The Bullet ® Aluminum Bottom Dump OPERATIONS MANUAL
For more information, visit us at www.MACTrailer.com or call us 1-800-795-8454
PREFACE
2
Congratulations on your purchase of one of the finest bottom dump trailers available today! The Bullet trailer carries the unique distinction as a trailer with a trademark, which is more than just the Bullet name. How amazing is that? The trademark is Registration No. 1,622,364 dated Nov 13, 1990. This manual is provided to help you in the operation of your new trailer. It is meant to be a guideline, and may not cover all aspects of the safe operation of your trailer. This is not intended to be a maintenance manual. This manual includes the latest information at the time it was printed. MAC Trailer Enterprises, Inc. 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. The Bullet Trailer 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 MAC Trailer Enterprises, Inc., 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 MAC Trailer Enterprises, Inc. at: 1-800-795-8454. Privileged/confidential information is contained in this manual/drawing and is subject to legal privilege. Use by anyone without expressed written consent from MAC Trailer Enterprises, 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. 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”.
TABLE OF CONTENTS
3
DESCRIPTION
PAGE
Preface
2 4
Terms & Definitions
OPERATIONS
Safety Summary
5-9
General Safety Notice
5 5 6 6 6
Safety Terms Safety Decals
Safety Instructions
Preparation Nomenclature
10-11 12-13 14-28
Pre-Trip Inspection
Safe Coupling Procedure
Crank-Operated Landing Gear Troubleshooting
29 30
Pintle Hitch
Drawbar & Turntable
31-33 34-35 36-50 51-52 53-56
Access
Gate Operation
Loading
Unloading
Tarp (Optional)
57 58 59
Toaster Top (Optional) Vibrator (Optional)
Axles
60-61
Wheels
62
Air & Spring Suspension
63-64 65-66
Hubs
Brakes Nomenclature
67
Brakes
68-70
Electrical
71
General Maintenance
72-74
Preventative Maintenance Schedule
75
Grease Points
76-79
Reporting
80
Warranty & Support
81-85
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TERMS & DEFINITIONS
4
TERM
DEFINITION
BEARING PLATE
Steel reinforcement on gate ends to which the gate bearing and equalizer arms are attached.
CLOSURE DEVICE
A retractable tarp that covers the hopper opening.
EQUALIZER ARM
Steel bar that ensures both gates move equally when opened.
GATE
Lower opening mechanism for product discharge.
GATE LOCK
Mechanism which prevents gates from opening or closing. Device which limits gate opening for windrowing, and holds gates open for maintenance purposes.
GATE STOP
HOPPER
Load carrying cavity of trailer.
PULL 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 trailer as opposed to a fifth wheel plate and kingpin plate.
STIFF LEG SUPPORT
Landing legs attached to the gate ends for supporting an empty trailer.
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 kinpin plate and running gear.
VOID AREAS
Area inside front and rear end cones.
WINCHING EYE
Attachment point for pulling open stuck gates.
SAFETY SUMMARY
5
GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and 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 The following terms define the various precautions and notices in this manual.
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. This symbol alerts you to tighten fasteners to a specified torque value. This does not limit the need or use of torque settings to only those fasteners identified.
NOTICE
T
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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 MAC Trailer Enterprises, Inc. comprise only a portion of the total transportation system. Operators must be able to blend seamlessly the skills necessary to operate power unit, trailers and related eqiupment 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. Torque suspension parts per manufacturers specifications. 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 trailer, work site(s), and traffic 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 proper training and qualifications.
SAFETY SUMMARY
7
4. Before operating this equipment, every operator must read and understand this manual and the safety signs, and instructions contained therein. Should a difficulty 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 prior to operation. It is recommended that all operators first 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 manufacturer of that 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 factory of origin, found on the VIN or Serial Plate.
Do not remove or modify any of the original equipment without prior authorization from MAC Trailer Enterprises, Inc.. 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 lift stands of sufficient rated capacity. Do 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. This equipment may contain an OSHA-required confined space that should not be entered without proper training and procedures. Never enter a confined space that has not been properly certified for safe entry.
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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 sudden maneuvers such as abrupt lane changes. Long combination vehicles and pull trailers can off-track, to the inside of a corner reducing turn clearance. MAC Trailer Enterprises, Inc. cannot predict the lifetime of products, cleaning methods and materials, effluent discharge, or safety practices that a certain trailer will see and cannot be held responsible for any cleaning related or trailer entry problems.
NOTICE
MANUAL COMPARTMENT (EXAMPLE)
MANUAL IN HOLDER MOUNTED ON TRAILER (EXAMPLE)
SAFETY SUMMARY
9
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 BULLET TRAILER 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 equipment. If your product is missing this Caution decal, contact MAC Trailer Enterprises, Inc. at 1-800-795-8454 .
NOTICE
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 Bullet trailer factory of origin found on the VIN or serial plate if you need more of these vendor decals.
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10 NOMENCLATURE
NOMENCLATURE
11
NOTICE
The product configuration of this trailer is a Registered Trademark of MAC Trailer Enterprises, Inc.. Registration number 1,622,364 United States Patent and Trademark Office. Infringements of this Trademark will be prosecuted under Federal Law.
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12 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. It is imperative that the operator be satisfied the items listed below are in safe operational condition. It is also up to the operator to make sure that all compliance related items are satisfied. 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 that all tires are inflated to the proper pressure. Consult a tire professional for specific problems. 6. Rims/wheel nuts: Check for cracks, rust, or damage to rims. Look for loose, missing, or corroded fasteners. 7. Lights and reflectors: Make sure all reflectors and lights are in place, 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 tarps, doors, safety items, etc.
PRE-TRIP INSPECTION
13
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 entire trailer and components for any signs of fluid or air leakage. 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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14 SAFE COUPLING PROCEDURE
1. COUPLING PROCEDURE When coupling your trailer to the tow vehicle, be sure to use the correct procedure for your configuration. It is important that you read and understand the instructions for your configuration before beginning. 1.1 TRACTOR OR SEMI TRAILER TO SEMI TRAILER. 1. Inspect the fifth wheel for loose fasteners and verify that no fasteners are missing. Repair or replace cracked components. If you have a sliding fifth wheel, make sure both plungers are fully engaged.
2. Verify that the coupling area is flat, level and clear of people and other obstacles.
3. Lubricate the fifth wheel where it contacts the trailer’s upper coupler and tilt the ramps down. Also lubricate contact area between locking jaws and kingpin.
SAFE COUPLING PROCEDURE
15
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 brakes and actuate the fifth wheel control valve to open the locks.
5. Center the fifth 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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16 SAFE COUPLING PROCEDURE
7. Adjust the trailer height so the fifth wheel of the tow vehicle will lift the trailer. The trailer should contact the fifth wheel 4”-6” behind the fifth wheel bracket pin. Some height adjustment can be made by exhausting the tractor’s air ride suspension.
8. Slowly back the tow vehicle into the trailer until the king pin is coupled in the fifth 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 coupling the rear semi of a B-Train configuration, 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 the tractor and verify that the fifth wheel is properly coupled to the kingpin as shown in the next step.
SAFE COUPLING PROCEDURE
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11. Get out of the tractor and visually inspect that the locks are closed.
If you do not obtain a proper couple, repeat the coupling sequence. Do not use any fifth 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.
Failure to properly operate or maintain a fifth wheel could result in tractor/trailer or trailer/trailer separation causing death or serious injury.
Do not exceed the load capacity of any fifth wheel device.
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18 SAFE COUPLING PROCEDURE
1.2 SEMI TRAILER HITCHED TO PULL TRAILER
1. Verify that the coupling area is flat, level and clear of people and other obstacles. Do not exceed the rated capacity of the hitch or assembly.
2. Chock the trailer wheels and back the tow vehicle up to the drawbar of the pull trailer. 3. Open the coupling latch. 4. Have a spotter outside to help align the pintle hook to the drawbar eye and back under the eye. 5. Lower the drawbar eye down over the pintle hook and close the hitch latch. 6. Make sure the latch on the pintle hook is secure and the plunger is functioning correctly. 7. Connect air and electrical connections between equipment. 8. Turn the air supply valves on for each gladhand at the rear of the semi trailer. 9. 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. 10. Raise and secure the drawbar jack. 11. Re-check the brake lines and power cord and connect safety cables. Remove wheel chocks and continue with pre-trip inspection. 12. Check that all lights are functioning correctly. 13. Charge trailer with air and check brakes. 14. Release the brakes and slowly drive away only after all systems are working correctly and required pre-trip inspections are complete.
SAFE COUPLING PROCEDURE
19
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.
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.
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20 SAFE COUPLING PROCEDURE
Safety cables that are worn, frayed, cut, kinked, missing clamps, or otherwise abused are a safety hazard. Immediately fix any unsafe drawbar safety cable, components, and connections. Safety cables, connection components, and their installation are all designed for your specific trailer. Safety cable components, fasteners, and connections are rated and follow specific 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.
Raise the drawbar jack and rotate to its stored position.
Jack-knifing the drawbar can damage it along with the connecting components. Properly replace a damaged drawbar, hitch, or any other connecting parts including safety cables and air/electrical lines and hoses.
SAFE COUPLING PROCEDURE
21
1.3 AIR, ELECTRIC AND HYDRAULIC CONNECTIONS Air and electrical connects can vary greatly due to variations in trailer equipment and truck configurations. Following these general guidelines will help you in 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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22 SAFE COUPLING PROCEDURE
2. UNCOUPLING PROCEDURE 2.1 SEMI TRAILERS 1. Position the tow vehicle and trailer on firm level ground that is clear of people and obstacles.
2. Chock the trailer wheels and set the trailer brakes. 3. Slowly back the tow vehicle tightly against the trailer. 4. 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 2.1.2 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 original Manufacturer’s Serial Plate that reflects a 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 MAC TraILER ENTERPRISES, INC.. 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 repair. 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 ONLY APPLIES TO A 2-SPEED LANDING LEG PROPERLY INSTALLED AND SUPPORTED.
SAFE COUPLING PROCEDURE
23
7. Emergency support of a loaded trailer. If there are any questions please contact the factory of origin found on the VIN plate.
8.
Disconnect the brake lines and power cords.
9.
If equipped, pull and secure the secondary lock handle.
10. Pull the primary release handle. If fifth wheel is equipped with air release, actuate the fifth wheel control valve to open the locks.
11. Release the tow vehicle brakes and slowly drive away from the trailer.
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24 SAFE COUPLING PROCEDURE
2.1.1 LANDING GEAR Your Bullet trailer is/could be equipped with either a set of landing gear, stiff leg, drop tube, or a drawbar jack depending on the trailer’s configuration. This 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.
SAFE COUPLING PROCEDURE
25
• 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.
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 factory of origin for consultation.
DROP TUBE LANDING GEAR
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26 SAFE COUPLING PROCEDURE
2.1.2 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 (if equipped). 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.
Pull air bag deflation valve prior to lowering landing 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. Do not move without proper air spring inflation pressure.
TYPICAL AIR RIDE EXHAUST VALVE
Follow all safety alerts itemized in “coupling” section of this manual.
NOTICE
SAFE COUPLING PROCEDURE
27
UNCOUPLING PULL TRAILER 2.2 PULL TRAILER 1. Position the tow vehicle and trailer on firm level ground that is clear of people and obstacles. 2. Chock the trailer wheels and set the tow vehicle and trailer brakes. 3. Turn the air supply valves off on each gladhand at the rear of the semi. 4. Disconnect the glad hands and store in a safe location off the ground. 5. Disconnect the electrical connections and the safety cable and store in a safe location. 6. Open the coupling latch. 7. Lower the drawbar jack and raise the drawbar eye up and clear of the hitch.
8. When it is safe, release the tow vehicle brakes and slowly drive away from the trailer. 9. Safely support the drawbar.
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28 SAFE COUPLING PROCEDURE
3. B-TRAIN FIFTH WHEELS 1.
B-Train designs include a fifth wheel at the rear of the lead semi trailer. Typically this is a Holland “Kompensator” design with unique features. 2. Couple and uncouple this fifth wheel with the same care as described in 1.1 and 2.1. 3. Consult the manufactures’ care and maintenance procedures for this fifth wheel.
Failure to properly operate or maintain a fifth wheel could result in tractor/trailer or trailer/trailer separation causing death or serious injury.
Do not exceed the load capacity of any fifth wheel device.
CRANK-OPERATED LANDING GEAR TROUBLESHOOTING
29
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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30 PINTLE HITCH
OUT-OF-SERVICE CRITERIA
(Installation may vary based on model)
• Follow manufacturer’s acceptance/rejection criteria using factory-specified 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 manufacturer’s specifications.
HITCH FASTENERS MUST BE KEPT TIGHT. Use properly torqued Grade-8 bolts and nuts with hardened washers. Contact the Bullet trailer factory of origin for the correct replacement fasteners. Do not reuse fasteners once removed.
T
DRAWBAR & TURNTABLE
31
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 more than factory-specified tolerances. • The drawbar eye cannot be worn more than factory-specified tolerances.
Properly check the turntable, hinges, and drawbar eye for wear according to the manufacturer’s specifications.
TURNTABLE
TURNTABLE FASTENERS MUST BE KEPT TIGHT. Use properly torqued 5/8” diameter, Grade-8 bolts and nuts with hardened washers. Contact the Bullet trailer factory of origin for the correct replacement fasteners. Do not reuse fasteners once removed.
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DRAWBAR & TURNTABLE
32
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 and confirm that the slider tube 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.
DRAWBAR & TURNTABLE
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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 slider housing by first completely backing off 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
Do not slam the reach into the housing when extending or retracting the drawbar.
NOTICE
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34 ACCESS
LADDERS, WALKWAYS, STEPS AND DRAWBARS
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 Bullet trailer 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. STEPS can be installed at front, side, back or on a slope of a trailer depending on the design demands. Steps can also access drawbars, platforms, ladders, or other walkways and surfaces. WALKWAYS can be located on the front or rear of a Bullet trailer 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.
Watch your step when using access devices.
Use both hands when climbing on or off equipment.
Never occupy the space between opened gates or use as a point of access without first following the gate lockout procedure.
ACCESS
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Surface could be slippery.
CAUTION
WATCH YOUR STEP TRAILER ACCESS EQUIPMENT MUST BE PROPERLY MAINTAINED BY 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 hopper. There may be hazards inside the hopper like sharp fasteners, or edges. Product hazards may be present as well such as slick or an otherwise difficult work environment.
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36 GATE OPERATION
GATE NOMENCLATURE
GATE AIR CYLINDER BEARING PLATES
GATE BEARING
GATE EAR CURB-SIDE GATE
EQUALIZER ARM DRIVER’S SIDE GATE
PINCH POINT
ELECTRICAL - GATE CLOSURE
Disconnecting the electric supply will cause gate closure.
GATE OPERATION
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GATE CONTROL VALVE (STREET-SIDE REAR) The trailer gates are typically operated from both the truck cab and from the side of the trailer. CAB OPERATION Cab operation switches for the two individual trailer gates are usually installed by the customer or truck dealer. Some installations have a master switch and a switch for each trailer. The master switch can have a bomb cover on it or all three switches are installed with bomb covers. An alternative setup includes a single switch for each trailer and each switch might have a bomb cover, no master switch. The bomb cover is extra protection from the switch being activated when it is not intended to be used. The gate switches are two position electric switches, either open or closed. The gates cannot be feathered using this arrangement meaning they can only be opened or closed from the cab, and cannot be stopped anywhere between the two positions. The typical gate control electrical power is run on a 2-wire cable from the tractor to the rear of the semi and then continued to the rear trailer valve. A 4-way plug system is typically used to make the connections between the units involved. Air operated gate valve controls have also been installed as an option. Use all the same precautions with this design. Use all the same precautions with this design. SIDE OPERATION Operating the gates from the side of the trailer is a typical windrow situation while the trailers are in motion.
As a driver or gate operator, always be aware of your surroundings and any potential hazards involved with working, or having someone working close to a moving trailer. Follow all job site and company safety requirements while operating this equipment.
The gate control valve is designed to require the palm valve feature built into the gate valve, be depressed before the gate operator valve handle is moved and the gates operated. To operate the gates from the side of the trailer push the palm valve to exhaust the air which will allow the handle on the gate control valve to be moved to open the gates. This feature is included as a two step feature so the gate cannot be opened in a single step by simply moving the handle. The palm valve will reset itself when the gates are closed either from the side or from the cab. The side mounted gate control valve will allow the gates to be trimmed to the desired opening width.
Open or Close the gates only when it is safe to do so. Close the gates when the trailer is emptied and always before joining traffic.
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38 GATE OPERATION
CAB-MOUNTED CONTROL
POWER SWITCH (LOCATED UNDER THE RED COVER)
TRAILER-MOUNTED CONTROL
BUTTONS FOR OPERATING GATES (LOCATED ON THE DRIVER’S SIDE OF THE TRAILER.)
If your trailer is equipped with a tarp/closure device, open it before unloading. A closed cover will create a vacuum while unloading, and can damage the closure device or hopper.
NOTICE
GATE OPERATION
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GATE LOCK-OUT PROCEDURE
It is strongly recommended that any maintenance that requires an individual to be exposed to the pinch and crush zones of the trailer, including those associated with the gates, be performed by a qualified facility.
SHOULD IT BE DECIDED NOT TO USE A QUALIFIED FACILITY, IT IS THAT INDIVIDUAL’S RESPONSIBILITY TO FOLLOW EFFECTIVE LOCKOUT AND SAFETY PROCEDURES INCLUDING, BUT NOT LIMITED TO THE FOLLOWING: 1. ENSURE THAT ALL PERSONS ARE CLEAR AND AWAY FROM THE TRAILER BEFORE PREPARING IT FOR MAINTENANCE AND WHILE PERFORMING MAINTENANCE TO GATES. 2. DISCONNECT the AIR and ELECTRICAL from the power unit or lead semi setting the park brakes. 3. BLOCK the tires to prevent the trailer from moving during service operation. 4. SUPPORT the trailer at the king pin (if it is a semi trailer). Often the landing gear is located on the gates so the unit must be adequately supported at the king pin. In all cases, ensure that the TRAILER BRAKES ARE SET. 5. INSPECT Gate Stops, the GATE STOP ATTACHMENT PLATES and FASTENERS, and LOCK PINS for CRACKS, WEAR, DEFORMATION, or MISSING PIECES. If ANY DEFORMITIES are found, DO NOT PROCEED. Contact MAC Trailer Enterprises, Inc. for replacement parts.
Gates move rapidly. Stay clear and follow all safety procedures.
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40 GATE OPERATION
GATE LOCK-OUT PROCEDURE (CONTINUED)
PIN HOLDER BRACKETS
6. Ensure all persons STAY CLEAR of PINCH POINTS while opening the gates to the full open position. 7. SECURE GATES using the GATE STOP provided on BOTH SIDES of the trailer. • Open gates completely • Remove the locking pin and cotter pin from the PIN HOLDER BRACKET and insert pin in top hole of the gate stop on BOTH SIDES of the trailer. • Secure the lock pins with the supplied cotter pins.
GATE OPERATION
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GATE LOCK-OUT PROCEDURE (CONTINUED)
8. LOCATE the exhaust valve found directly inside the rear void of the trailer • Turn the ball valve handle to the GATES EXHAUST (FOR SERVICE) position.
• This will empty the entire air system which operates the gates, including the air cylinders, air lines, and 45 gallon gate reservoir tank. 9. WAIT UNTIL ALL THE AIR HAS EXHAUSTED before proceeding. 10. ENSURE THAT THE GATES ARE INOPERABLE BY TRYING TO OPERATE THE GATES to ensure that the system is DE-ENERGIZED.
Proceed ONLY if gate system is totally inoperable.
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42 GATE OPERATION
GATE TROUBLESHOOTING - ELECTRICAL
If the gates do not operate properly, inspect the following components:
ELECTRICAL SYSTEM 1. Check for positive connections at 6 and 7 way receptacles. 2. Check receptacles for damaged pins; repair or replace as needed. 3. With the main power switch in the “On” position, check connection posts on Buss bar for power. 4. Check connection posts on switches for power (a second person is required). 5. Check ground connection in rear void; make sure 7-way connector is plugged into ground unit.
PRESSURE GAUGE
SOLENOIDS
MAIN SOLENOID VALVE
Buss Bar Connections
MAIN VALVE BODY
S - WHITE SEMI OPEN
A - BLACK SEMI CLOSED
LT - YELLOW PUP OPEN
TM - RED MAIN POWER
GD - GREEN NOT USED (SPARE)
RT - BROWN PUP CLOSED
GROUND
GATE OPERATION
43
GATE TROUBLESHOOTING - ELECTRICAL
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44 GATE OPERATION
GATE TROUBLESHOOTING - AIR
AIR SYSTEM 1. Make sure the gate ball valve in the rear void is turned to “Gate Operation.”
GATE EXHAUST (SERVICE)
GATE OPERATION
EXHAUST VALVES
2. Make sure exhaust valves are closed. 3. Verify that the pressure gauge in the rear void reads 80 psi or higher. If the gauge does not read a pressure, move the ball valve to the service position and listen for exhausting air. If no air is exhausted from the system, there is no air in the rear 45 gallon tank. This indicates that the pressure protection valve could be bad.
GATE OPERATION
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GATE TROUBLESHOOTING - AIR
PRESSURE PROTECTION VALVE
4. With the main power off, disconnect the 1/8” air line from port #2 on the rear of the Main Solenoid Valve. This line should have air pressure. When the main power is on, this line should not have pressure.
1/8” LINE
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46 GATE OPERATION
GATE TROUBLESHOOTING - ELECTRICAL / AIR JOGGING VALVE SCHEMATIC - IN-CAB
SCH-BC-02-02 11-18-04
GATE OPERATION
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GATE TROUBLESHOOTING - ELECTRICAL / AIR JOGGING VALVE SCHEMATIC - SEMI
SCH-BC-02-02 11-18-04
LOGIC: WITH MASTER OFF, THE 3-PORT SOLENOID VALVE IS OPEN AND AIR FLOWS FROM PORT 12, THROUGH 3 TO 2. THIS KEEPS THE GATES CLOSED WITH AIR. WITH MASTER ON, POWER CLOSES THE 3-PORT SOLENOID VALVE AND EXHAUSTS AIR FROM PORT 2 OUT PORT 1. NOW THE APPROPRIATE TOGGLES MAY BE OPERATED TO OPEN AND CLOSE GATES.
REXROTH VALVE AND BASE: REMOVE TAB FROM BASE PLATE GASKET TO SUPPLY AIR TO PORT 12.
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48 GATE OPERATION
GATE TROUBLESHOOTING - ELECTRICAL / AIR JOGGING VALVE SCHEMATIC - PULL
SCH-BC-02-02 11-18-04
GATE OPERATION
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GATE ALIGNMENT
If the gates are out of alignment, the problem is most often caused by the equalizer arms being bent or broken. To correct the problem, complete the following steps: For removal or replacement of the equalizer arms. 1. Start with the gates in the closed position. For this operation, the trailer must be adequately supported at the kingpin plate. 2 Shut off the air supply to the trailer and drain all the air from the system. 3. Remove both the air lines from each cylinder on both sides of the gates. 4. Remove the lower pin from the equalizer arm. 5. Using a come-along connected to the winching eyes, open the street-side gate.
When manually opening gates, do so from the street side only, using the winching eye. Failure to do so may damage gate mechanism.
6. Remove the upper pin.
Use caution when lowering the gate. Make sure no equipment or personnel are in the path or vicinity of the gates when lowering them.
7. Release the come along and lower the gate. 8. Align the gates by moving both gates to the curb-side or to the driver’s side to even the gate floors as much as possible. 9. After alignment, measure the distance between the holes of the equalizer arm center-to-center. Be sure to measure both the front and the back as sometimes the measurements can be different. 10. Adjust the equalizers to the measured length and lock them into place with the lock nuts. If the equalizer arms are the nonadjustable type, drill a hole centered at the measured distance. 11. For reinstallation of the arms, follow the same steps in the reverse order.
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50 GATE OPERATION
GATE AIR CYLINDER REPLACEMENT
To replace the gate air cylinder, use the following the procedure: 1. Adequately support trailer at the kingpin plate. 2. Bleed out all air from the system. 3. Remove air lines from gate cylinder. 4. Pull pin located at the large end of the cylinder. Let the large end of the cylinder pivot to the ground. 5. Pull the pin located at the small end of the cylinder and remove the ram. 6. For reinstallation, install the new gate cylinder in reverse order.
Make sure that the air lines are not crossed during reinstallation.
The gate cylinders do not require lubrication. Do not attempt to lubricate these gate cylinders in any manner.
NOTICE
MANUALLY OPENING GATES (STUCK GATES)
When manually opening gates, do so from the street side only, using the winching eyes. Failure to do so may damage gate mechanism.
WINCHING EYES
LOADING
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LOADING 1. Open tarp closure device (if equipped). 2. Verify that all gate switches in the cab are in the “OFF” position during loading. These switches must remain off until the trailer is ready to unload. This ensures full tractor air on the closed side of the air cylinders. 3. a) Overhead hopper or conveyor When loading from an overhead hopper or conveyor, the driver should slowly advance the trailer as needed to make sure it is loaded evenly.
Make sure the semi is done loading before moving to load the pull trailer
b) Front-End Loader If the trailer is loaded with a front-end loader, the driver should inspect the trailer to make sure it is loaded evenly. An unevenly loaded trailer can be more difficult to control and increases the possibility of a rollover. If any part of the loader contacts the trailer, the driver should immediately inspect the trailer for damage. Repair any damage before using the trailer. Be aware of 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. 4. Close the tarp/closure device (if equipped). Make sure the tarp is fully extended and the load is properly covered. Tarp/closure regulations can vary. Know the regulations that apply to your equipment.
Do not load a trailer without proper support. The trailer may become unstable and result in damage
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