make sure all couplings and connections are secure to prevent spillage and material loss. Make sure the relief valve is operational and is set to operate at 5 psi over the operational pressure of the tank. The valve
NOTICE
NOTICE
NOTICE
As the hoppers start to empty out, it may become necessary to close the line control valve down further to divert more air to the tank.
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52 UNLOADING
If the unloading bin is improperly vented, a pressure reading will show up on the gauges after the product has been discharged. Determine the cause of this problem and correct it before proceeding. The tank may be under pressure. Do not open the dome. Do not open the valves. Do not remove any couplers or hoses until the pressure has been relieved.
NOTICE
The aerators will begin to vibrate the shell as the hoppers empty out. This will help to remove any material still clinging to the shell of the tank. The line control valve will have to be closed even further during this process.
When both tank and line pressure begin to fall simultaneously, the line
may still be in the discharge line.
After the dischar valve and shut off the air source.
The manholes may be opened after all pressure gauges read zero and there is no more air coming out of the blow down valve.
The manhole cover assemblies must be kept clean in order to permit proper sealing of the gaskets. Clean the manholes every time before closing.
Manhole cover assemblies must be properly adjusted to retain pressure. Make sure all safety and lid retention devices are in proper working order.
53 UNLOADING
UNCLOGGING PLUGGED LINES Signs that the discharge line is plugged: 1. The unloading hose does not move. 2. Tank and line pressure increase simultaneously. 3. The pressure relief valve opens. STEPS FOR CORRECTING A PLUGGED LINE.
1. Close all product valves. 2. Close the aeration valves. 3. Open the line control valve completely. Repeat a few times to see if changes 4. If the line remains plugged, stop the air source, open the blow down line and completely depressurize the tank. Then close the blow down line. Put full air pressure on the product line and quickly open the product valve on the least full hopper. This should be done after the pressure relief valve activates. This may take many times to clear the line. FOOD GRADE TRAILERS Food Grade trailers should be properly cleaned on a regular basis after unloading. The cleaning detail will depend on the product and the tank interior complexity among other reasons. Piping connections can be provided with easily removed clamps to reduce cleaning time. Gaskets, seals, valves, and material should be food grade quality and maintained to protect the product. Hopper outlets can be provided with drop tees for more accessible cleaning. Gravity doors and dust covers can be opened or removed for proper cleaning.
removed or disconnected for cleaning purposes.
INTERIOR CLEANING Interior cleaning is the carriers’ responsibility and should satisfy not only your established in-house procedures, but also those industry, religious, governmental, and customer requirements to name a few. Know the cleaning requirements for your operation. Proper cleaning is not limited just to equipment transporting food grade products and should be an integral part of carriers’ quality program.
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