Pneumatic Trailers - Owners Manual

PNEUMATIC TANK TRAILERS

OWNER’S MANUAL

For more information, visit us at www.MACTrailer.com or call us 1-800-795-8454

TABLE OF CONTENTS

GENERAL Introduction……………………………………………………………………………………………….…3 Warranty Claims and Inquiries…………………………………………………………….…..…3 Directional Reference………………………………………………………………………….….……3 Warranty Statement…………………………………………………………………………………….4 Important Safety Messages………………………………………………………………5 thru 9 General Nomenclature……………………………………………...……………….…10 thru 11 OPERATING INSTRUCTIONS Safety Decals………………………………………………………………………………..10 thru 12 Identification of Piping System Components……………...………….….13 thru 14 Specific Operating Instruction……………………………………………….……….……..…15 thru 25 Operating Tips………………………………………………………….………………………….……21 thru 23 PREVENTIVE MAINTENANCE INSTRUCTIONS Introduction……………………………………………………………………………………..…………24 Maintenance Schedule……………………………………………………………….…………….…25 Relief Valve Test Rig Drawings……………………………………………….…….26 thru 28 Inspection, Lubrication and Service……………………………………………..29 thru 42 Torque Charts………………………………………………………………………………………………43 REPORTING SAFETY DEFECTS…………………………….………..Inside Back Cover

Publication Disclaimer The information and specifications included in this publication were in effect at the time of approval for printing. MAC Trailer Manufacturing, Alliance, OH USA reserves the right, how-ever, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatsoever. Revision 5/2023.

INTRODUCTION This manual is designed to help ensure safe and efficient operaƟon of the Heil Trailer Petroleum Transport. The manual is divided into three secƟons. SecƟon 1 will familiarize you with the unit. SecƟon 2 gives operaƟng procedures and Ɵps. SecƟon 3 covers the maintenance necessary to keep the unit in safe operaƟng condiƟon. TO THE OWNER MAC Trailer Manufacturing takes pride in the products we manufacture. We trust you will be well saƟsfied with your purchase. Properly operated and maintained, the PneumaƟc Bulk Transport will provide many years of low-cost, trouble-free service. WARRANTY CLAIMS & INQUIRIES The MAC Trailer Warranty Statement is included in this manual. In the unlikely event you need war- ranty service on your tank equipment purchased from MAC Trailer or its distributors, contact the dis- tributor or MAC Trailer (800-795-8454) directly, for warranty claims, service and/or repair proce- dures. For all parts contact the distributor or MAC Trailer (800-647-9424). For warranty claims, or specific inquiries about your MAC Trailer, refer to the model and serial number of your unit. This in- formaƟon is found on the vehicle idenƟficaƟon plate.

Example Vehicle IdenƟficaƟon Plate

DIRECTIONAL REFERENCE For your reference the sides of the tank transport are determined by facing in the direcƟon of for- ward travel. The right side is the “Curbside”; the leŌ side is the “Drivers’ Side, Roadside or Streetside”.

MAC Trailer Manufacturing Warranty Statement MAC Trailer Manufacturing, Inc. warrants each new trailer manufactured (hereinaŌer referred to as the equip- ment) to be free from defects in materials and workmanship, provided the equipment warranted hereunder is operated by the purchaser in accordance with generally approved pracƟces, with loads that not above operaƟng temperatures or pressures, and with loads not exceeding the manufacturer’s rated capacity. Vessel tank, plaƞorm frame structure, sub-frame or frame parts of the equipment found to be defecƟve within the warranty periods shall be repaired or replaced (at MAC’s sole discreƟon as set forth below) at MAC’s factory or an authorized dealership, provided however, the purchaser noƟfies MAC or an authorized dealership as soon as any defect becomes apparent. The period of the warranty is 100% for five years from date of delivery of the purchased equipment and MAC shall bear only that porƟon of the cost of repairing or replacing defecƟve parts of the equip- ment. MAC will review the costs for labor and noƟfy the coverage allowance. Component warranty schedule: Any parts not manufactured by MAC Trailer Manufacturing, inc. will carry their own warranƟes and are carried out according to their own individual component warranƟes. For example: axles, rims, hubs, suspensions, landing gear, wheels, hydraulic cylinders, brakes, valves, air bags, shock absorbers, tarps and etc. to name a few have their own warranƟes. Axle and/or suspension alignment: MAC Trailer Manufacturing, Inc. or authorized dealership must be called within 30 days aŌer delivery. Paint: 12 month limited warranty on workmanship and material. Surface corrosion caused from stone chips, scratches or reverse impact are not includ- ed in the warranty. This warranty does not enlarge upon, expand, or alter in any way, the warranƟes provided by the manufacturers and suppliers of component parts and accessories. The purchaser agrees to return the defecƟve equipment or parts to MAC’s factory locaƟon, freight prepaid, within ten days aŌer the defecƟve condiƟon is discovered. This warranty also excludes the following: normal wear, tear and deterioraƟon of the equipment, maintenance items including, but not limited to, light bulbs, brake linings, drums, springs, oil seals, paint and bearings, used equipment sold “as is”, equipment that has been repaired, replaced or altered by someone other than MAC Trailer Manufacturing, Inc. MAC and purchaser agree that in consideraƟon of the above expressed warranty, all other warranƟes other than Ɵtle, either expressed or implied, whether arising under law or equity including warranƟes of merchantability and fitness for a parƟcular purpose are excluded from the contract, further, the foregoing warranty is made solely to the first purchaser from MAC Trailer or from an authorized dealership. In the event the trailer is sold and sƟll has a remainder of the warranty leŌ the new owner may transfer the warranty for a two hundred fiŌy dollar ($250.00) administraƟon fee. This sole liability of MAC and exclusive remedy of the purchaser arising out of the manufacture, sale or use of the equipment provided hereunder, on warranƟes or otherwise shall be limited to the cost of repair or replacement of defecƟve parts as herein specified. Further, MAC’s maximum liability hereunder arising from any cause whatsoev- er, including but not limited to breach of contract price of the equipment furnished or parts of repairs made by others. In no event shall MAC be liable for removing defecƟve parts or for reinstalling said parts when repaired or replaced by anyone other than MAC or an authorized dealership. ConsequenƟal damages: Not withstanding any other provision of this agreement, in no event shall MAC be liable whether arising under con- tract, tort (including negligence) or otherwise for loss of use of capital or revenue, cost of money, claim of custom- ers, nonoperaƟon or increased expense or operaƟon cost of purchase or replacement equipment, los of anƟcipat- ed profits, damage to loads or contents of equipment, transportaƟon expenses due to repairs, or for any special, incidental or consequenƟal loss or damage of any nature arising at any Ɵme or from any cause whatsoever.

DANGER IF INCORRECTLY USED, OPERATED, MAINTAINED OR REPAIRED, THIS EQUIP- MENT CAN CAUSE SEVERE INJURY, DEATH, AND PROPERTY DAMAGE. THOSE WHO USE, OPERATE, MAINTAIN AND REPAIR THE EQUIPMENT SHOULD BE TRAINED IN ITS PROPER USE, OPERATION, MAINTENANCE AND REPAIR, WARNED OF ITS DANGERS, AND SHOULD READ THIS ENTIRE MANUAL BE- FORE ATTEMPTING TO USE, OPERATE, MAINTAIN, SET UP, ADJUST, SERVICE OR REPAIR THE TRAILER OR PRODUCT.

RECOMMENDED OPERATING PRACTICES FURNISHED IN THIS MANUAL ARE GENERAL PRACTICES. MAC TRAILER CANNOT POSSIBLY KNOW, EVALUATE, OR ADVISE ANYONE OF ALL CONCEIVABLE WAYS A TANK TRAILER OR ITS PRODUCT PAYLOAD MIGHT BE USED, OPERATED, MAINTAINED, SET UP, AD- JUSTED, REPAIRED, OR OF ALL POSSIBLE CONSEQUENCES OF EACH WAY.

ALL PERSONS WHO PERFORM ANY OF THESE TASKS MUST FIRST SATISFY THEMSELVES THOROUGHLY THAT NEITHER THEIR SAFETY NOR THE GENERAL PUBLIC WILL BE JEOPARDIZED BY ANY METHOD THEY SELECT. KEEP THIS MANUAL FOR FUTURE REFERENCE.

IMPORTANT SAFETY MESSAGES

DANGER WARNING CAUTION

NOTICE

THESE SAFETY ALERT SYMBOLS INDICATE IMPORTANT MESSAGES THROUGHOUT THIS MANUAL.

WHEN YOU SEE THESE SYMBOLS CAREFULLY READ THE MESSAGES THAT FOLLOW AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY, PROP- ERTY DAMAGE, OR DEATH TO YOURSELF OR OTHERS.

IMPORTANT SAFETY MESSAGES CAUTION InspecƟon of equipment, safety devices and working areas must be per- formed before each trip to ensure personal and operaƟonal safety, and to correct potenƟal of actual hazards. DANGER Do not alter or modify any part of the equipment or components pro- vided with this tank trailer. Use of non-MAC Trailer parts or non-OEM component parts may cause serious personal injury, including death. WARNING Before moving the tank trailer into a building, the vessel must be free of product and checked with an approved gas analyzer to ensure it is free of hazardous and/or flammable vapors. DANGER Never climb onto a tank trailer that has not been completely depres- surized. Such an unsafe pracƟce could result in personal injury, includ- ing death.

IMPORTANT SAFETY MESSAGES DANGER Do not enter the tank trailer vessel unƟl each of the following condi- Ɵons have be saƟsfied: 1. Pressure inside the vessel has been completely relieved. 2. The vessel has been completely purged and vented. 3. The vessel has been degassed and/or professionally cleaned and cerƟfied by an authorized cleaning facility. 4. The MSDS for the last product hauled has been reviewed. 5. The OSHA 1910.146 Confined Space Requirements are strictly ad- hered to. Failure to follow any one of these instrucƟons may result in serious personal injury, including death. CAUTION The pressure relief valve must be removed and bench tested every 90 days to ensure it will maintain system pressure within safe limits DANGER Do not exceed the designed working pressure of the vessel as defined on the trailer VIN plate. If the internal pressure rises above the de- signed pressure limits, open the blow down line valve to relieve excess pressure. If over pressurizaƟon conƟnues, immediately shut down the blower and invesƟgate. Over pressurizaƟon can cause severe damage to the tanks, and cause serious personal injury, including death.

IMPORTANT SAFETY MESSAGES CAUTION The blow down line valve must remain OPEN except when loading of unloading the trailer. Leaving the valve open prevents the vessel from being unknowingly pressurized with changes in ambient temperatures, fricƟon, product expansion, etc. DANGER The tank trailer shall not be operated if any of the following dondiƟons exist: 1. Damage to the lighƟng fixtures, wiring or electrical conduits, or inoperaƟve lights 2. Leaking of malfuncƟoning equipment components 3. Damage to the tractor of tank trailer, including , but not limited to, internal damage. 4. InoperaƟve braking systems, primary or parking. 5. Vents or valves plugged, inoperaƟve or removed. Plugged or inop- eraƟve vent valve can cause extensive vessel damage if the de- signed pressure is exceeded or a vacuum situaƟon is created. Failure to follow any one of these instrucƟons may result in serious personal injury, including death. WARNING Proper operaƟon of the tank trailer’s primary braking system is essenƟal for the safe operaƟon of the vehicle. A funcƟonal system check is neces- sary each and every Ɵme the trailer is put into service.

Important Safety Decals

PIPING SYSTEM COMPONENT DESCRIPTIONS AND FUNCTIONS 1. AIR SUPPLY INLET LINE - Provides connecƟon of trailer-mounted air supply unit or alternaƟve air source. Includes 3” buƩerfly valve which, when closed, prevents air from alternaƟve source from flowing upstream.

1. MAIN AIR SUPPLY LINE CHECK VALVE - Permits one-direcƟon flow from power source to tank and prevents air-borne product from backing up to power source when pressure in tank is greater than in supply lines.

1. MAIN AIR SUPPLY LINE - Transfers air from tractor air supply line to aeraƟon and discharge lines.

1. PRESSURE RELIEF VALVE - Prevents pressure inside vessel from exceeding maximum operaƟng pressure.

1. BLOW DOWN VALVE - Opens/closes blowdown line to atmosphere.

1. BLOW DOWN LINE - Exhausts tank air to atmosphere. Used to pressurize tank when top air kit is installed.

1. PRESSURE CONTROL VALVE - Controls product line pressure. Used to pressurize product line to discharge product from line to silo/ receiver vessel.

1. AERATION CONTROL VALVE - Controls main air supply line pressure. Used to control air to aerators.

1. PRODUCT DISCHARGE VALVE - Regulates the flow of aerated material from the hopper to the product tee. 2. PRODUCT DISCHARGE LINE - Facilitates pneumaƟc discharge of mate-rials from hoppers. 3. AERATION - Induces air into hopper to aerate product and make it flow-able. See figure X for idenƟficaƟon of aeraƟon units. Refer to AeraƟon System OperaƟon on page XX for detailed descripƟon. 4. PRODUCT DISCHARGE TEE - Facilitates transfer of materials from hopper to product line. 5. REAR DISCHARGE LINE - Extension of product line to rear of trailer. Used to connect vessel to silo/receiving vessel. 6. TANK PRESSURE GAUGES - Register air pressure in tank and product line. 7. TOP AIR LINE - Provides a means to pressurize vessel to force material down and out of hoppers. 8. AERATION MANIFOLD - Directs supply air to individual aeraƟon lines. 9. INDIVIDUAL HOPPER AERATION CONTROL VALVE - Controls air flow to individual hoppers.

OPERATING INSTRUCTIONS

WARNING Never operate a pneumatic tank trailer unless you are fully aware of the location of all the control valves and shut down procedure.

HOOKING TRACTOR TO TRAILER

Prior to backing tractor under trailer, check the following items:

1. Trailer brakes are set or wheels blocked to prevent trailer from rolling. 2. Upper 5th wheel is at approximate height of lower 5th wheel. 3. Latch on lower 5th wheel is in “Open” posiƟon. 4. All personnel are clear of the area.

Then proceed as follows: 1. Back tractor under trailer, aligning king pin with slot in lower 5th wheel. When latch “sets” around king pin, check hookup by aƩempƟng to pull for-ward. 2. Shut down engine and apply parking brake. 3. Double Check latch on 5th wheel to ensure that it is fully engaged. 4. Connect tractor supply and control brake hoses to glad hands on trailer. The glad hands are marked for correct installaƟon. 5. Connect electrical connector to receptacle on trailer. 6. Raise landing gear supports. 7. Check brakes and lights for proper operaƟon. 8. AnƟ-Lock pilot light must be lit when brakes are applied.

PRE-TRIP SAFETY CHECK A vehicle safety check should be performed daily prior to operaƟon. See PrevenƟve Maintenance SecƟon.

DANGER NEVER open a manhole unless vessel is completely depressized and blow down line valve is open. Even a slight amount of residual pressure can cause the manhole cover to violently fly open when unlatched.

START-UP When units are parked, especially over night, moisture can form inside the tank and piping. To clear out most of the moisture, remove dust cap on dis-charge line, start compressor or blower and pres- surize unit. Then open each of the hopper discharge valves to blow out the unit. This procedure will help prevent the discharge valves and aerators from becoming clogged.

CAUTION Blow down line valve must be OPEN at all Ɵmes, except when unload- ing. This will help prevent residual pressure buildup due to changes in ambient temperature, fricƟon, product expansion, etc..

LOADING The type of cargo being hauled and the loading situaƟon will determine the best method of loading. Heavier materials such as sand and sugar can normally be loaded through the center manhole and allowed to overflow into the adjoining hoppers. Light and bulky products such as flour or plasƟc pel- lets should be loaded through the individual manholes for beƩer distribuƟon. The pneumaƟc loading line, on units so equipped, offers an alternate loading method. 1. Close all valves except the blowdown valve before loading and while in transit. 2. Secure all manhole covers aŌer loading.

LOADING AND UNLOADING SITE EXAMPLES

PNEUMATIC UNLOADING PROCESS

NOTICE Never discharge payload into a storage facility of unknown contents or capacity. Before unloading check to ensure the storage facility will accept the total payload. DANGER Always ensure the discharge hose is secured at both ends prior to pressurizing the trailer vessel. A loose hose will bull whip potenƟally causing injury.

1. PosiƟon trailer for opƟmum unloading. 2. Retrieve discharge hose and connect it to the discharge line. 3. AƩach opposite end of hose to adapter on storage facility fill line.

4. Open the pressure control valve. 5. Engage blower or compressor. 6. Open all aeraƟon valves and close pressure control valve and blow down valve to pressurize unit. If cargo does not require aeraƟon, open the Top Air Supply Valve to pressurize the unit. 7. When unit has reached operaƟng pressure open the proporƟoning valve ½ to ¾ of full open. 8. SLOWLY open discharge valve on rear hopper. 9. Adjust the pressure control valve to maintain maximum operaƟng pressure and slight movement of discharge hose. 10. Close the front and center individual hopper aeraƟon control valves on units so equipped. 11. When tank pressure begins to drop rapidly, close rear discharge valve. 12. Open aeraƟon valve on center hopper. 13. SLOWLY open the discharge valve on center hopper.

14. Close the aeraƟon valve on rear hopper. 15. Readjust pressure control valve if necessary. 16. When tank pressure begins to drop rapidly, close center discharge valve.

PNEUMATIC UNLOADING PROCESS

NOTICE When pressurizing vessel, look and listen for air leaks. If any air leaks are found, shut down immediately and repair the leak.

16. Open aeration valve on front hopper. 17. SLOWLY open front hopper discharge valve. 18. Close aeration valve on center hopper.

DANGER Do not exceed the maximum working pressure. If pressure eises above the maximum working pressure, shut down immediately and invesƟgate.

19. When tank pressure begins to drop rapidly, close front discharge valve. 20. Purge unit by opening all aeration valves and opening and closing dis-charge valves rear to front. 21. Open blow down line to return the unit to atmospheric pressure.

CAUTION Before opening blow down line valve, make sure no one is in or around the area of the blow down exhaust port. Dust and flying debris could cause personal injury.

22. Disengage blower or compressor.

DANGER Always relieve pressure in discharge line and the receiving container before disconnecƟng the product discharge hose.

23. Disconnect and stow discharge hose. 24. Close all valves except the blow down valve.

VACUUM LOADING PROCESS 1. PosiƟon trailer for opƟmum loading. Rear of trailer should be located as close to the product storage outlet as possible 2. Retrieve product hose from hose stowage tubes and connect it to the load line. Note: The passenger side load line extends inward near the center of the vessel. This line is used to fill the front half of the trailer. The drivers’ side load line extends inward to the last manhole and is used to fill the rear half of the trailer.

Load Lines

3. AƩach opposite end of hose to adapter on storage facility discharge outlet. 4. Open the vacuum control box and engage the air actuated vacuum control valve. 5. AƩach vacuum hose to blower intake outlet and vacuum return line at the front of the trailer.

Vacuum Relief

Vacuum Return

VACUUM LOADING PROCESS

6. Ensure all air control and product discharge valves are closed. 7. Engauge blower. Vacuum loading will begin immediately. 8. When unit has reached the tractor PTO controlled vacuum pressure, product can be felt moving inside the hose. 9. Monitor tank vacuum and filter cannister pressures. Vacuum must not exceed 13” Hg. The filter cannister pressure must not exceed 5 PSI 10. Once the front half of the trailer is loaded interrupt the vacuum process using the vacuum dump control valve and move loading hose from the passenger side load line to the drivers’ side load line. Note: Opening the vacuum dump control valve stops the loading process.

Vacuum Dump Valve

11. ConƟnue loading unƟl the trailer is filled to the desire payload. Notes:

Typically the desired payload load is achieved by monitoring the suspension load gauge and Ɵme. Payloads will vary based on federal and regional weight laws, and the bulk density of the material being transported.

OPERATING AND UNLOADING TIPS

NOTICE Variations or deviations to the unloading procedure may be necessary due to the type of product being unloaded or the nature of the unloading site. Operat- ing more than one hopper at a time is common with extremely large capacity blowers or a combination of compressor and blower. A second and third hop- per can be activated and maintained with a desirable product to air mixture.

MINIMIZING UNLOADING TIME The MAC Trailer pneumatic tank trailer is designed to be one of the fastest pneumatic discharges in the industry. However, unloading time will depend on variables such as type of product being unloaded, unloading site, condition of equipment, etc. The following points should be considered. 1. Vertical positioning of discharge hose results in smoother product flow. Product tends to “settle” in portions of hose which runs horizontally (see Horizontal Flow graphic below). This accumulation of product will restrict product flow, will in-crease unloading time, and may eventually clog the line. 2. Comparing product flow through a hose in the vertical portion of hose (see Vertical Flow graphic below). It is readily seen that vertical positioning of hose results in smoother product flow. If discharge hose must be run horizontally for any considerable dis-tance, elevate the hose at intervals to create slight “humps” in the hose. This will help keep the product flowing freely.

VerƟcal Flow

Horizontal Flow

MINIMIZING UNLOADING TIME (CON’T.) 3. The relaƟve density (product to air raƟo) decreases as the elevaƟon increases. The higher the storage fa- cility, the longer it will take to unload. The graphic below illustrates the relaƟve density at various elevaƟons. Note that as the product head (back) pressure decreases, the air velocity will increase and air pressure will decrease.

RelaƟve Density at Various ElevaƟons

4. Heavy, fine materials such as sand or sugar require considerably more unloading Ɵme. Light, bulky prod- ucts offer more resistance and are more easily carried by the air stream. Use the pressure control valve and the product discharge valve to maintain the opƟmum product-to air raƟo for the type of product being un- loaded.

PREVENTIVE MAINTENANCE INTRODUCTION LubricaƟon and service performed at regular intervals will keep MAC Trailer pneumaƟc tank trailer in top operaƟng condiƟon for the longest period of Ɵme. The importance of regular inspecƟon cannot be over- emphasized. Making necessary adjustments, Ɵghtening nuts and bolts, checking air lines, lights and wiring connecƟons will help prevent serious trouble and delays on the road. The driver is the first line of defense in PrevenƟve Maintenance. A conscienƟous and alert operator will promptly report all need for adjustment or repair. A vehicle safety check should be performed daily prior to operaƟon. LUBRICANTS MAC Trailer does not offer a list of approved lubricants or guarantee lubricant performance. The responsibil- ity for the quality of any lubricant rests solely with the distributor or manufacturer of the lubricant. DELIVERY INSPECTION All units are thoroughly tested and inspected at the MAC Trailer factory. As an added pre-cauƟon, the fol- lowing items should be double checked upon delivery.

Axles……………………………………………………………………….… Check king pin alignment Wheels…………………………………………………………………………...Check wheel lug torque Brakes……………………………………………Check for proper operaƟon and adjustment Lights and Wiring……………………………………………Check lights for proper operaƟon Air Spring Bolts……………………………………………………………..Check for proper torque Shock Absorber Bolts………………………...…………………………Check for proper torque Suspension Pivot ConnecƟon Bolts…………………………….…Check for proper torque Piping………………………………………………………………………………………...Check for leaks Manhole Cover………………………Check clamping device for proper cover closure Landing Leg Support Bolts…….……………………………...…….Check for proper torque Front and Rear Structure Bolts………………………………….…Check for proper torque

PREVENTIVE MAINTENANCE SCHEDULE

DAILY AnƟ-Lock Brake System…………………………………………….………………………Check for proper operaƟon Lights and Wiring……………………………………..…………………………Check all lights for proper operaƟon All Bolts……………………………………...…………………………………………….……...Visually check for Ɵghtness Air Reservoirs………………………………………………….……………………….……Drain at the end of each shiŌ Tires……………………………………………………………….………………...Check for proper inflaƟon and inflate WEEKLY Wheel Seals…………………………………………….……………………………….Check for oil leakage and oil level Wheel Lugs………………………………………………………………………………………….…Check for proper torque Wiring……………………………………………………………………………….……….….………....Check all connecƟons Suspension Bolts..…………………………………….………..……………………………….…Check for proper torque Piping…………………………………………………………………………………………….…Check for leaks and damage Manhole……………….………………………..…Check clamping device adjustment and gasket for damage Front and Rear Structure Bolts………………..……………...………………………….…Check for proper torque MONTHLY Manhole…………………………………………………..…………………………………..Clean manhole and oil clamps General InspecƟon……………………..…………………………………………………..Perform inspecƟon of trailer Supports………………….…………...………………………Lubricate; check mounƟng bolts for proper torque Axle CamshaŌs……………………………………………...………………………………….Lubricate all grease fiƫngs 90 DAYS Pressure Relief Valve………………….Remove and inspect relief valve for clogs of hardened material. Bench pressure test relief valve with a cerƟfied accurate gauge to ensure proper operaƟon. A test rig is easily constructed with common readily available components. NOTICE MAC Trailer does not design, build, or sell test rigs for pressure relief valves. The follow- ing drawing is merely an example of how a suitable bench test rig can be built with com- mon components.

INSPECTION EVERY 5000 MILES King Pin Alignment……………………………………………………Check for proper alignment Brakes………………………………………………………………………..…….………Adjust as needed Wiring…………………………....Check for chafed or broken wires, ground wire connecƟons, loose wire retaining clips and dielectric grease Upper 5th Wheel…………………………………………………………………..………………..Lubricate Suspension…………………………………….……………………...Check for proper bolt torque Piping………………………………….………Check all piping supports-Ɵghten if necessary AeraƟon……………………………………Check all aeraƟon tee bolts - hand Ɵghten only EVERY 10,000 TO 25,000 MILES Wheel Bearings………………………………….Verify proper end play and adjust as necessary Brakes………………………………………………..Inspect linings, free-up brake shoes and anchor pins EVERY TWO YEARS AeraƟon…………….…………………………….Inspect and replace aeraƟon components as necessary. At a minimum, trailers in abrasive product service should be inspected every six months. A recommended lubricaƟon chart is provided on the following page of this manual.

LUBRICATION AND SERVICE CHART Tank trailers must be inspected periodically to ensure compliance to DOT require- ments. Refer to the DOT TransportaƟon of Hazardous Materials Handbook (paragraph 177.824) if hazardous materials are to be hauled.

Drain water from air reservoirs

Check manhole clamp adjustments, cover for signs of leakage, and gasket for damage Clean manhole gaskets, wear plates and lubricate threaded manhole hardware

Check operaƟon of all lights and wiring connecƟons Check operaƟon of anƟ-lock brake system Check all wire harnesses for chaffing and damage Check brake operaƟon and adjust brakes as necessary Inspect slack adjusters, brake linings and brake chambers Inspect condiƟon of walkways, toe rails and ladder

X X

Check suspension bolt torque Check Ɵres for wear and damage Check axle alignment to king pin

Check lubricant level and oil seals on the axles Check operaƟon of pressure relief devices

X X X

Inspect aeraƟon system

Lubricated grease fiƫngs on axle camshaŌs

Check wheel bearings

Check wheel lug nut torque

Check piping supports and mounƟng fastener Ɵghtness Check front and rear structure mounƟng bolt Ɵghtness

X X

Check upper coupler fastener torque

Check all valves, piping and manholes for leakage Check landing leg mounƟng fastener Ɵghtness

X X

Check king pin wear

Lubricate upper coupler plate and king pin Visually check Ɵghtness of all fasteners

X X

Check all supports and brackets

NOTICE All tank trailers must be inspected periodically to ensure compliance

LUBRICATION & SERVICE 1. Manhole Cover -(Weekly)-check clamping device for proper cover clo-sure; check gasket for dam- age. (Monthly). Clean manhole gasket and lubricate clamps. 2. Lights and Wiring -(Daily)-check all lights for proper operaƟon. (Weekly)-Check all connecƟons. (Every 5000 miles)-Check for chafed or broken wires. 3. AnƟ-Lock Brake System -(Daily)-Check for proper operaƟon. Refer to AnƟ-Lock System Mainte- nance Manual. (Every 5000 miles)-Adjust brakes. (Every 10,000 to 25,000 miles)-Inspect linings, free-up brake shoes and anchor pins. 4. Rear Structure -(Weekly)-Check bolts for proper torque (150 Ō-lbs.) 5. Suspension -(Every 5000 miles)-Check for proper bolt torque. 6. Tires -(Daily)-Check for proper inflaƟon, cuts or other damage. 7. Axles -(Weekly)-Check oil level and for leakage around oil seals, see page 36. Check pivot bolt connecƟons for proper torque. (Every 5000 miles) Check axle alignment to king pin. 8. Wheels -(Weekly)-Check lug nuts or bolts for proper torque, see page 40. (Every 10,000 to 25,000 miles) Check wheel bearings. Tighten or replace as required. 9. AeraƟon -Clean or replace as required. (Every 2 years) 10. Piping -Check for loose clamps, damaged hoses or leaks. (Monthly) Perform general inspec- Ɵon. 11. Supports -(Monthly)-Lubricate; check mounƟng bolts for proper torque (150 Ō-lbs.). 12. Front Structure -(Weekly)-Check bolts for proper torque (150 Ō-lbs.).

AERATION SYSTEM GENERAL INSPECTION The following inspecƟon should be performed monthly.

1. Check pressure gauges for accuracy. 2. Close manhole covers. Close all valves except aeraƟon valves. Remove dust cap from product line. 3. Start compressor (or blower) and pressurize tank unƟl relief valve opens. DO NOT EXCEED MAXIMUM OPERATING PRESSURE

WARNING If relief valve does not open at pressure specified on valve, shut down blower and correct the cause of the inoperative relief valve.

4. AŌer tank is pressurized, close the aeraƟon valves and shut off compressor blower. Tank pressure should remain rela- Ɵvely constant. If pressure drops excessively, check for leaks in manhole cover, relief valve, blowdown valve and tank proper. If none are found with the above inspecƟon, check for air leaks in the aeraƟon, pressure control and product valves. 5. When inspecƟon is complete, open blowdown valve to exhaust the air in the tank. Replace dust cap on product line. If one or more hoppers does not discharge properly, and there are no leaks in tank or valves, the following service pro- cedure is recommended. 1. Remove product from these secƟons. 2. Check aeraƟon line for possible plug. 3. Check aeraƟon device on interior of tank. Look for torn molded neoprene cone(s), rotated wear plate(s) or plugged aerator housings. Clean, adjust or replace as necessary.

BRAKES-MAINTENANCE & ADJUSTMENT

NOTICE Refer to AnƟ-Lock Brake System Maintenance Manual for operaƟonal check and service instrucƟons.

The wheel brakes are equipped with slack adjusters for easy brake adjustment to compensate for brake lin- ing wear. It is recommended that slack adjuster arm travel be held to a minimum for most efficient braking acƟon. The brakes should be adjusted when total arm travel reaches 1-1/2”. To adjust brakes, depress lock sleeve on slack adjuster, then turn adjustment screw as required. Make sure lock sleeve returns to lock posiƟon when adjustment is complete. Every 5000 miles, the brake camshaŌs should be lubricated with approved chassis lubricant. Every 10,000 to 25,000 miles, the brakes should be serviced as follows: 1. Remove wheels and hubs. 2. Inspect brake roller shaŌs, cam rollers, anchor pins, camshaŌ sup-port bushings, spider bushings and camshaŌ for wear and replace if necessary. Lubricate these parts with chassis lubricant upon re- assembly. 3. Inspect brake linings for wear, loose rivets and any signs of grease on the braking surface. Oil-soaked linings are not reusable and must be replaced. Check to ensure that the linings have not worn to the point that rivet heads are contacƟng inside surface of drum. Reline or replace brake shoes if neces- sary. 4. Check inside surface of drum. RebooƟng of drums is not recommended, as the strength of refaced drums is greatly reduced. If drum is worn, replace it. 5. Service the wheel bearings and seals if required. Reassemble hubs and wheels.

NOTICE Refer to AnƟ-Lock Brake System Maintenance Manual for operaƟonal check and service instrucƟons.

WHEEL BEARINGS & SEALS The wheel hub revolves around the axle spindle on two roller bearings. The bearings are lubricated and the hub cavity is sealed against leakage by a seal which rides around an axle ring on the spindle shoulder. The graphic below illustrates the bearing and seal arrangement. Check oil level and for leaks around the oil seal at least once a week. If low, refill hub to oil level line on hub cap with a 75W90 syntheƟc gear oil. For best results and wheel end life, use only compaƟble lubricant prod- ucts.

Cross SecƟon View of Wheel Hub

Wheel Bearing Adjustment Bearing adjustment should be 0.001”-0.010” end play and a minimum of pre-load. Use the following procedure: 1. Tighten inner jam nut with a 12 inch wrench while turning wheel in both direcƟons unƟl there is a slight bind which indicates all bearing surfaces are in contact. 2. Back off inner jam nut 1/3 turn to allow the wheel to rotate freely. 3. Install washer and Ɵghten outer jam nut. 4. Final bearing adjustment should be with 0.001” to 0.010” end play. Tighten nuts at this posiƟon.

Oil Seal Replacement If oil leakage around the inner oil seal is noted, replace the oil seal (and axle ring, if required) as follows: 1. Remove wheels and hub 2. Remove and discard old seal. 3. Inspect axle ring. If piƩed or worn, replace as follows: a) Remove old ring. Take care not to damage spindle. b) Clean spindle thoroughly. Shoulder area must be smooth and free from weld spaƩer and burrs. c) If shoulder is not completely smooth apply sealer No. 2 to correct any defects and ensure an oil-Ɵght fit. d) Using axle tool, drive the axle ring firmly on shoulder. Edge of axle ring must be parallel and flush with shoulder face. Remove excess sealer, if used. 4. Install oil seal in wheel hub as follows: a) Remove all burrs from inside hub bore. b) If seal is not pre-coated with BLU-SEAL, or if wheel hub bore is not enƟrely free of nicks or burrs, apply a thin coat of sealer No. 2 to the O.D. perimeter of the oil seal. c) Lay wheel down, brake drum up. Check to ensure that hub cavity is clear of old grease, grit and metal parƟcles-steam clean if possible. Check bearing cones on spindle for proper slip fit. Install inner bearing in hub bore. Place seal in starƟng posiƟon in bore. d) Using hub tool and a hammer, drive seal squarely and evenly into bore. Seal should boƩom evenly all around against bearing cup. DO NOT conƟnue to hammer aŌer seal has boƩomed evenly, as damage to the seal will result. 5. Coat seal lip and inside diameter of inner bearing cone, then install wheel on axle. Take care not to damage seal during installaƟon. If wheel does not slip back in place easily, remove and check for burrs or possible component damage. 6. Install outer bearing, jam nuts and washer. Adjust bearing pre-load (see Wheel Bearing Adjust- ment). 7. Install gasket and hub cap. 8. Refill hub with recommended oil. See Wheel Bearings and Seals. 1 to 1-1/2 pints are required per hub, depending on wheel well de-sign. A minimum of 1 pint is required for proper lubricaƟon. Allow plenty of Ɵme for the oil to seep through the bearings. 9. Re-install vent plug.

WHEEL & TIRE MAINTENANCE Proper Ɵre inflaƟon and correct installaƟon of rims and wheels is essenƟal to safe, economical, trouble-free service. Check Ɵre pressures daily. Recommended inflaƟon pressure is noted on VIN Data Plate. DO NOT over-inflate Ɵres, as this is a common cause of rim failures and accidents. Never run vehicle on one Ɵre of a dual wheel assembly. Loss of air in one Ɵre of a dual set excessively overloads the other Ɵre if the vehicle is operated in this condiƟon. When checking Ɵre pressures, visually check studs and rim for looseness, cracks or other damage. Inspect Ɵres for uneven wear, cuts, cracks, etc., which would render the Ɵre unfit for further service. If the least doubt exists as to the Ɵres’ serviceability, replace the Ɵre.

DANGER Be extremely careful when working with Ɵres and wheels. Tires and wheels can come apart with explosive force.

Recommended InstallaƟon Procedure-Disc Wheels

1. Check all parts for damage, including wheels and rings. Insure that all studs, nuts and mounƟng faces of hub and wheels are clean and free from grease. Replace any defecƟve parts. 2. Mount inner dual wheel over studs, being careful not to damage stud threads. 3. Mount the outer wheel, being careful not to damage stud threads and hand Ɵghten wheel nuts. 4. Tighten nuts fully, using a crossing paƩern as shown in figure 20. Be sure to Ɵghten nuts only to the recommended torque. The correct wheel nut torque is 450-500 Ō-lbs. (dry).

AXLE ALIGNMENT Improper axle alignment will cause dog-tracking and excessive Ɵre wear. To check alignment of axles to king pin, use the following procedure: 1. Set empty trailer on level smooth surface, disconnect trailer brakes and bleed air tank. 2. Rock trailer back and forth for a distance of approximately 10 feet to relieve any binding in brakes or suspension bushings. 3. Tow trailer straight forward for a distance of approximately 30 feet. Stop trailer with tractor gears or tractor brakes only. 4. Disconnect tractor from trailer and ensure suspension ride height is properly adjusted. 5. Adjust landing legs to level trailer and set upper coupler to the correct ride height. 6. Do not remove wheels, but remove all hub caps and install axle center extensions. Use suitable kingpin jack or center extension to insure a clear path from the kingpin centerline to the axle center extensions. 7. Measure from kingpin extensions to both front axle center extensions. This distance should be the same on both sides (A = B) as shown in graphic below.

8. If not, remove and install new pivot bolts leaving them loose enough to adjust axle to square with the kingpin. Make sure there are no obstacles in front of wheels during alignment. 9. Measure from front axle center extensions to rear axle center extensions. This distance should be the same of both sides (C = D). If not, remove and install new pivot bolts leaving them loose enough to adjust rear axle to parallel with front axle. The suspension should now be in proper alignment with the kingpin.

AXLE ALIGNMENT CONTINUED

NOTICE Pivot bolts must be replaced during realignment of the suspension.

10. The QUIK-ALIGN® style pivot connecƟon uses two flanged collars inserted into slots on each side of the frame bracket. The eccentric collar on the outboard side of the frame bracket is used to adjust the posiƟon of the axle during an alignment. The alignment guides on the side of the frame bracket limit the eccentric collar to rotaƟonal movement in the frame bracket slot. RotaƟng the eccentric col- lar clockwise causes the axle to move forward. RotaƟng the eccentric collar counterclockwise causes the axle to move rearward. The maximum range of adjustment is ±45 degrees from the 12 o’clock po- siƟon.

Quick-Align OperaƟon

Pivot ConnecƟon Assembly

11. Using an E20 Torx socket, Ɵghten the shear-type bolt axle pivot connecƟon unƟl the Torx head shears off. This ensures the proper torque of 550 Ō. lbs. (±45 Ō. lbs.). Pivot bolts must be replaced when trailer is aligned. DO NOT aƩempt to reuse old pivot bolts. Assembly of pivot connecƟon shown in graphic above. 12. Connect tractor to trailer and connect trailer brakes on the lot. Make four or five Ɵght figure eights and an equal number of “panic” brake stops. Bring trailer back into shop and check axle align- ment. If axles are not in proper alignment, check for loose or worn bushings and bearings, loose or broken hangers, cross members, side rails or kingpin.

Trailer Suspension System Components and General Maintenance Guidelines HEIGHT CONTROL VALVE - The height control valve on the trailer air sus-pension automaƟcally responds to the relaƟve posiƟon of the axle and vehicle frame. It meters air into or out of the air springs. VariaƟons in load or temperature only affect the adding or exhausƟng of air. The trailer air suspension is a mechanically stable suspension, only one height control valve is necessary.

Suspension Height Control Valve When the actuaƟng lever of the height control valve moves up, the valve opens and connects the air supply to the air spring. When the actuaƟng lever moves down, the valve shuts off the air supply and opens the ex- haust port to vent excess air from the air springs. A check valve prevents the loss of air spring pressure if the air supply fails. In the central posiƟon, air does not flow in or out of the air springs. RIDE HEIGHT ADJUSTMENT 1. Connect the vehicle to a compressed air supply with approximately the pressure of the normal sup- ply system. 2. Ensure the inflaƟon of the air springs. 3. Measure the ride height by using this method: a. Measure from the underside of the trailer frame to the top of the axle as shown in figure 24 below b. Add half the diameter of the axle to the measurement

Trailer Suspension System Components and General Maintenance Guidelines ConƟnued

Measuring Ride Height

4. Raise or lower the trailer as necessary, so it is at the designed ride height. 5. Once the trailer is set to the correct designed ride height, set the HCV lever to the neutral (central) posiƟon.

NOTICE When adjusting the height control valve, block the tires and release the trailer brakes. The axle must rotate freely to avoid a false read- ing. Some height control valves have very small openings and a time de- lay of as much as 15 seconds. Allow sufficient time for the system to react to the adjustment. The response time will appear to be lengthy, but be patient.

6. Adjust the HCV linkage to fit between HCV lever and lower linkage aƩachment. 7. Once set to the designed ride height, test drive the trailer. AŌer the test drive, check the ride height to assure an accurate adjustment.

Trailer Suspension System Components and General Maintenance Guidelines ConƟnued

AIR SPRINGS - Air springs will last almost indefinitely in most applicaƟons. However air springs will fail quick- ly when rubbed, scuffed, or punctured. If an air spring fails, the trailer will seƩle on the internal rubber bumpers, so you can proceed to the nearest service facility at a lower speed. You should try to determine the cause of a failure, so you can avoid a costly repeat of the problem. Air Spring Replacement To replace an air spring, follow these steps:

1. Exhaust all air from the suspension system. 2. Raise and support the vehicle in a safe manner. 3. Unbolt the air spring. 4. Disconnect air-supply lines. 5. Replace the air spring.

6. Bolt the air spring in place. 7. Connect the air-supply lines. 8. Lower the trailer to the ground. 9. Supply air to the suspension system.

SHOCK ABSORBER - Shock absorbers absorb energy to prevent suspension oscillaƟon. Shock absorbers are also rebound stops in most air suspensions. The shock absorber limits the stroke of an air spring, which pre-

vents the air spring from being pulled apart. To remove a shock absorber, follow these steps: 1. Remove the end fasteners. 2. Insert the new shock absorber. 3. Secure with correct size locknut and bolts. 4. Torque fasteners to specificaƟon.

Trailer Suspension System Components and General Maintenance Guidelines ConƟnued

PIVOT CONNECTION - A correct pivot connecƟon is crucial to the life of the suspension. The pivot fastener must conƟnually provide a sufficient clamp load through the bushing to prevent premature suspension fail- ure. Hendrick-son INTRAAX suspension systems come equipped with QUIK-ALIGN pivot connecƟon hard- ware. The hardware consists of a specially plated shear bolt to ensure a proper clamp load, (550 Ō-lbs, H-45 torque). TRI-FUNCTIONAL BUSHING - have unique properƟes that will provide years of maintenance-free service. The TRI-FUNCTIONAL BUSHING (located at the suspension pivot connecƟon) provides a resilient connecƟon that allows an axle to walk without excessive flexing. The TRI-FUNCTIONAL BUSHING, in conjuncƟon with the rigid axle connecƟon, results in a roll-stable suspension design that resists trailer lean independent of the air spring loading. Reference Hendrickson service guide L427 for bushing replacement procedures.

Pivot ConnecƟon Assembly

NOTICE Failure to properly torque the pivot bolts may result in loss of warran- ty coverage.

TORQUE SPECIFICATIONS

RECOMMENDED SUSPENSION TORQUE

RECOMMENDED WHEEL TORQUES

REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the NaƟonal Highway Traffic Safety AdministraƟon (NHTSA) in addi- Ɵon to noƟfying MAC Trailer.

If NHTSA receives similar complaints, it may open an invesƟgaƟon, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot be- come involved in individual problems between you, your dealer or MAC Trailer.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at Monday-Friday 8am to 8pm at (888) 327-4236 , TTY: (800) 424-9153, or file and online form at www.nhtsa.gov. You can also ob- tain other informaƟon about motor vehicle safety from the Hotline.

MAC Trailer AŌermarket Parts Inc. 12241 Rockhill Ave. NE Alliance, OH 44601 parts@mactrailer.com 800-647-9424

Your Commercial Trailer Leasing Headquarters 330-422-8922 855-238-6766 sales@MadTrailerLeasing.com

MAC Trailer Enterprises Corporate Office 14599 Commerce Street, Alliance, Ohio 44601 800-795-8454

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