This operations manual will review safety, inspection requirements, loadings, unloading, electrical, suspensions, breaks, and more.
PETROLEUM OPERATIONS MANUAL TANK TRAILERS
For more information, visit us at www.beallmfg.com or email us information@beallmfg.com
2 PREFACE Congratulations on your purchase of a Beall Petroleum Tank! 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 Manufacturing, Inc. at: 1-855-219-5686. Privileged/confidential info rmation is contained in this manual/drawing and is subject to legal privilege. Use by anyone without expressed written consent from Beall Manufacturing, Inc. 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 Manufacturing, Inc. 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”.
3 TABLE OF CONTENTS
DESCRIPTION
PAGE
Preface
2 4 5 5 6 6 6
T erms & Definitions Safety Summary
5-9
General Safety Notice
Safety Terms Safety Decals
Safety Instructions
Pr eparation
Cargo T ank Motor V ehicle
9-11 12-19 20-21 22-36 39-41 42-43 44-46 47-48 37 38 50-51 52-53 54-58 49
Nomenclatu re
Pre-T rip Inspection
Safe Coupling P r ocedu re
Crank-Operated Landing Gear Tr oubleshooting
Pintle Hitch
Drawbar & T u r ntable
Access
Pr e-loading Instructions
Loading
Overfill P r otection Systems
Unloading
V apor Recovery System Power T ake-O f f (PTO)
Pump A rea
59
Axles
60-61
Wheels
62
Air & Spring Suspension
63-64 65-66 66-71
Hubs
Brakes
Electrical
72 73
Hydraulic Systems General Maintenance
74-76
Pr eventative Maintenance Schedule
78
T ank Ca r e and Operation
79-81 82-83
Gr ease Points
Reporting
84
W arranty & Support
85-89
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4 TERMS & DEFINITIONS
TERM
DEFINITION
One of possibly several cargo carrying portions of the cargo tank motor vehicle.
COMPARTMENT
DOME RAIL (VAPOR RAIL)
two structural members that run the length of the tank on the top. One is often used as a vapor recovery manifold.
DRY-BRAKE FITTING ON/OFF LOADER
oduct to be both
loaded and unloaded.
The components and system that facilitate communication with the loading rack to protect against exceeding the compartment volume when bottom-loading. 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
OVERFILL PROTECTION
PULL TRAILER
Piping that extends to the street-side of the trailer in addition to the curb-side.
T-BAR
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 OR SUBFRAME
Support structure for kingpin plate and running gear.
Space between double bulkheads.
VOID SPACE
The components and system that facilitate transporting vapors to and from the tank. This piping design facilitates loading through the top pipe of the Y-branch and discharging product through the bottom pipe.
VAPOR RECOVERY
Y-BRANCH
5 SAFETY SUMMARY
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 only. 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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6 SAFETY SUMMARY
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: the cab area, ground crews, equipment near the body 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
7 SAFETY SUMMARY
4. Before operating this equipment, every operator must read and understand this such as unfamiliar language be encountered, the owner 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 controls on an unladen unit. This familiarization should be performed with proper supervision in an approved site or yard. 5. Any persons who 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 original manufacture of the part, 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 supported with 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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8 SAFETY SUMMARY
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 Manufacturing, Inc. cannot predict the lifetime of products, cleaning 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 Manufacturing, Inc. assumes no responsibility for any potential product contamination.
NOTICE
NOTICE
9 SAFETY SUMMARY
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
NOTICE
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10 CARGO TANK MOTOR VEHICLE
SPECIFICATION CARGO TANK MOTOR VEHICLE
NOTICE
constructed in accordance with the General Design and Construction Requirements of Title 49 of the Code of Federal
Deviating from the original design and construction requirements set forth in 49 CFR will result in a non-DOT compliant Cargo Tank Motor Vehicle.
NOTICE
Motor Vehicle must conform to Part 180 of the Code of Federal Regulations.
with the D.O. T. and familiar with the requirements set forth in Part 180, subpart E, of this chapter can maintain this Cargo Tank Motor Vehicle.
CARGO TANK, PERIODIC TEST AND INSPECTION SEE 49 CFR PART 180.407(C) & EPA27 P - Pressure Test I - Internal Visual Inspection V - External Visual Inspection EPA27-Method 27 EPA Vapor Tightness of Gasoline Delivery Tank K - Leak Test T - Thickness Test L - Lining Inspection
PLACARD
Properly placard the load as required and maintain these placards and markings.
11 CARGO TANK MOTOR VEHICLE
HAZARDOUS COMMODITIES
Hazardous commodities are required to be placarded. Placarding helps identify what is in or was in the cargo tank. Consult the Hazardous Material Regulations for do not open a tank releasing product or vapors until they can be safely and properly dealt with. This cargo tank can contain hazardous commodities, their fumes, and product retain.
Petroleum tanks, piping and hoses typically contain Flammable or Combustible products and vapors. Vigilance must be maintained to keep this tank, components and ignition sources.
sources such as the general public at a service station.
DANGER
NO SMOKING OR OPEN FLAMES ON OR NEAR THIS VEHICLE.
NO SMOKING
D001
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12 NOMENCLATURE
TRUCK TANK (BODY TANK)
TRUCK TANK
BOTTOM LOAD DISCHARGE
HOSE TUBES
3-AXLE TRUCK CHASSIS
2-AXLE PULL TRAILER (DOUBLE CONICAL DESIGN)
REAR SUBFRAME
BOTTOM LOAD DISCHARGE
TURNTABLE FRAME
DRAWBAR
13 NOMENCLATURE
4-AXLE TRUCK TANK (BODY TANK)
STEERABLE LIFT AXLE
PLACARD BRACKET
4-AXLE PULL TRAILER (DOUBLE CONICAL DESIGN)
DRAWBAR TOOL BOX
T-BAR DISCHARGE TO STREET SIDE
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14 NOMENCLATURE
SEMI
15 NOMENCLATURE
TANK TRAILER TOP VIEW
VAPOR RAIL
DOME RAIL
OVERFILL PROTECTION PROBE
AIR & ELECTRICAL LINE PIPE
AIR OPERATED VAPOR VENT
FILL LID
NON-SKID WALKWAY
MANHOLE/FILL ASSEMBLY
OVERFILL PROTECTION PROBE
AIR OPERATED VAPOR VENT
LID
PRESSURE ACTUATED VENT
CLAMP RING
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16
NOMENCLATURE
SEMI TANK REAR VIEW
VAPOR RAIL
LADDER
CONSPICUITY
LIGHT BOX
REAR END PROTECTION DEVICE (CERTIFIED REPD)
OVERFILL CONTROLS AND OPERATOR BOX
OVERFILL CONTROL MODULE
AIR OPERATORS
AIR GAUGE
SOCKETS
API LOADING RACK CONNECTIONS
17
NOMENCLATURE
EXAMPLE OF API AREA WITH ON/OFF LOAD HEADS
ATTACHMENT PAD
VAPOR RECOVERY HEAD
ON/OFF LOADING HEADS
BRAKE INTERLOCK BAR
PRODUCT TAG
OPERATOR BOX
PRODUCT TAG
EXAMPLE OF API AREA WITH Y-BRANCH DISCHARGE
BOTTOM LOAD
VAPOR RECOVERY HEAD
GRAVITY DISCHARGE
PRODUCT DISCHARGE VALVE
VAPOR RECOVERY HEAD
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18 NOMENCLATURE
TRUCK TANK LOADING AND UNLOADING AREA GROUNDING STUD PRODUCT TAG BRAKE
INTERLOCK VALVE
LOADING HEAD
GRAVITY DISCHARGE
TRUCK TANK FEATURES
BOLSTER
HOSE TUBE
BOLSTER FOOT AND RUBBER
TRUCK FRAME
LOWER TIE DOWN
EMERGENCY SHUTOFF
19 NOMENCLATURE
TRUCK TANK REAR VIEW
HITCH/DRAWBAR CONNECTION
OPERATOR BOX
BOTTOM LOAD AREA
AIR & ELECTRIC CONNECTIONS
REAR END PROTECTION
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20 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 resolved. operational condition. It is also up to the operator to make sure that all compliance
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: 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. Tank and piping: inspect for any signs of product leakage. 11. Verify that all accessories are secure, such as hoses, doors, cones, etc.
21 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. 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. Make sure Conspicuity is well maintained and clean for maximum performance
NOTICE
NOTICE
Conspicuity should be maintained as originally installed.
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22 SAFE COUPLING PROCEDURE
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. both plungers are fully engaged.
2.
3.
e it contacts the trailer’s upper coupler and tilt the ramps down. Also lubricate contact area between locking jaws and kingpin.
23 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 air, set the tractor
5.
.
6.
Back the tow vehicle close to the trailer and STOP.
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24 SAFE COUPLING PROCEDURE 7.
pin. Some height adjustment can be made by exhausting the tractor’s air ride suspension.
8. wheel. 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 of the way. Note: If 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 the is properly coupled to the kingpin as shown in the next step.
25 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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26 SAFE COUPLING PROCEDURE
1. obstacles. Do not exceed the rated capacity of the hitch or assembly.
2. 3.
Center the tow vehicle with drawbar of the trailer.
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 differ 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.
27 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 leg, drop tube, 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.
b. To lower the landing gear, reverse the steps shown for raising the landing gear.
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28 SAFE COUPLING PROCEDURE
• 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.
29 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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30 SAFE COUPLING PROCEDURE
Safety cables that are warn, frayed, cut, kinked, missing clamps, unsafe drawbar safety cable, components, and connections. Safety cables, connection components, and their installation are installation demands. Do not replace safety cables 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.
31 SAFE COUPLING PROCEDURE
1.5 AIR, ELECTRIC AND HYDRAULIC CONNECTIONS Air and electrical connects can vary greatly due to variations in trailer equipment and truck and electric connections on your trailer. 1. Connect air for service and emergency. These are typically color coded. Red (emergency). Blue (service). 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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32 SAFE COUPLING PROCEDURE
2. UNCOUPLING PROCEDURE 2.1 SEMI TRAILERS
1. 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.
Do not assume that the landing gear or landing gear frame on your trailer can support a loaded trailer.
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 an attached 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 gear, frame, and support braces must be in proper re.pair 2. The trailer must be on level ground and all personnel must stand clear. 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 ANY DISTANCE 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 trailer, or any trailer components.
THIS IS A TRAILER-SPECIFIC DECAL AND DOES NOT APPLY TO ALL LANDING LEGS OR LANDING GEAR FRAMES.
C003
33 SAFE COUPLING PROCEDURE
7. Emergency support of a loaded trailer. If there are any questions please contact the Beall factory of origin found on the VIN plate.
9. 8.
Disconnect the brake lines and power cords.
If equipped, pull and secure the secondary lock handle.
fth wheel is equipped with air release, actuate
10.
11. Release the tow vehicle brakes and slowly drive away from the trailer.
2.1.1 TRAILERS 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.
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. Do
TYPICAL AIR RIDE EXHAUST VALVE
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34 SAFE COUPLING PROCEDURE
UNCOUPLING PULL TRAILER
2.2 PULL TRAILER 1. 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.
35 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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36 SAFE COUPLING PROCEDURE
3.1 B-TRAIN FIFTH WHEELS 1.
is a Holland “Kompensator” design with unique features.
2. 3.
e as described in 1.1 and 2.1.
Consult the manufactures’ car
result in tractor/trailer or trailer/trailer separation causing death or serious injury.
37
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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38 PINTLE HITCH
OUT-OF-SERVICE CRITERIA
(Installation may vary based on model)
tolerances. • 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
39 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 drawbar hinges and eye cannot have more than manufacturer’s-
Check the turntable, hinges, and drawbar eye for wear proper torque values.
T
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
T
for the correct replacement fasteners. Do not reuse fasteners once removed.
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40
DRAWBAR & TURNTABLE
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 trailer brakes 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.
41 DRAWBAR & TURNTABLE
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 the separation bolts to allow 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. EXTENDING OR RETRACTING THE DRAWBAR:
Do not lubricate the reach tube or slider housing.
NOTICE
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42 ACCESS
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.
STRAIGHT LADDER
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.
OPTIONAL EQUIPMENT STORAGE
Some drawbars can have optional equipment storage features such as toolboxes, cone holders, and bucket holders. Whether these features are being used or not, they can present access safety concerns.
43 ACCESS Watch your step when using access devices. Inspect the access device for trip hazards. Avoid these hazards for safe operation. 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. There are no steps, ladders, walkways or other devises designed to assist a person to exit the inside of the tank. There may be hazards inside the tank like fasteners, or sharp edges. Product hazards may be present as well such as slick
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44 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)
of Compliance. 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 with 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. Petroleum tanks are equipped with high level sensing devices which operate from the tractor electrical power. The tractor protection system. Negative ground only. This system will not operate otherwise.
NOTICE
45 PRE-LOADING INSTRUCTIONS
Check all valves and controls for damage and make sure that they are in proper working condition. If you are top loading, make sure that the valves are all closed as well. This includes the emergency valve control system.
Make sure that all the valves are functioning properly and are free from damage.
Make sure that all gaskets are in good condition. Check all the plumbing for bolt tightness. Check the seals and valves of the vapor recovery system. Make sure that all are in the proper working order. To avoid spillage, product discharge valves must be closed prior to loading and while in transit.
Check the lid assemblies for proper function, seals, and closure mechanisms. Make sure that the emergency venting systems are present and are in proper working order.
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46 PRE-LOADING INSTRUCTIONS
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. Make sure that they are not reactive or corrosive to each other. (see TTMA TB No.60) Typical DOT406 Petroleum Tank: There are several areas that gaskets and seals are employed to The emergency valve operation is synchronized with the vent valve(s). Proper synchronization of the valve(s) and vent(s) must and lubricated. internal seals. The Beall standard gaskets and seals have been chosen because they have proven over time to be successful when used in gasoline blends E10-E100 and ULSD. Our vendor supplied vents, emergency valves, and bottom load heads have also proven to be successful for this service. If you have other products intended to be carried in this equipment, special consideration should be taken to ensure that the gaskets and seals will work properly.
NOTICE
NOTICE
EMERGENCY SHUTOFF
Be aware of the type, location, and function of the emergency valve controls. Beall typically locates this street-side near the front.
EMERGENCY SHUTOFF IN THE “ACTIVATED” POSITION.
EMERGENCY SHUTOFF IN THE “STANDARD” POSITION.
47 LOADING
Set the trailer parking brakes in the cab before hooking up to the bottom loading heads.
If necessary, ground the tank to the loading platform to reduce the risk of static electricity causing an ignition of the product. 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. (see TTMA RP No. 75) 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. Stay away from the manholes during loading to avoid exposure to product or fumes. Make sure that the manholes are properly sealed before moving the trailer. Overtightening the covers can cause damage to the gaskets. (see TTMA RP No 92)
Bottom loading control receptacle. Compatible plug must supply only low power intrinsically safe electrical energy to the circuit to avoid spark hazard. Initial operation at a terminal should include manual probe operation or carefully controlled
Loading rack requirements can vary. Follow all loading rack instructions for safe loading.
NOTICE
Provide proper grounding when bottom loading, top loading, and recovering vapors.
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48
LOADING
If the tank is equipped for bottom loading, open the top vents, emergency valves, and product valves to compartments being loaded before beginning the loading process. This will prevent excessive spraying of product in the tank or piping. Close compartments. If loading different types of products which require isolation, any emission collection header provided must be disconnected from the compartment which requires isolation. Manifold-product-valves must be closed to prevent mixtures of products which could cause a dangerous reaction. (see TTMA TB Nos. 58,60,92,105) The vehicle's piping system, including components between the bottom loading adapter and any shutoff valve, is designed for 75 psi. Any component not rated for 75 psi must be isolated from the bottom loading system to avoid damage, rupture, or loss of product. (see TTMA RP No. 102) When bottom loading, make sure that the compartments that are being loaded are clean and empty to avoid potentially violent reactions and product contaminations. (see TTMA RP No. 102) The emergency valves and product valves must be closed at all times except when loading or unloading product. Before opening the emergency valves, be sure hoses are properly connected at both ends. Make certain emergency valves are closed and the hoses are drained before disconnecting the hoses. Close the doors of all cabinets before leaving the discharge area. In case of emergency, the emergency valves may be closed by operation of the remote control located at the front of the tank.
NOTICE
NOTICE
Make sure that the correct placards are in place before a trip.
Materials and vapors are potentially harmful. Avoid contact with them by keeping clear of open manholes and vapor recovery outlets.
DO NOT attempt to load this equipment by vacuum.
49 OVERFILL PROTECTION SYSTEMS
OVERFILL PROTECTION:
upper probes, lower probes, control module, and sockets for rack communication. These components must be operational in order for the trailer to be bottom loaded.
in any way. Immediately repair or replace any damaged
Individual loading racks vary and required equipment and wiring depends on these rack demands. Learn the signs of a functioning system as well as the signs of a system that is faulty.
protection system.
EXAMPLE OF OVERFILL PROTECTION COMPONENTS
LOWER PROBE
OPTIC SOCKET
CONTROL MODULE
UPPER PROBE
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50 UNLOADING
The tank may be under pressure. Do not open the dome. Do not open any valves. Do not remove couplers or hoses until pressure has been relieved. (see TTMA TB No. 80) Do not load or unload trailer without proper support. The trailer may become unstable and damage may result.
Make sure that the parking brake is set before unloading the equipment.
Make sure that all unloading gear (hoses, couplings, valves, etc.) are compatible with the product that you are unloading.
When discharging, opening manholes or vents of adequate capacity are required before opening the products discharge valve. This will avoid damage due to a vacuum collapse of the tank if pumping off or gravity discharging. This will also prevent the retention of product in the hose resulting in spillage. Drain the hose before disconnecting to avoid spilling product.
Properly connect vapor hoses and open vapor vent before unloading. Failure to properly vent can cause tank collapse during product discharge.
Provide vacuum relief to the tank in the form of vapor recovery, vent valves, or opening a manhole. Failure to relieve the vacuum can cause tank collapse and/or structural damage. Make sure both ends of the discharge line are secure before opening the discharge valve. When opening the discharge valve, crack it slightly to begin with to check for leaks.
Provide proper grounding when unloading using either a pump hose, gravity discharge hose, or vapor recovery hose.
51 UNLOADING
Do not unload this equipment with pressure.
unloading process.
Product valves must be closed before removing the bottom loading cap. Beware of possible product retention. Connect the discharge hose before opening product valves.
Loading and unloading can also be facilitated with suction or pump-off lines using hoses, swing-hose and manifolds.
SWING HOSE
MANIFOLD
SWING HOSE
MANIFOLD
SUCTION LINE
SUCTION LINE
The purpose of this piping arrangement is typically to draw product from the pull trailer truck can also be equipped with a suction line from the pump to the rear of the chassis. This arrangement can then allow for product movement from the trailer onto the truck.
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52
VAPOR RECOVERY SYSTEM
Petroleum tanks typically include a vapor recovery system to move vapor in and out of the tank in a closed system. This system allows for circulation of the vapors so they do not escape into the atmosphere. The vapors inside the tank are displaced as the tank is bottom loaded. The vapors are moved to the loading facility during this bottom loading process. The vapors inside the underground storage tank at the typical service station are displaced as the tanker drops fuel and those vapors are moved to the tanker as its payload is off-loaded. The vapor recovery system includes a vent on top of the tank, a vapor rail that runs the length of the tank, a vapor pipe between the vapor rail on top of the tank and the discharge area, and vapor recovery outlets at ground level. The vapor vents are inward opening, air operated valves located in the manholes on the top of the tank. These vents are open when the emergency valve(s) in the bottom of the tank are open for product loading or product discharge. There is a vent for every compartment and each is piped to the vapor rail with a hose. The vapor rail collects the vapors from each compartment and is connected to piping that runs from the top of the tank to the curb side bottom load area where the vapor recovery outlets are located. Vapor recovery tee piping can also be included to the street-side of the trailer. The piping from the vapor rail to the bottom load area may run through the tank or be an external pipe typically located at the rear of the tank. There can be several vapor recovery outlets depending on operational needs. Some or all of these outlets may have a brake interlock valve to set the brakes if a
UPPER VAPOR RECOVERY VENT
LOWER VAPOR RECOVERY OUTLET
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