BULK FEED UNIT AUGER UNLOAD - Walinga · AIR / AUGER UNLOAD and AUGER UNLOAD BULK FEED UNIT...

148
BULK FEED UNIT AUGER UNLOAD OPERATOR'S MANUAL Trailer Truck

Transcript of BULK FEED UNIT AUGER UNLOAD - Walinga · AIR / AUGER UNLOAD and AUGER UNLOAD BULK FEED UNIT...

Page 1: BULK FEED UNIT AUGER UNLOAD - Walinga · AIR / AUGER UNLOAD and AUGER UNLOAD BULK FEED UNIT Warranty Registration Form Inspection Report WARRANTY REGISTRATION ... 7 Unloading System

BULK FEED UNITAUGER UNLOAD

OPERATOR'S MANUAL

Trailer

Truck

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Head Office:RR#5

Guelph, Ontario,N1H 6J2PHONE (888) 925-4642

FAX (519) 824-5651www.walinga.com

FACTORY DISTRIBUTION AND SERVICE CENTRES:

IN CANADA: 70 3rd Ave. N.E. Box 1790 Carman, Manitoba Canada R0G 0J0

Tel (204) 745-2951 Fax (204) 745-6309 220 Frontage Rd. Davidson, Saskatchewan Canada S0G 1AO

Tel: (306) 567-3031 Fax: (306) 567-3039

IN USA: 1190 Electric Ave. Wayland, MI. USA 49348

Tel (800) 466-1197 Fax (616) 877-3474 579 4th Street NW

Sioux Center, Iowa USA 51250 Tel (800) 845-5589 Fax (712) 722-1128

PRINTED IN CANADAISSUE DATE: June, 1998 Auger UnloadREPRINT: January, 2008 Operators Manual OM PART# 34-17696-6

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SERIAL NUMBER LOCATION

The serial number plate is located on the Drivers Side of the unit, at the front of the bodyon the truck, and on the landing gear on trailers. Please mark the serial number and thedate of manufacture of the body in the space provided for easy reference.

DATE OF MANUFACTURE:

SERIAL NUMBER:

Dear Customer

Thank you for choosing WALINGA TRANSPORTATION EQUIPMENT. For your conven-ience, should you require any information related to Parts, Service or Technical Engineer-ing, please contact one of the following Walinga Personnel:

TECHNICAL - ENGINEERING:Janus Droog (ext: 259) email:[email protected]

Bill DeVries (ext: 238) email:[email protected]

Butch Medemblik (ext:250) email:[email protected]

WARRANTY CLAIMS:Amy Vanderzwaag (ext:254) email:[email protected]

SERVICE MANAGER:Andy Nijenhuis (ext: 228) email:[email protected]

PARTS MANAGER:Jack Lodder (ext: 224) email:[email protected]

Parts Department Fax: (519) 824-0367

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V.I.N. PLATE LOCATIONAlways give your dealer the V.I.N. (Vehicle Identifi-cation Number) of your Walinga Bulk Feed unitwhen ordering parts or requesting service or otherinformation.

The plate is located where indicated.

Please mark the number in the space provided foreasy reference. Also obtain and mark down theModel Number, Production Year and other pertinentinformation of your Trailer/Truck unit in the spacesprovided.

Truck (Serial Number Plate)

Trailer (VIN Plate)

V.I.N. Number

Model Number

Length

Suspension

Axles

Wheels

Tires

Date Purchased

Dealer Purchased From

Address

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AIR / AUGER UNLOAD andAUGER UNLOAD

BULK FEED UNITWarranty Registration Form

Inspection Report

WARRANTY REGISTRATION

This form must be filled out by the dealer and signed by both the dealer and the customer at the time ofdelivery.

Customer’s Name Dealer Name

Address Address

City, Prov./State, Code City, Prov./State, Code

Phone Number ( )

Model

VIN Number

Delivery Date

DEALER INSPECTION REPORT

Airlock and Blower Turn Freely (applies to air/auger unit only) Safety Signs InstalledBoom Swings Freely Manual SuppliedBottom, Vertical and Boom Augers Turn Freely All Reflectors Installed and CleanLanding Gear Moves Freely and Crank Stowed All Lights FunctioningAir and Hydraulic Lines Properly Stowed (No Leaks) Brakes Release at Proper PressureElectrical Connections Stowed Review Operating and SafetyInstructionsTires at Specified PressureRims and Tires TorquedBrakes Adjusted Properly

SAFETY

Operator’s Manual content, equipment care, adjustments, safe operation and applicable warranty policy.

Date Dealer’s Rep. Signature

Date Owner's Signature

The above equipment and Operator’s Manual have been received by me and I have been thoroughlyinstructed as to care, adjustments, safe operation and applicable warranty policy.

I have thoroughly instructed the buyer on the above described equipment which review included the

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WALINGA® INC.WARRANTY

The Seller warrants to the Buyer that the Equipment manufactured by the Seller will be free from defect inmaterial, workmanship and title for a period of one (1) year from the date of delivery to the Buyer. Thiswarranty is subject to the following:

a) The Seller's obligation under said warranty shall be limited to repairing or replacing (at the Seller'soption) EXW (ExWorks) Guelph, Ontario, Canada, any part of the Equipment which, if properlyinstalled, used and maintained, proves defective in material or workmanship, provided that notice ofany such defect and satisfactory proof thereof is promptly given by the Buyer to the Seller;

b) All costs of the installation or transportation pursuant to this warranty are for the account of the Buyer;

c) The obligations set forth in this clause are conditional upon:

i. Proper storage, installation (except where installation is supervised by or performed by the Seller),use, maintenance and compliance with any applicable recommendations of the Seller; and,

ii. The Buyer promptly notifying the Seller of any defect and obtaining authorization prior to proceed-ing with repairs, and if required, promptly making the goods available for correction;

d) In respect of any Equipment or part thereof supplied hereunder which are manufactured by others, theSeller gives no warranty whatsoever, and the warranty given by the manufacturer, if any, shall apply;

e) The Seller shall not be liable for any cargo loss, loss of equipment, use or any other incidental orconsequential damages resulting from any defective part or parts, the Seller's liability and the Buyer'sexclusive remedy being expressly limited to the replacement of defective parts as provided herein;

f) The warranty set out within this paragraph does not apply to:

i. tires, accessories, and other items including the items, if any listed on the face hereof as "BuyersSpecified Items", manufactured by others and the Buyer shall rely solely on the warranty, if any, ofthe manufacturer of such tires, accessories and other items; nor

ii. to any equipment, otherwise subject to this warranty, which shall have been repaired, modified oraltered in any way by anyone other than the Seller or one of its duly authorized service representa-tives.

g) With respect to used equipment sold hereunder, regardless of manufacture, the Seller makes nowarranty whatever, and all warranties, express or implied are hereby excluded. With respect to suchused equipment, the Buyer agrees to accept such used equipment on an "as is" basis.

WARRANTY VOID IF NOT REGISTERED

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TABLE OF CONTENTS

SECTION DESCRIPTIONPAGE

1 Introduction ........................................................ 92 Safety ................................................................. 10 2.1 General Safety .................................................... 11 2.2 Operating Safety ................................................. 12 2.3 Unloading Safety ................................................ 12 2.4 Maintenance Safety ............................................ 13 2.5 Hydraulic Safety.................................................. 13 2.6 Travel Safety ...................................................... 14 2.7 Tire Safety .......................................................... 14 2.8 Safety Signs ....................................................... 14 2.9 SignOff Form ...................................................... 153 Safety Sign Locations ...................................... 164 Operation Guidelines ....................................... 21 4.1 To the New Operator or Owner .......................... 21 4.2 Terminology ........................................................ 22 4.3 Break-In .............................................................. 23 4.4 Pre-Operation Vehicle Inspection Procedure ..... 25 4.5 Hooking Up/Unhooking ....................................... 28 4.5.1 Hooking Up .......................................................................... 28 4.5.2 Unhooking ........................................................................... 30 4.6 Controls .............................................................. 31 4.7 Machine Placement ............................................ 36 4.8 Operation ............................................................ 39 4.9 Transporting ....................................................... 49 4.9.1 Operating Instructions .......................................................... 49 4.9.2 Breaking Guildelines ............................................................ 50 4.9.3 Tires .................................................................................... 51

4.10 Optional Equipment ............................................ 525 Service and Maintenance ................................. 54 5.1 Service ................................................................ 54 5.1.1 Fluids and Lubricants ........................................................... 54 5.1.2 Greasing .............................................................................. 54 5.1.3 Hydraulic System ................................................................. 556 Trailer Servicing Intervals ................................ 56 6.1 Servicing Record Summary (Lubrication) ........... 677 Unloading System Servicing ........................... 68 7.1 Servicing Intervals .............................................. 68 7.2 Service Record ................................................... 748 Periodic Maintenance and Adjustments ......... 75 8.1 Torque Specification Summary .......................... 75 8.2 Kingpin and Fifth Wheel Plate ............................ 77 8.3 Fifth Wheel ......................................................... 78 8.4 Axle Alignment .................................................... 79

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TABLE OF CONTENTS

SECTION DESCRIPTIONPAGE

8.5 Wheel Hubs/Bearings ......................................... 81 8.6 Wheels ............................................................... 85 8.7 Tires .................................................................... 87 8.8 Brakes ................................................................ 89 8.9 Slack Adjusters ................................................... 92 8.9.1 Rockwell Automatic Slack Adjuster ...................................... 92 8.9.2 Manual and Automatic Slack Adjuster Maintenance ............ 93 8.10 Air Chamber/Spring Brake ................................ 101 8.11 Suspension System .......................................... 102 8.11.1 Air Ride Suspension .......................................................... 102 8.11.2 Mechanical Suspension ..................................................... 106 8.11.3 Suspension System Schematics ........................................ 107 8.12 Tire Wear Patterns ........................................... 108 8.13 Air System ........................................................ 110 8.13.1 Air System Inspection ........................................................ 110 8.13.2 Air System Functional ........................................................ 110 8.13.3 Air System Schematic ........................................................ 111 8.14 ABS Vehicle Control System ............................ 112 8.15 ABS Schematics ............................................... 114 8.16 Electrical System .............................................. 115 8.16.1 Electrical Schematics ......................................................... 116 8.17 Hydraulic Schematics ....................................... 117 8.18 Gate Tower Manual .......................................... 1249 Boom Rotation Drive System ........................ 12510 Trouble Shooting ............................................ 12611 Specifications ................................................. 141 11.2 Bolt Torque ....................................................... 142 11.3 Hydraulic Fitting Torque.................................... 14312 Index ................................................................ 144

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1 INTRODUCTIONWalinga appreciates your patronage and trust this unit will give you many years of trouble-free use. Weare pleased to have you join a growing number of people operating Walinga Bulk Feed units.

We take pride in building products to meet the demands of discriminating buyers in the feed transportingindustry. We have sought to anticipate your needs with respect to safety, convenience, design and engi-neering for your unit. Walinga provides information and service support to its customers through itsdistributor and dealer network. Contact them at once should you need assistance.

Safe, efficient and trouble free operation of your Bulk Feed unit requires that you and anyone else who willbe operating or maintaining the unit, read this manual carefully and understand the Safety, Operation,Maintenance and Trouble Shooting information contained within the Operator's Manual. Failure to readand follow the manual could lead to serious injuries or costly repairs.

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Keep this manual handy for frequent referenceand to pass on to new operators or owners.

OPERATOR ORIENTATION - The directions leftand right as mentioned throughout this manual,are taken as if the operator was in the driver's seatand facing in the direction of travel.

Although some of the diagrams and pictures maynot apply to all units, we have tried to show detailsof common adjustments and features that are onstandard production units.

Use the Table of Contents or Index as a guide inlocating the specific information applicable to yourunit.

Truck

Trailer

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3 Big Reasons

SIGNAL WORDS:

2 SAFETY

SAFETY ALERT SYMBOL

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Note the use of the signal words DANGER,WARNING and CAUTION with the safetymessages. The appropriate signal word foreach message has been selected using thefollowing guide-lines:

situation that, if not avoided, will resultin death or serious injury. This signalword is to be limited to the mostextreme situations, typically for ma-chine components that, for functionalpurposes, cannot be guarded.

Indicates a potentially hazardoussituation that, if not avoided, couldresult in death or serious injury, andincludes hazards that are exposedwhen guards are removed. It may alsobe used to alert against unsafe prac-tices.

Indicates a potentially hazardoussituation that, if not avoided, may resultin minor or moderate injury. It mayalso be used to alert against unsafepractices.

DANGER - Indicates an imminently hazardous

WARNING -

CAUTION -

Accidents Disable and KillAccidents CostAccidents Can Be Avoided

Why is SAFETY important to you?

This Safety Alert symbol meansATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

The Safety Alert symbol identifiesimportant safety messages on theWalinga Bulk Feed unit and in themanual. When you see this symbol,be alert to the possibility of personalinjury or death. Follow the instruc-tions in the safety message.

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SAFETY 2.1 GENERAL SAFETY

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1. Read and understand theOperators Manual and allsafety signs before operat-ing, maintaining or adjustingthe unit.

YOU are responsible for the SAFE operation andmaintenance of your Walinga Bulk Feed unit.YOU must ensure that you and anyone else who isgoing to operate, maintain or work around theTruck or Trailer be familiar with the operating andmaintenance procedures and related SAFETYinformation contained in this manual.

Remember, YOU are the key to safety. Goodsafety practices not only protect you but also thepeople around you. Make these practices aworking part of your safety program. Be certainthat EVERYONE operating this equipment isfamiliar with the recommended procedures andfollows all the safety precautions. Remember,most accidents can be prevented. Do not riskinjury or death.

• Remember the difference between being justa driver and an efficient operator. Drivers mayonly drive but an operator is a very safe, costefficient and professional person.

• Bulk Feed unit owners must give operatinginstructions to operators or employees beforeallowing them to operate the equipment, andat least annually thereafter.

• The most important safety feature on thisequipment is a SAFE operator. It is theoperator’s responsibility to read and under-stand ALL Safety and Operating instructionsin the manual and to follow these. All acci-dents can be avoided.

• Walinga feels that a person who has not read,understood and been trained to follow alloperating and safety instructions is not quali-fied to operate the equipment. An untrainedoperator exposes himself and bystanders topossible serious injury or death.

• Do not modify the equipment in any way.Unauthorized modification may impair thefunction and/or safety of the equipment andaffect Truck or Trailer life.

• Think SAFETY! Work SAFELY!

2. Only trained competent persons shall operatethe unit. An untrained operator is not qualifiedto operate the unit.

3. Have a first-aid kit availablefor use should the needarise and know how to useit.

4. Do not allow riders outside the cab.

5. Have a fire extinguisher availablefor use should the need arise andknow how to use it.

6. Wear appropriate protective gear. This listincludes but is not limited to:

- A hard hat- Protective

shoes withslip

resistantsoles

- Heavygloves

7. Place all controls in neutral, disengage PTOclutch, stop engine, set park brake, removeignition key and wait for all moving parts tostop before servicing, adjusting or repairing.

8. Do not drink and drive.

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2.2 OPERATING SAFETY

1. Read and understand all the Operator’sManual and all safety signs before operatingor adjusting the Walinga Bulk Feed unit.

2. Perform circle check before driving.

3. Do not allow riders outside the cab during roador highway travel.

4. Drive very carefully when negotiating hilly oruneven terrain.

5. Keep hands, feet, clothing and hair away fromall moving parts.

6. Place all controls in neutral, disengage PTOclutch, stop the engine, set park brake, re-move ignition key and wait for all moving partsto stop before servicing, adjusting, repairing ormaintaining.

7. Stay away from power lines when movingboom or climbing on top of the trailer. Electro-cution can occur without direct contact.

8. Do not open access doors to airlocks, troughchain or augers while the air system or augerare running.

9. Use care when climbing on ladder(s) and/orplatform(s) to prevent falling.

10. Maintain running gear in good condition at alltimes. In addition, on trailers, maintain kingpin and fifth wheel assembly in good condition.

11. Clear the area of all bystanders, especiallychildren, before starting up and operating theunit.

12. Make sure that all lights and reflectors that arerequired by the local highways and transportauthorities are in place, clean and can be seenclearly by all overtaking and oncoming traffic.

13. Do not operate unit with spring brakes cagedor brakes disabled. Block wheels if unhooked.

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14. Before disconnecting the tractor from thetrailer unit(s) make sure that the tractor andtrailer are on level ground and that the trailerwheels are securely blocked. Lower landinggear and provide extra support if the ground issoft. Deflate air ride if so equipped prior touncoupling.

15. Do not unload unless vehicle is on a firm levelsurface.

16. Review safety items with all personnel annu-ally.

2.3 UNLOADING SAFETY

1. Position vehicle on a firm level surface beforeswinging boom or unloading unit. Soft oruneven terrain can result in tipping of framewhen swinging boom or unloading.

2. On semi units, position tractor and trailer in astraight line to provide maximum stabilitywhen swinging boom or unloading.

3. Stay away from power lines when swinging orraising the boom. Electrocution can occurwithout direct contact.

4. Use care when on ladder or on top of unit toprevent falling. Stay away from power lines toprevent electrocution.

5. Stay out of tank compartments when unload-ing and when engine is running.

6. Do not operate when any guards are removedor any access doors are opened.

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2.4 MAINTENANCE SAFETY

1. Read and understand all the information in theOperator’s Manual regarding maintenance,adjusting and servicing the Bulk Feed unit.

2. Place all controls in neutral, disengage PTOclutch, stop the engine, remove ignition keyand set the park brake before adjusting,servicing or maintaining any part of the BulkFeed unit.

2.5 HYDRAULIC SAFETY

1. Always place hydraulic controls in neutralbefore disconnecting from tractor or workingon hydraulic system.

2. Make sure that all components in the hydraulicsystem are kept in good condition and areclean.

3. Replace any worn, cut, abraded, flattened orcrimped hoses or lines.

4. Do not attempt any makeshift repairs to thehydraulic fittings or hoses by using tape,clamps or cements. The hydraulic systemoperates under extremely high-pressure.Such repairs will fail suddenly and create ahazardous and unsafe condition.

6. If injured by a concentrated high-pressurestream of hydraulic fluid, seek medical atten-tion immediately. Serious infection or toxicreaction can develop from hydraulic fluidpiercing the skin surface.

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5. Wear proper hand andeye protection whensearching for a high-pressure hydraulic leak.Use a piece of wood orcardboard as a backstopinstead of hands toisolate and identify aleak.

3. Follow good shop practices:

- Keep servicearea clean anddry.

- Be sure electricaloutlets and toolsare properlygrounded.

- Use adequatelight for the job athand.

4. Block wheels before de-activating brakes.

5. Maintain air system and brake components intop condition at all times.

6. Maintain fasteners in running gear systems attheir specified torque at all times.

7. Establish and maintain a Trailer PreventativeMaintenance (TPM) program on your equip-ment. Some jurisdictions require this programand the maintenance of records on everycommercial vehicle on the road for futurereference.

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2.8 SAFETY SIGNS

1. Keep safety signs clean and legible at alltimes.

2. Replace safety signs that are missing or havebecome illegible.

3. Replaced parts that displayed a safety signshould also display the current sign.

4. Safety signs are available from your Distribu-tor or the factory.

How to Install Safety Signs:

• Be sure that the installation area is clean anddry.

• Be sure temperature is above 50°F (10°C).

• Decide on the exact position before youremove the backing paper.

• Remove the smallest portion of the splitbacking paper.

• Align the sign over the specified area andcarefully press the small portion with theexposed sticky backing in place.

• Slowly peel back the remaining paper andcarefully smooth the remaining portion of thesign in place.

• Small air pockets can be pierced with a pinand smoothed out using the piece of signbacking paper.

2.6 TRAVEL SAFETY

1. Read and understand all the information in theoperator’s manual regarding procedures andsafety when operating the Bulk Feed unit onthe road.

2. Make sure all the lights and reflectors that arerequired by the local highway and transportauthorities are in place, are clean and can beseen clearly by all overtaking and oncomingtraffic.

3. Drive carefully and defensively at all times andespecially when negotiating uneven or hillyterrain.

4. Do not allow riders outside the cab during roadand highway travel.

5. Make sure you are in compliance with all localregulations regarding transporting on publicroads and highways. Consult your local lawenforcement agency for further details.

2.7 TIRE SAFETY

1. Failure to follow proper procedures whenmounting a tire on a wheel or rim can producean explosion which may result in serious injuryor death.

2. Do not attempt to mount a tire unless youhave the proper equipment and experience todo the job.

3. Have a qualified tire dealer or repair serviceperform required tire maintenance.

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DATE EMPLOYEE'S SIGNATURE EMPLOYER'S SIGNATURE

SIGN-OFF FORM

2.9 SIGN-OFF FORM

Walinga follows the general Safety Standards specified by the Society of Automotive Engineers (SAE) andthe Occupational Safety and Health Administration (OSHA). Anyone who will be operating and/or maintain-ing the Bulk Feed unit must read and clearly understand ALL Safety, Operating and Maintenance informa-tion presented in this manual.

Do not operate or allow anyone else to operate this equipment until such information has been reviewed.Annually review this information with all personnel.

Make these periodic reviews of SAFETY and OPERATION a standard practice for all of your equipment.

A sign-off sheet is provided for your record keeping to show that all personnel who will be working with theequipment have read and understand the information in the Operator’s Manual and have been instructedin the operation of the equipment.

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3 SAFETY SIGN LOCATIONSThe types of safety signs and locations on the equipment are shown in the illustration below. Good safetyrequires that you familiarize yourself with the various safety signs, the type of warning and the area, orparticular function related to that area, that requires your SAFETY AWARENESS.

• Think SAFETY! Work SAFELY!

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REMEMBER - If safety signs have been damaged, removed, become illegible or parts replaced withoutsigns, new signs must be applied. New signs are available from your authorized dealer or factory direct.

A

1. Read Operator’s Manual and safety signs before operating.2. Do not load trailer in excess of the gross vehicle weight

rating shown on the certification plate.3. Do not allow riders on the trailer.4. Keep hands, feet, clothing and hair away from all moving

parts.5. Place all controls in neutral, stop the engine, set park brake,

remove ignition key and wait for all moving parts to stopbefore servicing, adjusting, repairing or maintaining.

6. Maintain king pin, fifth wheel assembly and all running gearcomponents in good condition at all times.

7. Make sure that all lights and reflectors are clean andworking when transporting on public roads.

8. Keep all hydraulic lines, fittings and hoses tight, free ofleaks and in good condition at all times.

9. Do not operate unit with spring brakes caged or brakesdisabled. Block wheels if unhooked.

10. Stay away from overhead power lines when moving boom toprevent electrocution.

11. Raise boom only when trailer is on firm, level ground andevenly loaded.

12. Do not unhook trailer if it is loaded.13. Do not load trailer unless it is attached to a towing unit.14. Review safety items with all personnel annually.

ROTATING AUGER HAZARDKEEP AWAY

B

DANGER

To prevent serious injury or death fromrotating auger:1. Place all controls in neutral, stop

engine, set park brake, remove ignitionkey and wait for all moving parts tostop before servicing, repairing,adjusting or unplugging.

2. Do not operate with the auger guardsremoved.

3. Do not stand near augers when operat-ing. Keep others away.

CAUTION

53-17705-653-17706-6

G

B

E

G

D

G

B

B

G

G

G

EA

F

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The types of safety signs and locations on the equipment are shown in the illustration below. Good safetyrequires that you familiarize yourself with the various safety signs, the type of warning and the area, orparticular function related to that area, that requires your SAFETY AWARENESS.

• Think SAFETY! Work SAFELY!

REMEMBER - If safety signs have been damaged, removed, become illegible or parts replaced withoutsigns, new signs must be applied. New signs are available from your authorized dealer or factory direct.

C

DANGERGUARD MISSING

When this is visible

DO NOT OPERATEENTANGLEMENT HAZARD

can cause Serious Injury or Death53-17704-6

G

C

F

B

G

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The types of safety signs and locations on the equipment are shown in the illustration below. Good safetyrequires that you familiarize yourself with the various safety signs, the type of warning and the area, orparticular function related to that area, that requires your SAFETY AWARENESS.

• Think SAFETY! Work SAFELY!

REMEMBER - If safety signs have been damaged, removed, become illegible or parts replaced withoutsigns, new signs must be applied. New signs are available from your authorized dealer or factory direct.

E

FALLING HAZARDTo prevent serious injury or death fromfalling:1. Use care when climbing ladder or

working on platform.2. Keep unauthorized people off machine.3. Do not allow riders.

ROTATING PART HAZARDKEEP AWAY

D

To prevent serious injury or death fromrotating parts:1. Place all controls in neutral, stop

engine, set park brake, remove ignitionkey and wait for all moving parts tostop before servicing, repairing,adjusting or unplugging.

2. Close and secure guards beforeoperating.

3. Keep hands, feet, hair, and clothingaway from moving parts.

WARNING

53-17702-6

53-17703-6

WARNING

A A

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The types of safety signs and locations on the equipment are shown in the illustration below. Good safetyrequires that you familiarize yourself with the various safety signs, the type of warning and the area, orparticular function related to that area, that requires your SAFETY AWARENESS.

• Think SAFETY! Work SAFELY!

REMEMBER - If safety signs have been damaged, removed, become illegible or parts replaced withoutsigns, new signs must be applied. New signs are available from your authorized dealer or factory direct.

F

DANGERELECTROCUTION HAZARDTo prevent serious injury or death fromelectrocution:• Stay away from power lines when

transporting and raising or loweringboom.

• Electrocution can occur withoutcontacting power lines.

53-17701-6

G

B

G

F

G

A

EGF B

G

G

G

B

D

B

E

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The types of safety signs and locations on the equipment are shown in the illustration below. Good safetyrequires that you familiarize yourself with the various safety signs, the type of warning and the area, orparticular function related to that area, that requires your SAFETY AWARENESS.

• Think SAFETY! Work SAFELY!

REMEMBER - If safety signs have been damaged, removed, become illegible or parts replaced withoutsigns, new signs must be applied. New signs are available from your authorized dealer or factory direct.

G

WARNING

To prevent serious injury or death:• Relieve pressure on hydraulic system before

servicing or disconnecting hoses.• Wear proper hand and eye protection when

searching for leaks. Use wood or cardboardinstead of hands.

• Keep all components in good repair.

HIGH-PRESSURE FLUID HAZARD

53-15638-6

AA

G

F

G

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4 OPERATION GUIDELINES

OPERATING SAFETY1. Read and understand all the Operator’s

Manual and all safety signs before operatingor adjusting the Walinga Bulk Feed unit.

2. Perform circle check before driving.

3. Do not allow riders outside the cab duringroad or highway travel.

4. Drive very carefully when negotiating hilly oruneven terrain.

5. Keep hands, feet, clothing and hair awayfrom all moving parts.

6. Place all controls in neutral, disengage PTOclutch, stop the engine, set park brake,remove ignition key and wait for all movingparts to stop before servicing, adjusting,repairing or maintaining.

7. Stay away from power lines when movingboom or climbing on top of the trailer. Elec-trocution can occur without direct contact.

8. Do not open access doors to airlocks, troughchain or augers while the air system or augerare running.

9. Use care when climbing on ladder(s) and/orplatform(s) to prevent falling.

10. Maintain running gear in good condition at alltimes. In addition, on trailers, maintain kingpin and fifth wheel assembly in good condi-tion.

11. Clear the area of all bystanders, especiallychildren, before starting up and operating theunit.

12. Make sure that all lights and reflectors thatare required by the local highways andtransport authorities are in place, clean andcan be seen clearly by all overtaking andoncoming traffic.

13. Do not operate unit with spring brakes cagedor brakes disabled. Block wheels ifunhooked.

14. Before disconnecting the tractor from thetrailer unit(s) make sure that the tractor andtrailer are on level ground and that the trailerwheels are securely blocked. Lower landinggear and provide extra support if the groundis soft. Deflate air ride if so equipped prior touncoupling.

15. Do not unload unless vehicle is on a firmlevel surface.

16. Review safety items with all personnelannually.

4.1 TO THE NEW OPERATOR OR OWNER

The Walinga Bulk Feed units combine light weightconstruction methods combined with high strengthmaterials to become a safe, reliable and efficientfeed or grain hauling unit. Be sure to familiarizeyourself with the unit by reading this Operator'sManual, the Safety Alerts and any other materialprovided with the unit before attempting to operateit. With careful use and a good maintenanceschedule, the unit will give many years of trouble-free use.

It is the responsibility of the owner and opera-tor to be familiar with the weight and loadingof your trailer. Trailer weight and loadingrequirements vary from jurisdiction to jurisdic-tion. Be familiar with yours and any that youwill be travelling through.

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4.2 TERMINOLOGY

The Walinga Bulk Feed unit is available as a semi-trailer or a straight frame truck. High strengthaluminium is used for the tank and structuralcomponents to minimize weight and maximizepayload.

Augers are used at the bottom of the tank, in thevertical tube and boom to unload. All augers andpaddle chain are powered by a hydraulic motor toprovide maximum unloading efficiency. The boomrotates and raises to allow unloading into a varietyof customer feed storage facilities.

22

Sliding gates control the flow of material to thetank unloading auger. The controls for all sys-tems are located in the box on the left rear corner.Each truck or tractor section must be equippedwith a hydraulic power pack to provide oil flow tothe hydraulic motors and cylinders.

Fig. 4-1 PRINCIPAL SYSTEMS

A TankB BoomC Vertical AugerD Trough AugerE Boom Rotation DriveF Boom Lift CylinderG Control BoxH Remote Control (Optional)

A

B

F

C

E

DG

A

B F

C

EG

D

A

B

G

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4.3 BREAK-IN

23

Break-in is the most important time in a Truck or aTrailer's life. It is critical that the unit be checkedfrequently during the first 5000 miles to be surethat all components and systems are properlyadjusted and performing as required.

The following inspection schedule is provided as aguide for normal operating conditions. Morefrequent inspections are recommended in severeor extreme conditions.

Inspect at:50-100 miles, 1-2 hours500 miles, 8-10 hours1500 miles, 25-30 hours5000 miles, 100 hours:

1. BrakesIt takes a few weeks of operation for the brakeshoes to mate with the drum contour andburnish the surface. During this period oftime, the operator should check the brakesevery day. After the first month, inspection ofthe brakes every 2 weeks or every 10,000miles is required. Check the function andadjustment of the brakes on each axle. Allbrakes should apply evenly. No shoes shoulddrag on the drum when the brakes are notapplied.

2. TiresTires are designed to provide maximum lifeand performance when maintained at theirspecified inflation pressure. Although the tiresare inflated to their specified pressure at thefactory, the pressure can change before goinginto service. Always use an accurate gauge tocheck the pressure when the tire is cold.

3. Wheels/RimsAlthough lug bolts and rim fasteners arealways tightened to their specified torque atthe factory, it is normal for them to lose someof their torque during the first few miles ofoperation. Always retorque lug bolts and rimfasteners to be sure that they stay tight. Thengo to the retorquing interval defined in theMaintenance section of every 25,000 miles.Keep all fasteners tightened to their specifiedtorque to prevent damaging any components.

Whenever a wheel is removed from an axle,the above retorquing procedure must befollowed to be sure that the wheel is securedto the axle. If any component is damaged dueto loose fasteners, it will have to be replaced.

4. AxlesEach wheel bearing is assembled at thefactory with the required end play (refer toSection 8.5). This end play should bechecked to insure proper axle and bearingfunction. Check the temperature of the hub byhand after 10 to 15 miles (15 to 25 km) duringthe first trip. A hot hub must have the bearingend play reset before continuing.

Jack the axle up and support it on a stand.Turn the wheel by hand. The wheel shouldturn freely. If it does not, check if the brakesare dragging or if the bearing has too muchend play. If either of these conditions exist,correct before proceeding.

Move the wheel laterally on the axle shaft. Ifthe wheel wobbles, the bearing has lost itsend play. Tighten bearing and set end playbefore continuing.

5. Hub Lubricant Levelsa. Oil Bath:

Oil bath hubs are used on some trailersand are filled at the factory. Check hubsfrequently (at least daily) during the firstfew weeks of operation. Always checkwhen the oil is cold and the trailer is on thelevel. Use the level mark on the hub facewhen checking oil level. Replace sealsand gaskets if hub has an oil leak. Do notoperate without oil in the hub.

b. Grease Packed:Grease packed hubs are used on sometrailers and do not require servicing unlessthe wheel end is being serviced or re-moved.

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4.3 BREAK-IN (cont'd)

24

6. SuspensionA suspension system connects the axles tothe frame. All fasteners must be maintainedat their specified torque to ensure that allclamping and anchoring forces remain intact.If these forces are not maintained, compo-nents can shift or move and affect the per-formance and component life. Refer toMaintenance Section for the list of requiredtorque values for all fasteners in suspensionsystem. Any loosening can lead to componentshifting, misalignment and/or twisting. Any ofthese items can cause erratic handling,broken components or rapid tire wear. Alwaystighten the nut end of fastener. Specifiedtorque values apply only to nut end torquing.

7. Axle AlignmentAxle alignment is properly set at the factorywhen the unit is new and will remain alignedunless fasteners loosen or components wear.Use a steel measuring tape to check thealignment. Refer to Maintenance Section foralignment checking procedure. Axles that areout of alignment can cause erratic handlingcharacteristics, broken components andaccelerated tire wear.

8. Fifth Wheel Assembly ComponentsThe king pin, anchor frame and upper andlower fifth wheel assemblies must be in-spected to check for mechanical integrity of allcomponents. All components and systemsmust be kept in good condition to safely andreliably transmit the accelerating, braking andside loads between the trailer, fifth wheel andtowing vehicle.

a. King Pin:Check the king pin for cracks, chips, orwhether it is bent. Check that there are nocracks or distortions between the king pinand its anchor frame. If any defects arefound, replace the king pin and its anchorframe before resuming work.

b. Fifth Wheel Assembly:

The fifth wheel assembly consists of theking pin locking mechanism, surface plate,frame, pivot and anchor system. Checkthat the king pin locking mechanism locksand unlocks easily and that all movingsurfaces are coated with grease. Checkthat the surface plate is free of grit andcoated with grease.

Check the surface plate and anchor framefor cracks, bends or distortions. Replaceany damaged components. Retorquefasteners to maintain the proper clampingforces on all components. Loose fasten-ers can cause components to move orbend and create mechanical or safetyproblems during operation.

9. Electrical, Hydraulic and Air LinesElectrical, hydraulic and air lines extend fromthe front of the unit to each electrical, hydraulicand air operated component. Although theyare all anchored along their routing pathwaysfrom the factory, they occasionally do comeloose and will sag. Inspect all lines. Useplastic ties to secure line to frame if any areloose and sag. Replace if any are pinched,kinked, cut or abraded. Extra care should betaken in cold or extreme operating conditions.Ice, mud or brush can pull lines loose fromtheir anchors and cause damage. Cleancomponents, repair damage, re-anchor andinstall protectors if appropriate. Do notoperate with damaged components.

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4.4 PRE-OPERATION VEHICLE INSPECTION PROCEDURE - FOR TRAILERS

The safe and trouble-free use of a Walinga BulkFeed Unit requires the operator to maintain theunit in good operating condition. To assist theoperator, a pre-operation checklist is provided thatshould be followed each time before the unit isused.

NOTE

The tractor items, part of theDepartment of Transport(D.O.T.) walk around sequence,have been omitted.

WALK AROUND SEQUENCE

Step 1 - Trailer Frontal Area

1. Air, Hydraulic and Electrical Connectionsa. Glad hands properly mounted, free of

damage, not leaking and not worn.b. Electrical line receptacle properly

mounted, free of damage, plug adequatelyseated and safety catch engaged toprevent accidental disconnection.

c. Hydraulic couplers properly seated andtightened, no leaks and properly securedagainst tangling, snagging and chafing,with sufficient slack for turning.

d. Air, electrical and hydraulic lines properlysecured against tangling, snagging andchafing with sufficient slack for turns.

2. Lights and Reflectorsa. Front trailer clearance and identification

lights - should be clean, operating andproper color.

b. Reflectors and conspicuity tape clean andproper color.

Step 2 - Coupling System Area

1. Fifth Wheel (Lower)a. Securely mounted to frame.b. No missing or damaged parts.c. No visible space between upper and lower

fifth wheel.d. Locking jaws around the shank and not

the head of kingpin.e. Release lever properly seated and safety

latch lock engaged.

2. Fifth Wheel (Upper)a. Kingpin not worn, bent or damaged.b. Anchor frame not cracked, bent, worn or

damaged.

3. Air, Hydraulic and Electric Lines VisibleFrom This Pointa. Should be secure from dangling, snagging

and chafing.b. Should be free from damage and clean.

Fig. 4-2 WALKAROUND SEQUENCE

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4.4 PRE-OPERATION VEHICLE INSPECTION PROCEDURE - FOR TRAILERS (cont'd)

Step 3 - Right Side of Trailer Area

1. Front Trailer Support (Landing Gear)a. Fully raised, no missing parts, not bent or

otherwise damaged.b. Crank handle secured.

2. Spare Tiresa. Carrier or rack not damaged.b. Tire and/or wheel securely mounted in the

rack.c. Tire and wheel condition adequate.

Proper spare tire size, correctly inflated.

3. Lights and Reflectorsa. Trailer side clearance lights clean, operat-

ing and proper color.b. Reflectors and conspicuity tape clean and

proper color.

4. Frame and Bodya. Frame and cross members not bent,

cracked, damaged or missing.b. Body parts not damaged or missing.

5. Air Tanka. Drain moisture from air tank(s). Pull on

cable attached to drain valve. Hold cableuntil the tank moisture is drained.

Fig. 4-3 WALKAROUND SEQUENCE

NOTE

In cold weather, it is best todrain the moisture from thetanks at the end of the day toprevent ice build-up in the tanks.

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Step 4 - Right Rear Trailer Wheel Area

1. Dual Wheelsa. Condition of wheels and rims, no cracked

or bent rims, broken spacers, studs,clamps or lugs.

b. Condition of tires - properly inflated, valvestems not touching wheel rims or brakedrums, valve caps in place, no seriouscuts, bulges, tread wear or any signs ofmisalignment and no debris stuck be-tween the tires.

c. Tires all same type e.g. do not mix radialand bias types on the same axles.

d. Wheel bearings and hub - no obviousleaking.

e. Mud flaps in place and in good condition.

2. Tandem or Triaxlesa. Repeat wheel and tire inspection as

above.b. Flexible air lines not cracked, cut, crim-

pled or otherwise damaged, securedagainst tangling, dragging or chafing.

c. Sliding axle anchor pins locked in place.

3. Suspensiona. Mechanical:

Condition of spring(s), spring hangers,equalizers and U-bolts.

b. Air:Condition of air bag(s), axle clampingbolts, pivot arm and height control valve.

c. Check that air suspension is inflated andat proper ride height.

Step 5 - Brakes

27

2. Check Unloading SystemsCheck that access doors are closed andsecured, compartment gate crank is stowedand secured, the boom is in its transportcradle, tank covers are closed, control boxdoor closed and secured, and all guards inplace and secured.

1. Brakesa. Condition of brake drum(s).b. Condition of hoses, lines and valves.c. Check slack adjusters.d. Check air chamber mounting.e. Check spring brakes (if so equipped).f. Drain moisture from air tank with cable.

Step 6 - Rear of Trailer

1. Lights and Reflectorsa. Rear clearance and identification lights,

clean and operating and proper color.b. Reflectors and conspicuity tape clean and

proper color.c. Tail-lights clean, operating and proper

color.

Step 7 - Left Rear Trailer Wheel Area

Check all items as done on right side (Step 4"Right Rear Trailer Wheel Area").

Step 8 - Left Side of Trailer Area

1. Check all items as done on right side (Step 3"Right Side of Trailer Area").

2. Tank Gate Systema. Check that tank slide gates are down and

secured with retainer.b. Check that tank gate crank is stowed and

secured.

Step 9 - Trailer Functional Check (Tractor Attached)

1. Check for proper connection of the air brakeglad-hands, hydraulic system couplers andsecure contact of electrical connection.

2. Start engine.3. Build up air pressure in the tractor-trailer

systems.4. Turn on lights and inspect for proper function

of:a. Clearance lights.b. Identification lights.c. Turn signals and 4-way flasher.d. Sidemarker lights.e. Tail lights.f. Stop lights.

5. Check the function of brakes.a. Apply service brakes.b. Apply parking/emergency brakes.c. Stop engine.

i. Release trailer emergency brakes.ii. Apply service brakes

Air loss should not exceed3 psi per minute on single vehicles.4 psi per minute on combination.

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4.5 HOOKING UP/UNHOOKING TRAILER

King Pin

Fifth Wheel

Fig. 4-4 COUPLING COMPONENTS

28

Special care should be taken whenhooking up or unhooking trailer to besure the equipment is in good conditionand all systems are functioning asrequired.

4.5.1 HOOKING UP

Follow this procedure when hooking upthe trailer to tractor:

1. Back the tractor up in a straight lineto the trailer and align the fifth wheelopening with the trailer king pin.

2. Stop before the fifth wheel makescontact with the trailer and apply thetowing vehicle parking brake.

3. Inspect all the coupling componentsbefore hooking up:a. Inspect trailer coupling compo-

nents. Check that king pin isnot broken, bent or chipped.Check that the anchor frame isnot distorted or cracked. Ifproblems found, correct beforeproceeding.

b. Inspect fifth wheel couplingcomponents. Check that thefifth wheel assembly is securelyanchored to the tractor frame.Check that the structure of theframe, pivot and fifth wheel isnot bent, broken or cracked.Check that the jaws of the lockare open. If problems found,correct before proceeding.

c. Be sure that the fifth wheel plate iscleaned and greased.

4. Check that the trailer is at the required heightto slide onto the fifth wheel.a. Use the crank on the landing gear to raise

or lower the trailer as required.

The trailer frame should contact the fifth wheeljust behind the pivot point as the tractor backsunder the trailer.

5. Connect brake and electrical lines. Route thelines so they do not get pinched.

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6. Back slowly under trailer keeping theking pin centered in the fifth wheeljaws.

7. Back up until the fifth wheel couplerlocks on the trailer king pin.

8. Move the towing vehicle forwardsharply while the trailer brakes areengaged to check that the jaws havelocked around the king pin.

9. Set tractor parking brake, stopengine and dismount.

10. Visually check that the coupler jawsare securely locked around the kingpin and the coupler release lever is inthe locked position. Release andhook up again if the jaws are notsecurely locked around the king pin.

11. Check that the trailer frame is restingon the fifth wheel.

12. Check brake application by applyingand releasing brakes. If brakes donot release, air lines may becrossed. Do not continue unlessbrakes are functioning properly.

13. Connect and secure the pressureand return hydraulic lines. Starthydraulic pump and check that thereare no leaks.

5th Wheel

Lock

Fig. 4-5 COUPLER LOCKS

29

14. Check that all electrical circuits are completedand that all lights are working.

15. Route the electrical, hydraulic and air lines toprevent snagging, dragging and pinching.

16. Raise the landing gear. Use the crank to raisethe legs. Place drive gear in low ratio andstow crank.

17. Check that the air ride bags are inflated toproper height.

18. Remove blocks or chocks from the wheels.

19. Perform Pre-Operation Inspection beforestarting.

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4.5.2 UNHOOKING TRAILER

1. Position tractor and trailer in astraight line on a clear, level andfirm surface.

2. Apply the trailer brakes and theparking brakes on the tractorbefore dismounting.

3. Place blocks or chocks in front ofand behind trailer wheels if not ona level surface.

4. Check that the surface under thelanding pads can support thetrailer. Support with blocks orplanks if required. This is particu-larly important if the trailer isloaded or will be loaded whileunhooked.

5. Deflate air suspension system.

30

6. Lower landing gear. Use crank tolower leg on landing gear. Lowerleg until pads solidly contact theground but do not lift trailer offfifth wheel. Stow crank.

7. Unhook fifth wheel coupler.

8. Disconnect air and hydraulic linesand electrical connector.

9. Release tractor parking brakeand pull slowly forward until thetrailer frame just slides down thefifth wheel ramp. Stop.

10. Set the parking brake on thetractor before dismounting.

11. Disconnect air and hydraulic linesand electrical connector.

12. Install glad hands on dead endconnectors if so equipped.

13. Drive tractor away from trailer.

Fig. 4-7 UNHOOKED

Fig. 4-6 LANDING GEAR

14. Drain air tanks if operating in cold tempera-tures to eliminate ice build-up.

15. Inspect the equipment. Document problemsfound so they can be corrected before the unitwill be used the next time. Record problemsand repairs for your files.

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4.6 CONTROLS

31

Before starting to work, alloperators should familiarizethemselves with the location andfunction of all controls. Eachunit is controlled by the controlsin the box on the left rear cornerof the machine.

1. Control Box (Inside):a. Flow Divider:

An automatic or manualflow divider sets theamount of oil flowing tothe trough auger. Theautomatic systemmaintains the pressurein the vertical and boomdrive system between1500 and 2000 psi(10245 and 13660 kPa).Use the manual flowdivider to obtain thesame pressure range.

b. Air Dump Valve:This 2 position valve islocated in the dump linefor the air suspensionair system. Move thehandle toward the backof the unit to close thedump line. The valvemust be in this positionto re-inflate the airsuspension. Move thehandle at right angles tothe truck to dump the airfrom the suspension.

Trailer

e. Boom Lift:This spring-loaded-to-neutral-centre levercontrols the position of the boom height. Pulland hold the lever to raise the boom. Re-lease the lever and it will return to its centredneutral position to stop the boom lift. Pushon the lever and hold to lower the boom.Release the lever to stop its motion.

f. Boom Rotation:This spring-loaded-to-neutral-centre levercontrols the direction of the boom rotation.Push on the lever and hold to swing theboom to the right (clockwise). Release thelever and it will return to its centred neutralposition to stop the boom rotation. Pull onlever and hold to swing the boom to the left(counter-clockwise).

TruckFig. 4-8 CONTROL BOX (INSIDE)

c. Boom Movement Speed:This flow control valve controls the amount ofoil flowing to the boom lift and boom rotatecircuits. Turn the knob clockwise (in) to closethe valve and slow the speed and counter-clockwise (out) to increase the speed.

d. Trough Conveyor Pressure Gauge:This pressure gauge monitors and shows thepressure in the trough conveyor drive system.Normally this system should operate between1000 to 1800 psi (6830 to 12294 kPa) whenthe machine is equipped with the boom/troughoptional compensating valve. When equippedwith the standard manual flow adjuster, setthe adjuster to operate the trough auger in thisrange.

a

d

e f

b

a

c

d

e f

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4.6 CONTROLS (cont'd)

1. Control Box (cont'd):g. Trough Auger:

This 2 positionhydraulic valvecontrols the flow ofoil to the troughauger drive motor.Pull the leverforward to direct theflow of oil to themotor and run thetrough auger. Pushthe lever back tostop the flow of oiland stop the troughauger.

An optional 3position valve isavailable wherepushing the leverwill reverse theauger and is usefulto assist in unplug-ging.

h. Rear Light:This toggle switchcontrols the powerto the working lightson the back of themachine. Move theswitch up to turnthe lights ON anddown for OFF.

i. Spotlight:

TruckFig. 4-9 CONTROL BOX (INSIDE)

Trailer

This 3 position hydraulic valve controls theflow and direction of flow to the verticaland boom auger drive systems. Pull thelever forward to run the augers for unload-ing. Place the lever in its centred positionto stop the augers. Push the lever into itsrearmost position to run the augers in theirreverse direction. It is recommended thatthe boom and vertical augers be run onlymomentarily in the reverse direction asthis position is provided to assist in un-plugging either auger as required.

n. Manual Flow Control:This manual flow control valve controls the

This toggle switch controls the power to thelight illuminating the end of the boom. Movethe switch up to turn the lights ON and downfor OFF.

k. Pressure Gauge:This pressure gauge monitors and shows thepressure in the vertical and boom auger drivesystems. Normally this system can operatebetween 1500 to 2000 psi (10245 to 13660kPa) when fully loaded during unloading andthe unit is equipped with the boom/troughoptional compensating valve. When equippedwith the standard manual flow adjuster and onthe floor auger, set the adjuster to operate theboom auger drive system in this range. Theamount of material fed by the floor augercontrols the pressure in the boom and verticalauger drive system.

m. Vertical and Boom Auger:

k

h i

gm

d

k

g m

i

32

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Fig. 4-10 MANUAL FLOW CONTROL

Truck

Fig. 4-11 CONTROL BOX (OUTSIDE)

2. Control Box (Outside):a. Roof Cover Position (Front):

This 2 position toggle switch con-trols the flow of air and direction ofair to the cylinders that set theposition of the cover over the fronttank. Move switch to its fully upposition to close the front tankcover. Move the switch completelydown to open the cover over thefront tanks.

b. Roof Cover Position (Rear):This 2 position toggle switch con-trols the flow of air and direction ofair to the cylinders that set theposition of the cover over the reartank. Move switch to its fully upposition to close the rear tank cover.Move the switch completely down toopen the cover over the rear tanks.

Trailer

amount of oil flowing to the troughconveyor drive system to set thedischarge speed. Set the pointerbetween 0 and 10 on the scale toadjust the speed ratio between 0and 100% of the available speed.Use the divider to set the verticaland boom auger drive circuitpressure at 1500 to 2000 psi(10245 to 13660 kPa) duringoperation.

a b

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3. Tank Gate Position:A. Manual

This square shaftcontrols the position ofthe gates over thetrough conveyor in thebottom of each tanksection. Use the crankprovided with each unitto turn the shaft clock-wise to open the gatesand counter-clockwiseto close. Always closethe gate(s) beforeloading the tank(s).

a. Open

b. Close

4.6 CONTROLS (cont'd)

Fig. 4-12 TANK GATE

Crank - Manual

Machine is shown with guardremoved or access dooropened for illustrative pur-poses only. Do not operatemachine with guard removedor access door opened.

WARNING

B. AirThis two position toggleswitch controls thepower to the valve thatdirects the air to thecylinder inside the gatetower. Move the switchup to open the gate anddown to close.

a. Open

b. Close

Switch - Air

Manual AirTower Opened

b

a

ab

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4. Cab Controls:Each tractor section or power unit must beequipped with an auxiliary hydraulic system toprovide pressurized oil to operate the machine.The hydraulic pump is powered through thePTO drive with the control box located in thedoorway to the left of the driver. The control forthe pump PTO will be labelled.

Pull the yellow collar up and move the red knobforward to engage the PTO and drive thehydraulic pump. Push down to disconnect thedrive and stop the pump. Most systems are not"live" and cannot be engaged and disengagedwithout depressing the clutch.

Fig. 4-13 PTO CONTROLS

a. ON/OFF Switch:This 2 position toggleswitch turns thepower on to the handheld radio transmit-ter. Move the switchto the left (toward theaerial) to turn OFFand to the right toturn ON.

b. Emergency Stop:This red buttonswitch is the emer-gency STOP controlfor the controllerfunctions. Depressthe button switch tostop all boom motion(lift and rotation).Turn the powerswitch OFF and thenON to re-activate thecontrol box prior tousing the controlleragain.

ReceiverTransmitterFig. 4-14 REMOTE CONTROL (OPTIONAL)

5. Remote Control (Optional):

NOTEPut truck in gear first to stop transmissionclash when engaging PTO. Then shift trans-mission to neutral again when PTO engaged.

c. Boom Rotation:This 3 position spring-loaded-to-centreneutral switch controls the boom rotationfunction. Move the switch to the left andhold to move the boom out (counter-clock-wise). Release the switch and it will returnto its centred neutral (OFF) position to stopthe boom rotation. Move the switch to theright and hold to swing the boom in (clock-wise). Release the switch to stop themotion.

d. Boom Lift:This 3 position spring-loaded-to-centreneutral switch controls the boom lift function.Move the switch up and hold to raise theboom. Release the switch and it will return toits centred neutral position to stop the motionof the boom. Move the switch down and holdto lower the boom. Release the switch tostop the boom motion.

b a

c

d

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Each Bulk Feed unit must be properly placed prior tounloading to obtain the optimum performance. Whenpositioning the machine, follow this procedure:

4.7 MACHINE PLACEMENT

1. Clear the area of bystanders,especially small children, beforemoving the machine into position.

2. Inspect the parking or unloadingposition to be sure the surface isfirm and level.

3. Drive the unit into its approximateunloading position with the tractorand trailer in a straight line andstop.

4. Do not position the unit on asurface that is not level or is sosoft that one set of wheels cansink while the boom is rotating orthe tanks are being unloaded.Boom rotation will shift the loadon the axles when it is at 90° tothe frame and can cause tipping ifthe suspension system flexes andone axle sinks into the ground.

DANGERELECTROCUTION HAZARDTo prevent serious injury or death fromelectrocution:• Stay away from power lines when

transporting and raising or loweringboom.

• Electrocution can occur withoutcontacting power lines.

Fig. 4-16 TRANSPORT CRADLE

Fig. 4-15 PLACEMENT

Correct Incorrect

IMPORTANT

Be sure the unit is on levelground during positioning orunloading to prevent tipping.

5. Do not position the unit where the boomwill be closer than 30 feet (10 m) tooverhead power lines when swinging theboom into position or unloading.

6. Set the parking brakes.

7. Deflate air suspension if so equipped.

8. Depress clutch and engage PTO drivingthe auxiliary hydraulic system.

9. Run the engine at 1000RPM to provide oil toposition the boom.

10. Dismount and opencontrol box door.

11. Raise the boom out ofits transport cradle.

12. Stay away from over-head power lines.

Correct Incorrect

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13. Slowly swing the boom around to the requiredposition.

Forward

Fig. 4-17 BOOM ROTATIONSide

Fig. 4-18 SUPPLY HOSES

14. Swing the boom to the left or the right asrequired for unloading, but watch thelocation of the boom drive hydraulichoses. Do not pull the supply hoses tightwhen positioning the boom. If thisoccurs, swing the boom around the otherdirection or reverse the direction of theunit to keep the hoses slack.

IMPORTANT

It is recommended that the boombe positioned to the left side of theunit or behind it for unloading toeliminate tight hydraulic hoses.Drive in from the opposite direc-tion if required.

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15. Swing the boom around and position theboom discharge over the feed storagefacility.

NOTE

It may be necessary to move theunit to centre the discharge inthe opening.

Fig. 4-19 BOOM

16. Leave the boom a small distanceabove the storage structure. Do notrest the boom on the storage structure.Boom sag while unloading coulddamage the structure.

17. Then proceed to section 4.8 Operationfor unloading procedure.

18. Reverse the above procedure whenunloading is finished and stowing theboom prior to transport.

Fig. 4-20 POSITIONED

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4.8 OPERATION

OPERATING SAFETY1. Read and understand all the Operator’s

Manual and all safety signs before operatingor adjusting the Walinga Bulk Feed unit.

2. Perform circle check before driving.

3. Do not allow riders outside the cab duringroad or highway travel.

4. Drive very carefully when negotiating hilly oruneven terrain.

5. Keep hands, feet, clothing and hair awayfrom all moving parts.

6. Place all controls in neutral, disengage PTOclutch, stop the engine, set park brake,remove ignition key and wait for all movingparts to stop before servicing, adjusting,repairing or maintaining.

7. Stay away from power lines when movingboom or climbing on top of the trailer. Elec-trocution can occur without direct contact.

8. Do not open access doors to airlocks, troughchain or augers while the air system or augerare running.

9. Use care when climbing on ladder(s) and/orplatform(s) to prevent falling.

10. Maintain running gear in good condition atall times. In addition, on trailers, maintainking pin and fifth wheel assembly in goodcondition.

11. Clear the area of all bystanders, especiallychildren, before starting up and operatingthe unit.

12. Make sure that all lights and reflectors thatare required by the local highways andtransport authorities are in place, clean andcan be seen clearly by all overtaking andoncoming traffic.

13. Do not operate unit with spring brakescaged or brakes disabled. Block wheels ifunhooked.

14. Before disconnecting the tractor from thetrailer unit(s) make sure that the tractor andtrailer are on level ground and that the trailerwheels are securely blocked. Lower landinggear and provide extra support if the groundis soft. Deflate air ride if so equipped priorto uncoupling.

15. Do not unload unless vehicle is on a firmlevel surface.

16. Review safety items with all personnelannually.

Follow these operating procedures to obtainmaximum performance and long life:

1. Review and follow pre-operation inspectionand checklist before operating.

2. Review the location and function of all con-trols.

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3. Loading Unit:

a. Drive the unit underconveyor or loadingsystem.

b. Check that allcompartment gatesare closed andlocked.

4.8 OPERATION (cont'd)

Closed

Control

Fig. 4-21 SLIDING GATES

Fig. 4-22 TOP COVER (TYPICAL)

c. Raise optionalcollapsible railing ifso equipped.

d. Open top covers over tanks.

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e. Fill the tank compartment(s) withdesired material.

Fig. 4-23 FILLED COMPARTMENTS

f. Close and secure the top cover(s).

g. Lower collapsible railing if soequipped.

4. Transport to the unloading area.

5. Position the unit per Section 4.7. Stay awayfrom power lines and be sure the unit is onfirm level ground.

Fig. 4-24 COVERS CLOSED

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4.8 OPERATION (cont'd)

6. Starting:

a. Open control box door andplace all controls in neutral orOFF/STOP position.

b. Start engine, set engine at lowidle (1000 RPM or less),disengage clutch, engagetransmission, engage PTO(s),disengage transmission (placein neutral), engage clutch.The PTO driving the hydraulicsystem and the PTO drivingthe blower have now been set.

c. Set engine speed at 1050-

Truck

Trailer

Fig. 4-26 CONTROLS

Fig. 4-25 PTO CLUTCH1100 RPM toprovide sufficientoil flow to theauger drivemotors.

d. Use hydrauliccontrol lever tostart the verticaland boom augerdrive motors.

e. Start the troughconveyor drivemotor.

f. Set flow to starttrough conveyormovement ifequipped withmanually oper-ated flow divider.

NOTE

On systems equippedwith the flow compensa-tor, the compensator willautomatically set thespeed (drive systempressure) of the troughauger to produce aboom and vertical drivesystem pressure of 1500to 2000 psi (10245 to13660 to kPa) whichprovides maximumcapacity.

fe

d

e d

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g. Open required tank compartment slidinggate starting with rear compartment.

h. Use the manual flow control on the troughconveyor drive system to set the verticaland boom auger drive pressure at 1500 to2000 psi (10245 to 13660 kPa) to maxi-mize unloading capacity.

IMPORTANT

Do not try to empty more than onecompartment at a time while unload-ing. When more than one tank isopen during unloading, the materialcan over-load the trough conveyorand cause stalling or plugging.

Fig. 4-29 SIGHT GLASS

Fig. 4-28 CONTROLS

Trailer

Truck

NOTE

Watch pressure on boomand vertical drive systemgauge.

j. When the compartment is empty,open the sliding gate over the nextcompartment. Repeat with the nextcompartment until all are empty.

i. Increase the speed of thetrough conveyor until thematerial starts to back upin the sight glasses.Reduce conveyor speedslightly until material flowssmoothly.

Fig. 4-27 SLIDING GATE

h

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4.8 OPERATION (cont'd)

7. Stopping:

a. Turn trough conveyor OFFand set manual flowcontrol to 10.

44

Fig. 4-30 CONTROLS

Fig. 4-31 LOCKED GATES

Fig. 4-32 PTO CLUTCH

8. Emergency Stopping:If an emergency occurs thatrequires immediate machine shut-down, place all controls in thecontrol box in neutral/OFF to stopthe machine or disengage PTOclutch. Refer to Step 6 "Starting"and follow the procedure whenrestarting the machine. Remem-ber, the augers are all full ofmaterial and the start-up loads willbe higher than normal. Alwaysreturn all controls to OFF beforeengaging the PTO drive.

c. Close all compartmentgates and secure withsafety pins.

d. Reduce engine speed to low idle.

e. Depress master clutch anddisengage PTO clutch.

b. Turn vertical and boomaugers OFF.

IMPORTANT

When the flow control isset at 10, the circuitbypasses all the oil andthe trough conveyor isOFF.

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Pressure Gauge

Sight Glass

Fig. 4-33 MAXIMUM CAPACITY

9. Maximum Capacity:The optimum operating conditions occurwhen the unloading system is providingmaximum capacity. The system isdesigned so the vertical and boom augersare the limiting components. Set thesystem to obtain maximum capacity in thevertical and boom augers by:

a. Increase the speed of the troughconveyor with the manual flow controlin the control box until the vertical andboom drive system pressure runsbetween 1500 and 2000 psi (10245 to13660 kPa) and

b. The material is flowing smoothly andevenly across the sight glass.

a

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10. Unplugging:When the unit plugs, follow thisprocedure to unplug:

a. Place all controls in neutral/OFF.

b. Disengage PTO clutch, stopengine, remove ignition keyand wait for all moving partsto stop.

c. Remove ignition keys.

d. Close all the compartmentgates.

e. Open access cover on theback of the conveyor tube.

Fig. 4-34 ACCESS DOOR

ROTATING AUGER HAZARDKEEP AWAY

To prevent serious injury or death from rotatingauger:1. Place all controls in neutral, stop engine, set

park brake, remove ignition key and wait forall moving parts to stop before servicing,repairing, adjusting or unplugging.

2. Do not operate with the auger guards re-moved.

3. Do not stand near augers when operating.Keep others away.

DANGER

4.8 OPERATION (cont'd)

k. If the trough conveyor plugs:

• Disengage PTO, stop engine and waitfor all moving parts to stop.

• Open access door and clean out tubeand transition.

• Close and secure access door.• Close and secure gates at the bottom

of each compartment.• Start engine, engage PTO, run vertical

and boom augers and start troughconveyor.

• Open the desired compartment gateonly enough to provide material to thetrough conveyor for unloading but notenough to plug it.

f. Clean out the material from the back ofthe conveyor tube and the transitioncross-over cavity.

g. Close and secure access door.

h. Start engine, engage PTO driving hydrau-lic pump and start the vertical and boomaugers.

i. If the augers will not move, run them in thereverse direction momentarily to dislodgethe plug or jam. Then run again theforward direction.

NOTE

If the trough conveyor will not runin the forward direction afterreversing momentarily, it will benecessary to shut down and cleanthe material out of the transitionarea again before resumingoperation.

Machine is shown with guard removed oraccess door opened for illustrative purposesonly. Do not operate machine with guardremoved or access door opened.

WARNING

j. Start the trough conveyor to bring materialto the vertical and boom augers but run ata slower speed to reduce the pressure inthe boom/vertical drive system.

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11. Operating Suggestions:

a. Use only fully trained operators atall times. Review safety andoperating instructions annually.

b. Position the unit on a firm levelsurface to unload. Be sure thetractor and trailer are in a straightline for unloading to provide maxi-mum stability.

Fig. 4-35 POSITION

c. Empty the rear tank first when unloading.The empty tank will allow excess materialto fill in if required as other compartmentsempty.

d. Stay away frompower lines whenraising or swingingthe boom, raisingthe collapsiblerailing or climbingon the top platform.Electrocution canoccur without directcontact.

DANGERELECTROCUTION HAZARDTo prevent serious injury or death fromelectrocution:• Stay away from power lines when

transporting and raising or loweringboom.

• Electrocution can occur withoutcontacting power lines.

e. Extend boom on the left side of thevehicle for unloading to keep boom drivemotor hoses slack.

Fig. 4-36 LEFT SIDE

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11. Operating Suggestions (cont'd):f. Relief Valve:

The hydraulic circuit driving the boomrotation motor is equipped with across circuit relief valve to plumb oilto the opposite side of the circuitwhen the pressure exceeds a presetvalue. Should the boom strike anobstruction while rotating, the reliefwill open and stop the movement. Inaddition, if the truck is moving, thevalve will bypass the oil to allow theboom rotation motor to run back-wards and swing the boom out of theway.

4.8 OPERATION (cont'd)

Fig. 4-37 RELIEF VALVE

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4.9 TRANSPORTING

Although all operating and transporting instructionsare common sense, it is wise to review themperiodically to refresh your memory. Good opera-tional procedures result in a safe workplace for theoperator and others.

4.9.1 OPERATING INSTRUCTIONS

Since this equipment can be used in a variety ofconditions, it is difficult to give instructions appro-priate for all applications. However, these generalguidelines apply to all situations:

1. Be sure that the trailer is securely attached tothe towing vehicle and locked into position.

2. Be sure that the air, hydraulic and electricallines are securely connected and that theyhave sufficient slack for turns.

3. Be sure that the brakes are properly adjustedand in good working condition.

4. Be sure that the electrical harness is securely attached and all lights and reflectors are clean

and operating.

5. Maintain the mud flaps in good condition to minimize road splash in wet conditions.

6. Always maintain the truck and trailer in goodmechanical condition.

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4.9.2 BRAKING GUIDELINES

Safe, reliable and trouble-free operation of yourunit requires that the brakes be maintained ingood operating condition at all times and the driverfollows good application techniques when driving.The irresponsible use of brakes by the driver whentraveling can contribute to low brake life or result insystem malfunctions, short life and poor tire wearpatterns. The following list summarizes somebasic operational guidelines for the driver.

1. Check the function of the brake system at thestart of each day.

2. Maintain a safe vehicle speed at all times.Slow down for rough road or slippery surfaceconditions, winding roads or congested areas.

3. Always provide sufficient vehicle spacing onthe road to allow for a safe stopping distance.

4. Apply brakes gradually to produce an evendeceleration until the vehicle is stopped.

5. Watch traffic patterns ahead. Anticipatepattern changes that could result in an emer-gency. Apply the brakes gradually in sufficienttime to produce a controlled stop.

6. Shift to a lower gear to use engine compres-sion as the retarding force when going downsteep grades.

7. Do not apply brakes for a long period of timesuch as when traveling on a long downgrade.The brakes will overheat. Instead, apply boththe tractor and trailer brakes for short periodsof time and the brakes have a chance to coolbetween applications.

8. Dry the brakes by applying them several timesafter going through water.

9. Release the brakes just before going overrailroad tracks or other rough conditions. Byallowing the wheels to turn over rough roadsurfaces, there will be no shock loads to thebrake system components or produce flatspots on the tires.

10. Wet, icy or snow-packed surfaces require

special care. Make cautious, intermittentapplications by fanning or pumping the brakesto reduce speed without skidding or lockingthe wheels.

11. Use wheel chocks, apply trailer and tractorparking brakes and place tractor in low gearwhen parking the unit.

12. Maximum brake retarding occurs just beforethe wheels lock up and the tires skid. Releasethe brakes should you feel them lock-up andreapply them.

13. When trailer parking brakes are applied withhot drums, it may result in a cracked drum.Allow them to cool before reapplying thebrakes.

14. Fanning or repeated on-and-off applicationswill use up the system air reserves. Thisprocedure is not recommended unless ad-verse road conditions are encountered. Thewasting of air reserves in this way could resultin insufficient application pressure should anemergency arise.

15. Hard or panic stops can overheat the liningsand drums. Overheating will cause brakefade. Severe overheating and fade can resultin the complete loss of braking capability.This will substantially reduce the expected lifeof brakes.

4.9 TRANSPORTING (cont'd)

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4.9.3 TIRES

When operating the unit, it is the responsibility ofthe driver to check the tires frequently. Inflationpressures, wear patterns and matching are criticalparameters that must be monitored. The followingfactors affect tire care:

1. Inspection frequency: Tires should alwaysbe checked at the start of a day and twiceduring the day or every 4 operating hours,whichever comes first. It is also a goodpractice to check the tires at each rest periodduring the day. When a driver hears unusualnoise or experiences unusual handling char-acteristics, the first item to check is the tires.Problems found early, during frequent tirechecks, can save more serious problems lateron. A sampling of typical abnormal wearpatterns are shown in the Maintenance sectionalong with their causes. Always correct thecause of the tire wear problem beforeproceeding.

2. Inflation pressure: Tires should always beoperated at their specified pressures. At theirspecified pressures, the tire is designed to runwith the full width of the tread flat on thecontact surface. Operating at other thanspecified pressures will change the tread

contact patterns and can dramatically shortentire life. In addition, the tires will run hotter andcan lead to blow-outs.

Check tire pressure when the tire is cold. A hottire can read as much as 20 psi higher than acold tire. If tires are over-inflated, check forpoor load distribution, uneven surface contact,over-loading or poor operating conditions.

3. Tire matching: Do not mix ply types on thesame axle. Their operating characteristics aredifferent and will lead to uneven tire loading,rapid tire wear and adverse handling charac-teristics. Matching also includes combiningtires that have the same amount of treadremaining. A tire with more tread has a largerrolling radius and will have to carry a higherload. The best performance will be obtainedwhen the rolling radius is within 1/8" for alltires on an axle.

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4.10 OPTIONAL EQUIPMENT

The trailers can be equipped with severaloptions or attachments to adapt it tospecial customer requirements.

1. Several types of compartment coversare available. Select the style thatbest fits your application.

Air Opened

Canvas

Fig. 4-38 COVERS

Individual

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3. Suspension Systems:A variety of types and styles of runninggear is available for use on the trailerincluding air or mechanical suspensions.Select the type that best suits yourapplication.

Mechanical

Fig. 4-40 SUSPENSION TYPES

Air

2. Collapsible Railing:A collapsible railing is available for the topplatform and is raised and lowered with anair cylinder. Always lower it when trans-porting to bring the vehicle height withinlegal limits.

Fig. 4-39 COLLAPSIBLE RAILING

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5 SERVICE AND MAINTENANCEReview the manual provided with the truck forservice and maintenance information.

This section provides information on daily andperiodical service and maintenance of the Trailerunit. Follow these recommendations for safe anddependable operation of the Trailer unit. Refer tothe safety section at the front of the operator'smanual for all applicable safe maintenance andoperating procedures.

Be sure that all operators are familiar with theoperation and maintenance procedures andrelated safety information contained in the opera-tor's manual.

5.1 SERVICE

5.1.1 FLUIDS AND LUBRICANTS

1. Grease:Use an SAE multi-purpose lithium basedgrease with extreme pressure (EP) character-istics.

2. Wheel Hub Oil:a. Use an SAE 80W90 for normal tempera-

ture conditions (-10°F to 100°F ambients).

b. Use an SAE 85W140 for hot temperatureconditions (100°F and hotter ambients).

c. Use an SAE 30W motor oil for ambientsbelow -10°F.

Capacity: 1 pint (500 ml) approximately

3. Hydraulic Oil:Refer to 5.1.3 for Hydraulic Oil Specifications.

4. Storing Lubricants:Your unit can operate at top efficiency only ifclean lubricants are used. Use clean contain-ers to handle all lubricants. Store them in anarea protected from dust, moisture and othercontaminants.

5.1.2 GREASING

Refer to Section 5.1.1 for recommended grease.Use the Service Record checklist provided tokeep a record of all scheduled servicing.

1. It is recommended that a hand-held grease gunbe used for greasing. An air-powered greasingsystem can damage the seals on bearings andlead to early failure.

2. Wipe grease fitting with a clean cloth beforegreasing, to avoid injecting dirt and grit.

3. Replace and repair broken fittings immediately.

4. If fittings will not take grease, remove and cleanthoroughly. Also clean lubricant passageway.Replace fitting if necessary.

54

MAINTENANCE SAFETY

1. Read and understand all the information inthe Operator’s Manual regarding mainte-nance, adjusting and servicing the BulkFeed unit.

2. Place all controls in neutral, disengage PTOclutch, stop the engine, remove ignition keyand set the park brake before adjusting,servicing or maintaining any part of the BulkFeed unit.

3. Follow good shop practices:- Keep service area clean and dry.- Be sure electrical outlets and tools are

properly grounded.- Use adequate light for the job at hand.

4. Block wheels before de-activating brakes.

5. Maintain air system and brake componentsin top condition at all times.

6. Maintain fasteners in running gear systemsat their specified torque at all times.

7. Establish and maintain a Trailer Preventa-tive Maintenance (TPM) program on yourequipment. Some jurisdictions require thisprogram and the maintenance of records onevery commercial vehicle on the road forfuture reference.

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5.1 SERVICE (cont'd)

5.1.3 HYDRAULIC SYSTEM

1. Oil Specifications:

MaximumOperating

Temperature

82°C / 180°F

82°C / 180°F

Min. Start-up(No Load)

-16°C / 3°F

-16°C / 3°F

MinimumOperating

Temperature(Loaded)

-2°C / 28°F

-10°C / 14°F

a. All hydraulic systems will be filled withHydrex XV.

b. Check with dealer or factory for oil require-ments when using other oils or in othertemperature ranges.

2. System Operation:a. Be sure your oil specifications meet or

exceed the pump manufacturer require-

ments.

b. Do not exceed starting and operatingtemperatures as specified above.

c. When operating a unit and the oil tem-perature is over 180°F (82°C), the pumpsystem must be shut down, or run sloweruntil the system cools down.

d. If overheating persists, check the systemfor possible causes (see Section 10.7).

e. Hydraulic oil filter must be changed beforethe gauge needle is in red on 10 MICRONreturn filters.

f. Hydraulic oil should be checked regularly.(Testing of oil is recommended once ayear).

g. Always maintain a proper level in thehydraulic tank and keep oil clean.

h. Do not over speed the hydraulic pump, itcauses overheating of the hydraulic oil.(Run the engine as shown on RPM tag ondash).

i. Check vent filler cap and keep it clean.

PUMPMODEL

P197(PERMCO)

P3100 / P5000/DMD25-064(PERMCO)

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6 TRAILER SERVICING INTERVALS

56

A standard servicing schedule on yourtrailer unit is provided as a guide for yourconvenience. In unusual or extremeoperating conditions, increase thefrequency or perform additional serviceitems to customize this schedule to yourapplication.

Refer to the Service Section of the truckmanual for truck servicing information.

A. Servicing:8 Hours, Daily or 500 Miles

1. Drain moisture from air tanks(use cables to open drainvalves).

2. Check tire air pressure. Add asrequired.

Tank Drain

Valve

Fig. 6-1 DRAIN CABLE(S) (TYPICAL)

Fig. 6-2 TIRES (TYPICAL)

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Weekly, 10 Days or 5000 Miles

1. Grease slack adjusters(1 location each adjuster).

2. Grease camshaft bearings(1 location each camshaft).

Fig. 6-3 SLACK ADJUSTER (TYPICAL)

Fig. 6-4 CAMSHAFT BEARING

Do not overgrease.

IMPORTANT

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Weekly, 10 Days or 5000 Miles (cont'd)

Schematic

Hub

Fig. 6-5 HUB OIL LEVEL

3. Check wheel hub oil levels.

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4. Retorque the following fasteners:

b. Landing gear bolts.

1/2 in. 115 ft. lbs.5/8 in. 220 ft. lbs.

a. Brake/wheel endsystem fasteners.Refer to Section 8.8.

Fig. 6-7 LANDING GEAR MOUNTING BOLTS

Fig. 6-6 BRAKE/WHEEL END

Manual Bearing Adjustmenta. Tighten to 200 ft-lbs.b. Completely loosen.

c. Tighten to 50 ft-lbs.d. Loosen 1/4 turn

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Weekly, 10 Days or 5000 Miles (cont'd)

60

Table 1 Recommended Wheel Bolt Torque (Spoke Wheels)

Bolt Size

5/8" - 11

3/4" - 10

Do not over-torque fasteners.Over-torquing can stripthreads, collapse spacers orlead to other problems thatcause loose fasteners. Usean accurate torque wrenchwhen tightening fasteners.

IMPORTANT

Ft-lbs Torque (Dry)

150 - 175

210 - 260

Torquing Sequence

5 Spoke3 Spoke

Wheel (Typical)

Fig. 6-8 CAST WHEEL RIM NUTS

6 Spoke

c. Retorque cast spoke wheel rimnuts if so equipped.

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d. Retorque for stud pilotinner and outer wheelnuts if so equipped.

Table 2 Recommended Wheel Stud Torque (Disc Wheels)

Weekly, 10 Days or 5000 Miles(cont'd)

StudSize

3/4" - 16

1-1/8" - 16

15/16 - 12

1-5/16 - 12

WheelType

Disc

Disc

Disc

Disc

BudUnimount

10

WHD-8

Ft-lbsTorque(Dry)

450 - 500

450 - 500

750 - 900

750 - 900

390 - 440

400 - 600

e. Retorque hub pilotedwheel single nuts if soequipped.

Inner Schematic (Typical)

OuterFig. 6-9 10 STUD WHEEL NUTS

Fastener Schematic

Wheel

Fig. 6-10 SINGLE NUTS

Table 3 Recommended Wheel Stud Torque

Ft-lbsTorque(Oiled)

450 - 500

280 - 330

StudSize

M22 x 1.5(33 mm or 1-1/2 Hex)

M20 x 1.5(30 mm Hex)

Do not over-torque fasten-ers. Over-torquing canstrip threads, collapsespacers or lead to otherproblems that cause loosefasteners. Use an accu-rate torque wrench whentightening fasteners.

IMPORTANT

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62

Weekly, 10 Days or 5000 Miles (cont'd)

f. Retorque suspension system fasten-ers. (Refer to charts for torque levelsin Maintenance Section 8.1.

Air

Mechanical

Fig. 6-11 SUSPENSION SYSTEM U-BOLTS

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10,000 Miles (15,000 km) or Monthly

1. Grease landing gear bearings.

2. Retorque landing gear and suspension.

a. Landing gear.

b. Torque mechanical system suspen-sion (refer to Section 8.1).

Left Side

Fig. 6-12 LANDING GEAR

Right Side

Fig. 6-13 MECHANICAL SUSPENSION SYSTEM

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25,000 Miles (40,000 km), Quarterly or Every 3 Months

1. Check condition of wheel ends.Release brakes, jack up the axleand spin the wheel. Check:

a. Wheel bearings.b. Wobble.c. Rims and tires.d. Brake drag.

64

Fig. 6-14 WHEEL END

Fig. 6-16 ELECTRICAL (TYPICAL)

3. Inspect electrical systemcomponents for:

a. Binding.b. Rubbing/abrasion.c. Looseness/dangling.d. Cracks/tears in harness.e. Burned out lights.

2. Inspect frame andstructure for bends,distortions or cracks.

a. Kingpin.b. Fifth wheel and mounts.c. Longitudinal and

transverse frames.d. Compartment structure.e. Unloading system

structure.f. Suspension system

anchorage.g. Axles.h. Optional Accessories

i. Side Coversii. Top Covers Fig. 6-15 TRAILER (TYPICAL)

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4. Inspect air system andcomponents for:

a. Leakage by perform-ing leak-down test.

b. Rubbing/abrading.

c. Cracked hoses.

65

6. Check brake liningthickness. Replaceas required.

5. Clean gladhand screensif so equipped.

Fig. 6-17 AIR SYSTEM (TYPICAL)

Fig. 6-19 BRAKE LINING

Fig. 6-18 SCREENS

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100,000 Miles (150,000 km) or Annually

1. Reline brakes as required.

2. Change oil in hubs.

Fig. 6-20 BRAKES

66

Fig. 6-21 HUB OIL (TYPICAL)

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6.1 SERVICE RECORD SUMMARY (LUBRICATION)

67

LOCATION DESCRIPTION FREQUENCY LUBRICANT

Fifth wheel.Coat pivot pinsand lock

Landing gear

Wheels

Brakes

Camshaft bearing

Slack adjuster

Brake shoe anchorpin bushing

Also at brake reline.

Coat bearing surface.

Gearbox and screws.

Check oil level.

Bearings.

Change oil.

Lubricate

Lubricate

Lubricate

Chassis grease.*

Chassis grease.*

SAE 80W90 gear oil.

SAE 80W90 gear oil.

Chassis grease.*

Chassis grease.*

Chassis grease.*

Daily or as needed.

Periodic basis (weekly).

Weekly, 10 Days or 5000 m(8000 km)

25,000 miles (40,000 km).

100,000 miles (150,000 km).

5,000 miles (8,000 km)or monthly.

5,000 miles (8,000 km)or monthly.

30,000 miles (50,000 km) oryearly.

As appropriate.

* Use a good quality lithium based extreme pressure grease throughout. MIL-G-25013C in below -40°F.

NOTE: Do not use excessive lubricant.

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7 UNLOADING SYSTEM SERVICING

68

7.1 SERVICING INTERVALS

8 Hours, Daily or 500 Miles

1. Check condition of hydraulicsystem filter.

Fig. 7-1 HYDRAULIC SYSTEM FILTER

Fig. 7-3 TROUGH AUGER BEARINGS REAR

Weekly, 10 Days or 5000 Miles

1. Grease trough auger bearingsfront.

Fig. 7-2 TROUGH AUGER BEARINGS FRONT

Monthy or 10,000 Miles (15,000Km)

1. Grease trough auger bearingsrear.

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Monthy or 10,000 Miles (15,000Km) (cont'd)

2. Grease the verticalauger: top and bottom.

Fig. 7-4 VERTICAL AUGERBottom

Top

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3. Grease boom auger bearings:drive, driven and supportbearings, if so equipped.

Drive

Driven

Support

Fig. 7-5 BOOM AUGER BEARINGS

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4. Grease boom rotationcollar.

71

Monthy of 10,000 Miles (15,000 Km) (cont'd)

Fig. 7-6 BOOM ROTATION COLLAR

6. Grease or oil boom rotationdrive roller chain.

Fig. 7-8 ROTATION DRIVE ROLLER CHAIN

5. Grease boom lift collar.

Fig. 7-7 BOOM LIFT COLLAR

Lift boom out of saddleand rotate to left 270°while lubricating chainthen rotate back to right360°. When lubricatingchain ensure that com-plete chain gets lubri-cated. Rotate 360°.

IMPORTANT

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7. Grease the boom lift cylinderbushings (each end).

72

Fig. 7-11 SLIDING GATE SHAFTS

Fig. 7-10 BOOM ROTATION DRIVE SPROCKET

8. Grease the boom rotation drivesprocket shaft.

Fig. 7-9 LIFT CYLINDER BUSHINGS

9. Grease the tank sliding gateshafts.

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1. Change hydraulicsystem oil.

73

100,000 Miles (150,000 km) or Annually

Fig. 7-12 DRAIN PLUG

2. Change hydraulicsystem filter(s).

Fig. 7-13 FILTER

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74

7.2 SERVICE RECORD

See Lubrication and Maintenance sections for details of service. Copy this page to continue record.

ACTION CODE: L LUBRICATE C CHANGE š CHECK

HOURS

SERVICED BY

MAINTENANCE

š Hydraulic System Filter

Weekly, 10 Days or 5000 Miles

L Trough Auger Bearings front

L Vertical Auger - Top & Bottom

L Boom Auger Bearings

10,000 Miles or Monthly

L Boom Lift Collar

L Boom Rotation Dr. Roll Chain

L Tank Sliding Gate Shafts

L Boom Rotation Dr Sprckt Shaft

100,000 Miles or Annually

C Hydraulic System Oil

C Hydraulic System Filter(s)

8 Hours, Daily or 500 Miles

L Boom Rotation Collar

L Boom Lift Cylinder Bushings

L Trough Auger Bearings rear

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8 PERIODIC MAINTENANCE AND ADJUSTMENTS

75

MAINTENANCE SAFETYYour trailer can only operate at top efficiencywhen it is maintained in good operating condition.The maintenance procedures are summarizedfrom the component manufacturers instructionsincluded with this manual. Only standard industryand component procedures are required to keepyour trailer in top condition. All maintenanceintervals are established for normal operatingconditions. In light or intermittent conditions, theservicing and maintenance intervals can beextended. In heavy, extended or severe off-highway application, reduce the intervals forservicing and maintenance to keep theequipment in good condition. When a problem isfound, correct the condition before continuing.

A good maintenance program will find conditionsearly when they are easily and quickly correctedbefore they become major problems. Operatingyour trailer in a defective condition, can lead toserious mechanical problems or can createsafety hazards for the driver, bystanders or otheroperators.

1. Read and understand all the information in theOperator’s Manual regarding maintenance,adjusting and servicing the Bulk Feed unit.

2. Place all controls in neutral, disengage PTOclutch, stop the engine, remove ignition keyand set the park brake before adjusting,servicing or maintaining any part of the BulkFeed unit.

3. Follow good shop practices:- Keep service area clean and dry.- Be sure electrical outlets and tools are

properly grounded.- Use adequate light for the job at hand.

4. Block wheels before de-activating brakes.

5. Maintain air system and brake components intop condition at all times.

6. Maintain fasteners in running gear systems attheir specified torque at all times.

7. Establish and maintain a Trailer PreventativeMaintenance (TPM) program on your equip-ment. Some jurisdictions require this programand the maintenance of records on everycommercial vehicle on the road for futurereference.

8.1 TORQUE SPECIFICATION SUMMARY

Table 1 Recommended Torque Specifications

Description

Quik-Align™Pivot Bolt

Shock Bolt

Air Spring Bolt (Lower)

Air Spring Nut (Upper)

Brake Dust Shield Bolt

ABS Bracket Bolt

7/8"-9

3/4"-10

1/2"-13

3/4"-16

5/16"-18

1/4"-20

Size

475-525 Ft. Lbs

150-175 Ft. Lbs.

25-35 Ft. Lbs.

45-55 Ft. Lbs.

160-180 In. Lbs.

75-100 In. Lbs.

Torque

1. Air Ride Suspension

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Table 1 Recommended Torque Specifications (cont'd)

2. Mechanical Suspension

Description Size Torque

Equalizer Shaft (All Spread)49" Spread54"-65-1/2" Spread72"-109" Spread

U-Bolt Nuts

Torque Arm Bolt Nuts

Torque Arm Clamping Nuts

Spring Retainer Nuts

Ft. Lbs. N.m

1-1/4" Nut3/4" Capscrew

2-1/2" Nut1-1/2" Nut

1"

1/2"3/4"

1/2"

575-625200-225300-325200-225

300-325

160-200

80175-200

80

780-850270-305410-445270-305

410-445

216-270

110236-270

110

4. Wheel Nut

Ft-lbs Torque(Dry)

450 - 500

450 - 500

390 - 440

400 - 600

Wheel Type

Disc

Disc

Bud Unimount 10

WHD-8

Stud Size

3/4" - 16

1-1/8" - 16

Ft-lbs Torque (Dry)

150 - 175

210 - 260

Bolt Size

5/8" - 11

3/4" - 10

3. Wheel End Components

Description FastenerSize

Torque Range (lb-ft) N.m

1. Hub-cap bolts2. Hub fill plug3. Adjustment nut - manual bearing

adjustment (double nut)

4. Jam nut - manual bearing adjustment5. Brake mounting bolt6. Two-piece dust shield bolts (shown)

• Forged spider7. Bolt-on bushing bolts8. Cam bushing bolts9. Air chamber nuts

Tighten to 200,loosen, tightento 50, loosen1/4 turn and

check end play250-300130-165

15-2025-3525-35

80-125

10-1515-20

13-2020-27

5/16"3/8"

Size depends on axle modeland adjustment method.

5/8"

3/8"3/8"3/8"5/8"

13668

340-408177-224

20-2734-4834-48

109-170

76

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8.2 KINGPIN AND FIFTH WHEEL PLATE

The kingpin at the front of the trailer is the struc-tural component used to transmit accelerating anddecelerating loads into the trailer frame. It mustbe in good condition to perform as required.

Visually inspect the kingpin as part ofthe pre-trip inspection, at 5,000 miles(8,000 km) or weekly and annually aspart of your normal preventativemaintenance program. Be sure thekingpin does not have excessive wear,looseness, chipped out areas, cracksor bent mounting frame. If any kingpinshows such defects, it should bereplaced immediately.

Visually inspect the frame and structure for bends,cracks or distortions as part of the pre-trip inspec-tion procedure. Thoroughly inspect the structuralintegrity of the assembly every 25,000 miles(40,000 km) or every three months as part of yourpreventative maintenance program. Replace theentire assembly if any structural defects are found.

77

Fig. 8-1 KINGPIN

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8.3 FIFTH WHEEL

A fifth wheel system is usedon the towing tractor tosecure the kingpin and carrythe weight of the attachedtrailer. It must be maintainedin good condition to performas intended.

Visually inspect the fifthwheel as part of the pre-tripinspection to check forcracks, bends, chips ordistortions of the frame andupper plate.

78

Fig. 8-2 FIFTH WHEELNOTE

Use a high-pressure washeror steam cleaner to removeall the dirt and grease fromthe fifth wheel assembly priorto each weekly inspection.Apply a fresh coat of greaseto the fifth wheel assemblyprior to hooking-up the trailer.

To adjust the lock:

1. Obtain a Holland kingpin lock testerand place in the throat of the lock.Close the lock.

2. The jaws should be snug around thetester but not binding.

3. Use the adjusting nut on the frontedge of the fifth wheel to set theclearance of the jaws.

4. Use a light oil to lubricate all movingparts prior to returning to service.

Fig. 8-3 KINGPIN LOCK

Clean the assembly every 5,000 miles (8,000 km)or bi-monthly and annually to perform a thoroughinspection. Check the frame and upper plate forcracks, bends, chips or distortions.

When the components are clean, check that thelock closes completely around the kingpin.

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8.4 AXLE ALIGNMENT

A standard axle is used as the main transversestructural member to transmit loads between thetrailer frame and the surface contacting compo-nents. All running gear components are attachedto or form part of the axle assembly.

Although there is very little that can go wrong withthe axle itself, loose, bent or damaged attachingcomponents can cause the axle to go out ofalignment. This misalignment will be found duringthe regularly scheduled 25,000 mile inspection.However, axle misalignment shows itself mostcommonly by accelerated tire wear anddogtracking by the trailer. Visually check the tirewear when checking air pressure. The drivershould identify these handling characteristics toservice personnel for correction.

To check axle alignment, follow this procedure:

1. Select a working area that is level, with acompacted surface and is large enough toprovide access from all sides.

2. Move the trailer forward and backward severaltimes to remove any binding from the compo-nents.

3. Stop the trailer when moving in the forwarddirection without using trailer brakes. This willgive the components a forward bias with nobinding.

4. Unhook the trailer and support on the landinggear at the normal height or parallel to theground.

5. Install a commercially available axle extenderon each axle or remove the wheels to preventany components from interfering with themeasurements.

79

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8.4 AXLE ALIGNMENT (cont'd)

6. Attach an S hook to a steeltape and measure the distancebetween the kingpin and theend of each axle. DimensionsA and B should be equal within± 1/8 inch (0.125 in) (3.1 mm).

7. Adjust the suspension mount-ing system as required to setdimension A and B within 1/8inch (0.125 in) (3.1 mm).Refer to suspension systeminstruction brochure for de-tailed adjustment procedure.

8. Use a trammel bar to measure the road andcurbside dimensions between the first andsecond axles. Dimensions C and D should bewithin 1/16 inch (0.0625 in) (1.6 mm).

80

Fig. 8-5 TRAMMEL BAR

Fig. 8-6 ALIGNED

Fig. 8-4 AXLE DIMENSIONS

IMPORTANT

Always use a torque wrench whentightening fasteners. The correcttorque on a fastener provides theproper clamping force on theadjacent components and they willperform as expected.

9. Adjust the suspension system as required toset this dimension to its recommended toler-ance.

10. Repeat measuring and adjustment procedureon the third axle if so equipped.

11. Tighten all fasteners to their specified torque.Do not allow any suspension system orrunning gear fasteners to loosen.

12. The front axle must be aligned to the kingpinwith second and third axles adjusted to thefront axle.

13. Always check axle alignment after repairingthe suspension system.

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8.5 WHEEL HUBS/BEARINGS

A. Oil Leaks:Visually inspect the hub for leaksevery time the tire pressures arechecked. Leaks will normally bevisible as dust collects on theescaping oil. Stop and correct theleak immediately to prevent runningthe hub low on oil. Running low orwithout oil will quickly overheat thehub and cause the bearings toseize. Change the oil in the hubwhen installing new seals to correcta leak.

B. Oil Level:1. Check the oil level in each

wheel hub every 5,000 miles(8,000 km) or weekly andwhenever an oil leak is found.Clean the end plate of the hubto remove the dust, dirt or mudbuild-up.

The oil should be visible to thetop of the outer concentric circleof the end cap. Add oil asrequired through the fill plug inthe hub. Always use clean oiland prevent contaminants fromentering the hub when adding orchanging oil.

81

Some axles use an oil bath design for lubricatingwheel bearings. It is a virtual zero maintenancesystem providing that the oil remains in the hub.

Visually check the hub every day for leaks whenchecking tire pressure during pre-trip, daily,refueling, or rest stop inspections. If oil leaks aredetected on any hub, repair the leak and refill thehub before proceeding.

Hub

Schematic

2. Change the oil every 100,000 miles(160,000 km), annually or whenever theaxle nuts are retorqued or the brakes arerelined. The hub cavities must be openedwhen retorquing axle nuts and changingoil should be done as part of the proce-dure.

Fig. 8-7 OIL LEVEL

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8.5 WHEEL HUBS/BEARINGS (cont'd)

b. Place chocks in front ofand behind each wheel.

c. Jack each axle up untilthe tire clears the ground.

d. Support the axle on asafety stand to preventslipping or tipping.

e. Turning the wheel slowlyto check the condition ofthe bearings and todetermine if the brakesare dragging.

f. Dragging Brakes: Can

be felt as a steady drag on the turningof the wheel or at the same position orarc of the rotation. Adjust the brakesto eliminate the drag before resumingwork.

g. Bearing Condition: Can be felt asthe wheel turns. Bearings in goodcondition turn easily and smoothly.Bearings in poor or bad condition canbe felt through the wheels as scrap-ing, grinding, dragging or bumps.Replace bearings before resumingwork.

h. Wobble: Grasp each side of the

wheel or tire and wiggle the wheel andassembly. If the wheel or hub wobbleon the spindle, the bearings have losttheir end play and the axle nutsrequire tightening.

NOTE

If the bearings are not in goodcondition, replace them beforesetting the end play.

82

C. Wheel Bearings:Wheel bearings carry and transmit the loadbetween the wheels and the axles. In addition toproper lubrication, the bearings must have therecommended end play to perform as expected.Bearing end play is set and controlled by thetorque of the axle nuts on the end of eachspindle. Each hub must seat securely on itsbearings to prevent wobble or slop in the system.Turning the wheel or wobbling it indicates thecondition and tightness of the hub/bearingassembly.

1. Turning/Wobble:a. Park the trailer on a level, hard surface

and release the brakes.

Fig. 8-8 WHEELS

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8.5 WHEEL HUBS/BEARINGS (cont'd)

83

C. Wheel Bearings (cont'd):

2. Bearing End Play:a. Place a pan under

the hub drain plug.b. Remove the drain

plug from the huband drain the oil.

c. Remove the hub endplate and lay to theside.

d. Remove the setscrew from the jamnut.

e. Remove the jam nutand perforated lockwasher from thespindle.

f. Use a torque wrenchto tighten the adjust-ing nut 200 ft-lbs.(136 N.m) whilerotating the wheelassembly in bothdirections.

g. Back the adjustingnut off to zerotorque.

h. Retorque the adjust-ing nut again to 50 ft-lbs (68 N.m) oftorque while rotatingthe wheel assemblyin both directions.

i. Loosen the nut 1/4turn.

j. Install the perforatedlock washer. Besure the adjustingnut pin aligns withthe hole in the lockwasher. Turnwasher over and/oradjusting parts asrequired.

k. Install jam nut andtighten to 250-300 ft-lbs. (340-408 N.m).

123456789

101112131415161718192021

CapscrewLockwasherHub capGasketWheel bearing jam nutLockwasherWheel bearing adjusting nutCone outer wheel bearingCup - bearing outerBrake drumCup - bearing innerCone - bearing innerSeal wheel-bearingBushing anchor pinPin anchorBeam axleCamshaft (left)Camshaft (right)WasherSealBushing

DESCRIPTIONITEM ITEM DESCRIPTION

Snap ringCapscrewAir chamberLockwasherLocknutCamshaft bushing assemblyCapscrewWasher slack adjusterLocknut - slack adjusterAutomatic slack adjusterWasher slack adjusterSnap ring slack adjusterSpring - brake shoe returnBrake show and lining assy.Spring - brake shoe retainingRetainer - brake shoe rollerRoller - brake shoePin - shoe return springDust shieldHub

2223242526272829303132333435363738394041

Fig. 8-9 SPINDLE COMPONENTS

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84

l. Check bearing end play by:i. Attaching a magnetic base

dial gauge indicator to theend of the spindle.

ii. Push the wheel in whilerotating the wheel slightlyuntil the dial gauge readingdoesn't change.

iii. Zero dial gauge.

iv. Pull wheel assembly outwhile rotating wheel slightlyuntil dial reading doesn'tchange.

v. Dial indicator will readbearing end play.

vi. If end play does not registerbetween .001-.005 inches(0.025-.125 mm), readjustend play.

vii. Replace components ifreadjusting does not giveend play tolerance withinspecs.

m. Install a new gasket on hub facecap.

n. Install hub face cap and tightenmounting cap screws to theirspecified torque.

o. Add the specified amount of oil

Fig. 8-10 DIAL INDICATOROut

In

to the hub and secure fill plug. Checkfor leaks. Correct leaks beforeresuming operation.

p. Remove safety stand from under axleand lower wheel to the ground.

q. Repeat checks on all other axles.

8.5 WHEEL HUBS/BEARINGS (cont'd)

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8.6 WHEELS

A variety of steel or aluminum wheels can be usedon the trailer depending on customer preferenceor application requirements. Wheels must bemaintained in good condition and all fastenerstightened to their specified torque level to obtainthe expected life and performance.

Loose fasteners are the most common cause ofwheel problems on a trailer. Always retorque thewheel fasteners per the break-in schedule of 100,500, 1500 and 5,000 miles (160, 800, 2500 and8000 km) when the unit is new and after a wheelhas been removed. Always use an accuratecalibrated torque wrench when tightening fasten-ers. A loose fastener is defined as one that is nottightened to its specified torque. A loose fastenerdoes not provide the required clamping, anchoringor holding forces to stabilize the adjacent compo-nents. Insufficient clamping forces can lead toflexing, bending, cracking, hole elongation or othercomponent deterioration that cause failures and/oraccidents. Always keep fasteners tightened totheir specified torque. Over-torquing can overloadcertain components, causing compression cracksand strip nuts or studs. Over-torquing fastenerscan be as detrimental as under-torquing. Alwaystighten fasteners to their specified torque.

Use an accurate torque wrench to retorque wheelfasteners every 10,000 miles (15,000 km) ormonthly whichever comes first. Always retorquewheels per the break-in schedule whenever awheel is removed and remounted.

Always follow the recommended mounting proce-dure when installing wheels to the trailer.

1. Disc Wheels (Stud Pilot Style):

a. Mount single or inner dual wheel on hub.Be careful not to damage the threads onany of the studs.

b. Snug the nuts up in the alternating se-quence shown to center it on the hub andinsure an even contact between the wheeland hub.

c. Tighten nuts to their specified torque usingIMPORTANT

Left-hand threads are used on theleft side of the vehicle. Right-hand threads on right.

the same alternating sequence.

d. Mount outer dual. Do not damage thethreads when sliding the wheel over thestuds.

e. Snug up the nuts in the alternating se-quence shown to center it on the hub andto provide even contact.

f. Tighten the outer wheel nuts to theirspecified torque.

When retorquing inner nuts ofdouble nut design, always back offouter nut several turns, thenretorque them.

IMPORTANT

Fig. 8-11 NUT TORQUE SEQUENCE

6 StudSTUD PILOTED 10 Stud

Table 2 Recommended Wheel Stud Torque (Disc Wheels)

Stud Size

3/4"-16

1-1/8"-16

15/16-12

1-5/16-12

Ft-lbsTorque (Dry)

450 - 500

450 - 500

750 - 900

750 - 900

390 - 440

400 - 600

Wheel Type

Disc

Disc

Disc

Disc

Bud Unimount 10

WHD-8

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2. Hub Piloted Wheels:a. Mount inner wheel on the hub.

b. Slide on the hub guide until the wheel issnug against the hub. Be careful not todamage the threads on any of the studs.

c. Mount outer dual wheel on the hub andsnug up against the inner wheel.

8 Stud

Fig. 8-12 HUB PILOTED

Add a drop or 2 of oil on the endof the bolt, threads and the nutsand flanges.

NOTE

10 Stud

86

d. Install nuts and tighten in alternate se-quence shown.

Table 3 Recommended Wheel Bolt Torque

6 Spoke

Fig. 8-13 RIM/WHEEL TORQUE SEQUENCE

Do not over-torque fasteners.Over-torquing can strip threads,collapse spacers or lead to otherproblems that cause loose fasten-ers. Use an accurate torquewrench when tightening fasteners.

IMPORTANT

3 Spoke 5 Spoke

Table 4 Recommended Wheel Bolt Torque (Spoke Wheels)

Ft-lbs Torque (Dry)

5/8" - 11

StudSize

M22 x 1.5(33 mm or 1-1/2 Hex)

M20 x 1.5(30 mm Hex)

Ft-lbsTorque(Oiled)

450 - 500

280 - 330

c. Secure clamps evenly in position.

d. Snug up the nuts in the alternatingsequence shown to allow the insiderim to seat itself on the mountingbevel and avoid wheel wobble.

e. Tighten the nuts evenly in smallincrements in the shown alternatingsequence until all nuts are tightenedto their specified torque.

f. Check for runout and redo if neces-sary.

3. Rim/Wheel (Cast Spoke):a. Inspect and clean all the parts. Replace

any damaged components.

b. Place rims and spacer band on wheel.Be sure to space valve stem betweenspokes.

3/4" - 10 210 - 260

150 - 175

Bolt Size

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8.7 TIRES

Tires are one of the most important componentson a trailer and must be maintained in top condi-tion to obtain their desired load carrying capacityand durability. Tire wear rate can be used as anindicator of the condition of the axle alignment orsuspension system. Poorly maintained tires willwear rapidly or deteriorate and fail quickly andsuddenly. A poorly maintained tire can and willaffect adjacent components leading to theirpotential failure as well.

Proper tire maintenance includes but is not limitedto:

1. Inflation Pressure:Operating at an incorrect inflation pressure isthe most common maintenance problem withtires. Tires should be checked frequently tobe sure they are at their specified pressure.

It is recommended that tire pressure bechecked at the start of each working day andat least one other time during the day. Alwaysuse an accurate hand gauge when checkingthe pressure and check each tire. Carry it withyour unit so it is always available whenneeded. Best time to take tire pressure iswhen tire is cold. Every tire has its specifiedoperating pressure molded into the sidewall.Adjust the pressure as required to obtain thespecified inflation pressure when the tire iscold.

Tire pressure will normally increase 10 to 15psi during operation as the tire heats up. If thepressure exceeds this normal increase, itindicates the tire may be overloaded,underinflated, driven too fast, improperly sizedor a combination of these factors. Identify thecause of the problem and correct it beforeresuming work.

a. Underinflation:Operating at lower than the specifiedpressure is a tire's worst enemy. Use anaccurate tire pressure gauge to check thepressure at the start of each working day,every few hours during the day and/orwhenever the handling characteristicschange suddenly. Underinflation willincrease tread wear and cause a deterio-ration of the tire body leading to a separa-tion of the tread from the body. Anunderinflated tire is soft and deflects morethan it should causing fatigue cracks orbreaks in the body cord constructionleading to sudden air loss.

Operation with a low or flat tire on a dualwill generate a lot of heat in theunderinflated tire from internal friction thatit can and will disintegrate or catch on fire.It also causes overloading of the adjacenttire on the axle or axles and could lead totheir failure also.

b. Overinflation:Inflating a tire over its specified pressurecan lead to serious problems also.Overinflation creates a more rigid tire thatdoes not absorb road shocks as well as itshould. Shock loading from impactingbumps or pot holes can break the fabric ofthe tire and/or transmit the higher loadsinto the rim, wheel and adjacent compo-nents causing them to fail as well.Overinflated tires cut, snag or puncturemore easily than properly inflated tires.Also overinflating tire will not increase itsload carrying capacity.

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2. Tire Matching and Spacing on DualsTires on a dual assembly must be matched for size (diam-eter or rolling radius) and type of construction to obtain thedesired and expected performance and life.

a. Matching of Size:Tire sizes can vary between manufacturers and as theywear. Special care must be taken to be sure the tiresize (rolling radius, diameter or circumference) is withinthe following dimensions:

Rolling radius: 1/8 inch (3 mm)Diameter: 1/4 inch (6 mm)Circumference: 3/4 inch (19 mm)

Measure the tire when it is mounted, inflated to itsspecified pressure and not loaded. The easiest methodis to use a steel tape to measure the circumference ofthe tire.

Unequal sized tires will require the larger tire to carrymore of the load and potentially overload it. Overloadingaccelerates the wear and can lead to tire failure. Whenthe one tire fails, the remaining tire or tires will then alsobe overloaded. The smaller tire will not contact the roadsurface properly and will wear in an irregular mannergiving poor durability.

b. Tire Construction:Customers can use radial or bias ply tires on their trailer.However, it is recommended that different types of tiresnot be mixed on an axle. Each type of tire has differentdeflection, cornering and spring characteristics. Thesediffering characteristics cause the tires to always fighteach other during operation and will give erratic handlingand poor wear characteristics when mounted on thesame axle. Different types can be mounted on differentaxles but not on the same axle.

c. Tire Spacing:A wide variety of rims can be used on the trailer andeach will provide a different offset. Select the rims toprovide sufficient space and clearance between thesidewalls of the tires. Normally there should be at least2 inches (50 mm) and 3 inches (75 mm) between thesidewall of a bias ply and radial dual tire assemblyrespectively. This spacing will provide sufficient clear-ance for each type of tire to deflect as they rotate andwhen the impact a pothole or bump in the road. If theytouch during operation, they will wear or abrade at thecontact point. In addition, tires that are too close do notshed dirt, trash or stones that can get between themduring operation as well as properly spaced tires.

8.7 TIRES (cont'd)

Fig. 8-14 TIRE DIMENSIONS

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8.8 BRAKES

All components in the brakesystem must be maintained ingood condition for the system toperform at top efficiency. It isrecommended that brakes andassociated components bechecked, serviced and maintainedper the Trailer Preventative Main-tenance Schedule (TPM) for thetrailer. In this section, the basicbrake disassembly and assemblyprocedure will be covered. Referto the axle manufacturers servicemanual for a more detailed repairand rebuilding procedure.

Check brakes frequently to keepthem in top condition. Poorlymaintained brakes will not stop thetrailer as effectively as well-main-tained brakes and in the extremecould fail completely leaving nobrakes or no ability to stop the unit.

It is recommended that the driver

89

Fig. 8-15 BRAKE SYSTEM

checks the brakes at least once during eachworking day when checking tire pressure andperforming a quick visual of the unit. Use yourhand to check the temperature of the drum. Alldrums should be approximately the sametemperature if the system is functioning properly.If any drum is significantly warmer or colder thanthe rest, it indicates a problem. Determine thecause of the problem and correct it before resum-ing work. By discovering and correcting it while itis minor, major repair, expense and down time canbe prevented.

At 25,000 miles (40,000 km) or every 3 monthswhen the axle is raised off the ground for thecomplete wheel end inspection, check the brakesat the same time. When the wheels are turned byhand, the wheel end should decrease speedslowly. If it does not, the brakes could be draggingor there could be a problem with the bearings.Dragging brakes will also be detected by hotdrums during the daily drum temperature checks.Adjust the brakes to correct the problem.

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Remove the brake dustcovers (if so equipped) toaccess the shoes. Checkthe thickness of thelinings. Reline or replaceshoes when the liningthickness is less than 1/8inch (3 mm). Unevenwear among the brakeshoes on a trailer indicatethat the braking systemhas not been set ormaintained properlycausing uneven applica-tion and wear. If unevenlining wear appears, resetthe system to provideeven application of all theshoes. Do not operatewhen the linings are lessthan 1/8 mile (3 mm) toprevent the lining anchorrivet or bolts from contact-ing the drum. Headcontact with the drum willcut grooves in the surfaceand require extra machin-ing to remove them whenrebuilding the brakes.

Several types of friction material are available for use onthe brake shoes. Each has its own friction coefficientand braking characteristics. Select the one that best fitsyour application but do not mix materials on the sametrailer. Differing materials require different applicationforces to obtain the same braking force and a brakingsystem can only apply one force when it is properly set.

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Recent changes in envi-ronmental laws havebanned the use of asbes-tos including brake linings.Always use the appropriatesafety gear when removingbrake shoes containingasbestos from your trailer.Replace the shoes that areequipped with approvedmaterial.

Fig. 8-16 EXPLODED VIEW

Fig. 8-17 AXLE

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A. Removing Brakes:1. Position the trailer on a level hard surface.2. Exhaust all the air from the air system.3. Jack the axle up and place on safety

stands.4. Remove the wheel assembly from the

axle.5. Release the slack adjuster (Refer to

Section 8.6).6. Disable or cage spring brakes if so

equipped.7. Drain oil from hub and remove spindle end

components.8. Remove the hub and drum assembly.

Support with a hoist as the assemblyslides off the spindle. Use a puller ifrequired.

9. Remove roller retaining clip from thebottom and top brake shoe cam rollers.

10. Disconnect and remove bottom shoereturn spring.

11. Rotate bottom shoe to remove retainingsprings.

12. Lift top shoe to remove.13. Disconnect push rod from slack adjuster.14. Back off and remove slack adjuster.15. Remove cam shaft.

B. Installing Brakes:1. Inspect all the components. Replace any

that are cracked, bent or worn.2. Lubricate the camshaft spline, slack

adjuster gear and slack adjuster pins withanti-seize compound.

3. Install cam shaft and slack adjuster.Secure with snap rings.

4. Adjust slack adjuster to its required angleand attach to the push rod. Release slackadjuster pawl if so equipped.

5. Use a good quality brake grease tolubricate the anchor pins and rollers wherethey contact the brake shoes.

6. Place the upper shoe in position.7. Place the lower shoe in position and

attach 2 new retaining springs.8. Rotate lower shoe forward and attach new

brake shoe return spring.9. Install both cam rollers and secure with

retainers.10. Install and secure the remaining wheel

and components.11. Repeat with other wheel ends as required.12. Tighten all fasteners to their specified

torque.

Fig. 8-18 BRAKE/WHEEL END COMPONENTS

Description FastenerSize

1. Hub-cap bolts2. Hub fill plug3. Adjustment nut - manual bearing

adjustment (double nut)

4. Jam nut - manual bearing adjustment5. Brake mounting bolt6. Two-piece dust shield bolts (shown)

• Forged spider7. Bolt-on bushing bolts8. Cam bushing bolts9. Air chamber nuts

Tighten to 200,loosen, tightento 50, loosen

1/4 turn250-300130-165

15-2025-3525-35

80-125

10-1515-20

13-2020-27

5/16"3/8"

Size depends on axle modeland adjustment method.

5/8"

3/8"3/8"3/8"5/8"

13668

340-408177-224

20-2734-4834-48

109-170

91

Torque Range

(lb-ft) N.m

Manual Bearing Adjustmenta. Tighten to 200 ft-lbs.b. Completely loosen.c. Tighten to 50 ft-lbs.d. Loosen 1/4 turn

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8.9 SLACK ADJUSTERS

8.9.1 ROCKWELL AUTOMATIC SLACK ADJUSTER

1. The air chamber push rod ex-tends beyond its pre-determinedoptimum stroke length, thechange in geometry between thechamber pushrod and slack leverarm raises the slack adjusteractuator rod.

2. The piston contacts the retainingring and lifts the actuator.

3. If adjustment is required, thespiral serrations on the actuatorare lifted over the serrations onthe pawl.

4. When the push rod retracts, itforces the actuator downward intothe pawl serrations and theactuator rotates.

5. As the actuator rotates downward,it turns the worn gear that turnsthe gear/spline/camshaft tomaintain the brake adjustment.

6. Pull the pawl out and block in theout position when disassemblingthe brake system.

7. Use the bottom nut to turn andadjust the gear position.

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Schematic

Installed

Fig. 8-19 ROCKWELL SLACK ADJUSTER (TYPICAL)

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In an S-cam type foundation brake, the final linkbetween the pneumatic system and the foundationbrake is the slack adjuster. The arm of the slackadjuster is fastened to the push rod of thechamber with a clevis and the spline end isinstalled on the brake camshaft.

Primarily, the slack adjuster is a lever that con-verts the linear force of the air chamber push rodinto a torque which turns the brake camshaft andapplies the brakes.

Two types of slack adjusters are in use: manualtype slack adjusters, which periodically require amanual adjustment and automatic slack adjusterswhich will automatically adjust during normalservice braking applications. All slack adjustersutilize the worm and gear principle and fundamen-tally differ only in their torque limit specification.

MANUAL SLACK ADJUSTERSManual slack adjusters contain four basic compo-nents: the body, worm gear, worm shaft, andlocking screw or collar. See Fig. 8-20.

The worm shaft of a slack adjuster incorporatesan external adjusting hex. Turning the adjustinghex rotates the worm shaft which turns the wormgear and brake cam shaft, thus spreading thebrake shoes and reducing drum-to-lining clear-ance.

Higher torque-rated slack adjusters use the lockball or plunger and worm shaft indent principleadjustment lock. The lock ball or plunger mustengage the worm shaft indent after the adjustmentis completed. An audible metallic click can beheard when engagement is made.

IMPORTANT

Manual and automatic slackadjusters are for brake adjust-ment and will not compensate forfaulty foundation brakes.

Fig. 8-20 MANUAL SLACK ADJUSTERS

Ball Indent Type Slack Adjuster Positive Lock Type Slack Adjuster

8.9 SLACK ADJUSTERS (cont'd)

8.9.2 MANUAL AND AUTOMATIC SLACK ADJUSTER MAINTENANCE

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8.9 SLACK ADJUSTERS (cont'd)

8.9.2 MANUAL AND AUTOMATIC SLACK ADJUSTER MAINTENANCE (cont'd)

AUTOMATIC SLACK ADJUSTERSWhile automatic slack adjuster designs vary in themanner in which they are installed and operate, allare designed to automatically maintain a predeter-mined shoe-to-drum clearance or brake chamberstroke. Some automatic slack adjusters adjustupon the brake application stroke, others adjustupon release. Automatic slack adjusters cangreatly reduce manual adjustments. Automaticslack adjusters do not reduce the need forperiodic maintenance.

Fig. 8-21 AUTOMATIC SLACK ADJUSTERS

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8.9 SLACK ADJUSTERS (cont'd)

8.9.2 MANUAL AND AUTOMATIC SLACK ADJUSTER MAINTENANCE (cont'd)

BRAKE ADJUSTMENT PROCEDURE

NOTE

All adjustments should be madewith cold brake drums and thebrakes fully released.

To avoid possible injury, proper precautionsmust be taken to prevent automatic actuationof the brake chambers while adjusting slackadjusters. Always block the wheels or me-chanically secure the vehicle. Spring brakesmust be mechanically cages or released withair. All brakes should be released.

WARNING

A. Manual Slack Adjuster Brake AdjustmentProcedure

1. Slack adjusters with locking collar(positive lock type):Jack up the vehicle. Thoroughly clean theadjusting hex and locking sleeve area.Position a wrench or socket over theadjusting hex and disengage the lockingsleeve by depressing it. With the lockingsleeve fully depressed, adjust the brakeswhile rotating the tire and wheel. Use thewrench or socket to turn the adjusting hexuntil the shoes contact the drum. Thenback off the adjusting hex until the tire andwheel turn freely. The actuator strokeshould be as short as possible without thebrakes dragging.

If the vehicle cannot be jacked up, thor-oughly clean the adjusting hex and lockingsleeve area. Position a wrench or socketover the adjusting hex and disengage thelocking sleeve by depressing it. With thelocking sleeve fully depressed, use thewrench or socket to turn the adjusting hexuntil it will go no further indicating thateither the shoes have contacted the drumor the adjusting hex has been turned inthe wrong direction. Pull on the slackadjuster to make sure it will not move. Ifthere is movement, adjustment was madein the wrong direction and the adjustinghex must be turned in the oppositedirection until it will go no further.After establishing solid shoe-to-drum

contact, back off the adjusting hex 1/4 turnfor worn linings and 1/2 turn when reliningbrakes. The actuator stroke should be asshort as possible without the brakesdragging. Measure the chamber powerstroke at 80-90 psi as described in sub-section "B", "Automatic Slack AdjusterBrake Adjustment Procedure," below.Take a free stroke measurement asoutlined in the section entitled FAILUREANALYSIS. Make sure you have at least3/8" of free stroke. Free strokes less than3/8" can cause brake drag. If you cannotmaintain the maximum legal stroke andthe free stroke is less than 3/8", contactthe brake manufacturer for foundation orbrake geometry problems.

When the manual slack adjuster brake adjust-ment is completed, the adjusting hex should bepositioned so the locking sleeve engages it,thus locking it in place. If the locking sleevedoes not engage the adjusting hex, the slackadjuster can back itself off.

CAUTION

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3. Measure the brake chamber face to thecenter of the clevis pin (see Fig. 8-23).

4. The difference between the brakes re-leased and applied measurements is thepower stroke measurement. If the strokeis less than the maximum stroke for thechamber size (see Table 5), the inspectionis complete. If the power stroke is morethan the maximum stroke for the chambersize (see Table 5), refer to the sectionentitled FAILURE ANALYSIS.

96

Fig. 8-22 PUSH ROD "AT REST"

Fig. 8-23 PUSH ROD "EXTENDED"

8.9 SLACK ADJUSTERS (cont'd)

8.9.2 MANUAL AND AUTOMATIC SLACK ADJUSTER MAINTENANCE (cont'd)

B. Automatic Slack Adjuster BrakeAdjustment ProcedureAn automatic slack adjuster should not haveto be manually adjusted except for initialinstallation and at brake reline. Instead ofmanually adjusting the slack, the followingprocedure should be followed during inspec-tion:

Chamber Power Stroke:A power stroke at 80-90 psi brake applicationpressure will check both adjustment andfoundation brake condition. Perform thefollowing:

1. Measure the brake chamber face to thecenter of the clevis pin at all wheellocations (see Fig. 8-22).

2. Make brake applications until the airreservoir gauge reads 90-100 psi. Thenhave an assistant make a full brakeapplication and hold it.

Chamber Type Maximum Legal Stroke

12

16

20

24

24 Long Stroke

30

36

Less than 1-3/8"

Less than 1-3/4"

Less than 1-3/4"

Less than 1-3/4"

Less than 2.0"

Less than 2.0"

Less than 2-1/4"

Table 5 Chamber Type vs. Maximum Legal Stroke at 80 PSI Brake Application Pressure

2. Slack adjuster with lock screw ballindent type lock mechanism:Back off (turn counter-clockwise) theworm shaft lock screw (if applicable).Make the necessary adjustment by turningthe adjusting hex as described in itemnumber 1, directly above. Following brakeadjustment, make certain that the lock ballor plunger engages the worm shaft indent.Without such engagement, the slackadjuster can back itself off.

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AUTOMATIC SLACK ADJUSTER ADJUSTMENTPROCEDURE AT RELINE AND INSTALLATION

An automatic slack adjuster should be manuallyadjusted after a brake reline and/or installationusing the following procedure:

1. Position a wrench or socket over the adjustingmechanism.

2. Rotate the adjusting mechanism until thebrake shoes contact the drum. Pull on theslack adjuster by hand to make sure it will notmove. If there is movement, adjustment wasmade in the wrong direction and the adjustinghex must be turned in the opposite directionuntil it will go no further.

3. Reverse the rotation, backing the slackadjuster off one-half (1/2 turn).

NOTE

If the automatic slack adjuster isequipped with a pawl, remove thepawl for the brake adjustmentand then properly reinstall thepawl (see Fig. 8-24 Style C).Tighten the pawl to 15-20 ft-lbs.

4. Measure the chamber power stroke at 80-90psi brake application pressure as described inthe previous section.

5. Take a free stroke measurement as outlinedin the section entitled FAILURE ANALYSIS.Make sure you have at least 3/8" free stroke.Free strokes of less than 3/8" can cause brakedrag. If you cannot maintain the maximumlegal stroke and the free stroke is less than 3/8", contact the brake manufacturer forfoundation or brake geometry problems.

Fig. 8-24 SLACK ADJUSTER TYPES

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8.9 SLACK ADJUSTERS (cont'd)

8.9.2 MANUAL AND AUTOMATIC SLACK ADJUSTER MAINTENANCE (cont'd)

ROADSIDE BRAKE ADJUSTMENTIf the driver has to adjust brakes on the road, thefollowing procedure is recommended:

If the vehicle is equipped with an automatic slackadjuster, use a pry bar to pull on the slack ad-juster. If movement is more than 5/8", a manualadjustment should be made following the sameprocedure as described below for a manual slackadjuster. If the automatic slack adjuster isequipped with a pawl, remove the pawl for thebrake adjustment and then properly reinstall thepawl. If the automatic slack adjuster needsadjustment, inform maintenance personnel.

1. Block the wheels or mechanically secure thevehicle. On the brakes to be adjusted, springbrakes must be mechanically caged or re-leased with air.

2. Rotate the adjusting mechanism until thebrake shoes contact the drum. Using a prybar, pull on the slack adjuster by hand tomake sure it will not move. If there is move-ment, adjustment was made in the wrongdirection and the adjusting mechanism mustbe turned in the opposite direction. Tap thebrake drum with a wrench; you should hear adull clunk indicating the brake linings are tightagainst the drum.

3. Back off the slack adjuster a small amount ata time, while tapping on the brake drum with awrench in between adjustments. Stop backingoff the adjuster when you hear a clear ringingsound from the brake drum when tapped witha wrench.

4. Using a pry bar, pull on the slack adjuster byhand. If movement is more than 5/8", adjust-ment was not done properly or there is aproblem with the foundation brake.

Some brake chamber push rods aremarked to warn of an over-stroke condi-tion. While the marking themselves mayvary, the marking system has two basicfeatures. They are: There is a mark onthe brake chamber push rod near its clevisattachment to signal that it incorporates astroke alert indicator (see Fig. 8-25 B).There also is a mark on the brake cham-ber push rod opposite its clevis attachmentend which is exposed from the brakechamber wherever over-stroke occurs (seeFig. 8-25 C).

NOTE

Fig. 8-25 PUSH ROD POSITION

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FAILURE ANALYSIS

Manual Slack Adjuster Failure AnalysisManual slack adjusters should be inspected forgear set wear. To do this, back off the adjustinghex until all spring pressure is relieved from theclevis. Work the adjusting nut 1/4 turn back andforth while watching for cam rotation. If you have1/8 to 1/4 turn of play without the cam rotating, themanual slack should be replaced. Repeat thisprocedure every 1/4 turn of the adjusting nut tocheck the whole gear set.

Automatic Slack Adjuster Failure AnalysisIf the power stroke is at or more than the maxi-mum stroke, measure free stroke to determine ifthe slack adjuster is operational.

FREE STROKE MEASUREMENTFree stroke is the amount of slack arm movementrequired to move the brake shoes against thedrum. To measure free stroke, perform thefollowing:

1. With brakes released, measure from thebrake chamber face to the center of the clevispin.

2. With a lever, pry the slack adjuster arm untilthe brake shoes contact the drum and meas-ure the slack adjuster movement (see Fig. 8-26).

3. The difference between the brake releasedand applied measurements is the free stroke.The free stroke should be 3/8" - 5/8". If thefree stroke is in the correct range, the out ofspec stroke is due to a foundation brakeproblem. Check for missing or worn compo-nents, cracked brake drums, or improperlining-to-drum contact. If the free stroke isgreater than recommended, an automaticslack adjuster function test should be per-formed.

Fig. 8-26 FREE STROKE

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Fig. 8-27 SLACK ADJUSTER TYPES

8.9 SLACK ADJUSTERS (cont'd)

8.9.2 MANUAL AND AUTOMATIC SLACK ADJUSTER MAINTENANCE (cont'd)

PREVENTATIVE MAINTENANCE

Every month, 8,000 miles, or 300 operating hours,check brake chamber push rod travel; strokeshould be as short as possible without the brakesdragging or the push rod binding. Adjust manualslacks if necessary. Due to different operatingconditions, adjustments may be necessary atearlier intervals.

Every 6 months, 50,000 miles, or 1,800 operatinghours, lubricate all slack adjusters and clevis pinswith manufacturer's recommended lubricant.Check for worn clevises, clevis pins, clevis pinbushings, and control arm/bracket wear. Failureto replace worn components will increase chamberstroke. Lubrication and inspection may benecessary at earlier, intervals due to differentoperating conditions.

AUTOMATIC SLACK ADJUSTER FUNCTIONTEST

1. Remove the pawl, then rotate the adjustingmechanism at least one complete turn as ifbacking off the brake adjustment (see Fig. 8-27 Style C). The pawl must be installedproperly and tightened to 15 - 20 ft-lbs. afterbacking off the adjuster.

2. Apply the brakes several times and observewhether the adjustment mechanism is rotatingin the direction needed to reduce brakechamber pushrod stroke. If the adjustingmechanism does not rotate, the slack adjustershould be replaced.

3. Check back-off torque by rotating the adjustinghex as follows:

Style A: Minimum 15 ft-lbs. counter-clockwise(CCW).

Style B: Minimum 15 ft-lbs CCW.

Style C: Less than 45 in-lbs. CCW (pawlremoved)

Style D: Minimum 15 ft-lbs CCW

Consult the manufacturer for more information.

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8.10 AIR CHAMBER/SPRING BRAKE

Air chambers mounted on the axle usethe air supply/pressure from the tractor toapply the service brakes for stopping thevehicle. In addition this air chamber maybe equipped with a spring brake thatapplies the brake when the service sideof the brake loses air. The spring brakeside of the system is used as a parkingand/or emergency brake if the serviceside fails.

Spring brakes should not be serviced byanyone in the field unless they have beentrained in the proper procedure. Do notwork on the brakes unless the springsare caged or locked out. Do not movethe trailer if the springs are caged.

When caging or locking out the springbrakes, follow this procedure:

1. Place chocks in front of and behindthe trailer wheels.

2. Insert the release bolt, stored on theside of the chamber, into the hole inthe head and through the piston.

3. Turn the release bolt clockwise untilit stops and locks.

4. Pull release bolt out as far as possi-ble and run the nut down whileholding the bolt in place.

5. Use a wrench to turn the release boltnut clockwise until the bolt extendsabout 3 inches.

6. Be sure the release bolt is locked inposition.

7. The spring is now caged and thetrailer can be moved.

8. Always release the spring beforeplacing the trailer back in service.

101

Axle

Fig. 8-28 SPRING BRAKE

Schematic

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8.11 SUSPENSION SYSTEM

The suspension system is the group of compo-nents that connect the axle to the main trailerframe and absorb the shock loads from the road.Walinga trailers can be equipped with either amechanical or air ride suspension system. Eithersystem works well and will provide many years oftrouble-free service.

102

Description

Quik-Align™Pivot Bolt

Shock Bolt

Air Spring Bolt (Lower)

Air Spring Nut (Upper)

Brake Dust Shield Bolt

ABS Bracket Bolt

7/8"-9

3/4"-10

1/2"-13

3/4"-16

5/16"-18

1/4"-20

Size

475-525 Ft. Lbs

150-175 Ft. Lbs.

25-35 Ft. Lbs.

45-55 Ft. Lbs.

160-180 In. Lbs.

75-100 In. Lbs.

Torque

Table 6 Bolt Torque Values For Hendrickson Turner Suspensions

Every 25,000 miles (40,000 km) or 3 months,visually inspect all components and welds forcracks, distortions or other damage. Repair orreplace all defective components before placingunit into service.

Every 5,000 miles (8,000 km) or monthly, checkthe clearance around all the suspension systemcomponents. Correct any interference problem.Retorque all the fasteners to their specifiedtorque.

Fig. 8-29 SUSPENSION

An air ride suspension consistsof air springs that are inflated andpressurized by the trailer airsystem and controlled by a heightcontrol valve. It is a simplesystem that requires minimalservicing and maintenance toperform well.

Visually inspect the trailer at thestart of the day or trip to checkthe condition of the suspension.When the suspension is in goodcondition, the frame will be leveland at the proper ride height.Also, check for loose fastenersor damaged components.Correct any problems beforeplacing the trailer into service.Problems caught early andcorrected minimize cost anddowntime.

8.11.1 AIR RIDE SUSPENSION

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2. Shock Absorber Replacement:Shock absorbers remove energy from thesuspension system as the trailer encountersholes and bumps on the road surface. Theyalso act as a stop for the air springs to preventthe axle from moving too far away from theframe and tearing or damaging the air spring.

a. Remove the upper and lower mountingbolts.

b. Remove old shock and install new one.

IMPORTANT

Use only correct HendricksonTurner replacement parts. Sub-stitute parts do not work with thesuspension system.

c. Secure shock by tightening mounting boltsto their specified torque of 250 ft. lbs. (338N.m).

3. Pivot Bushing:Pivot bushings are a very durable, long lastingcomponent. Bushing failures are rare andshould be attempted only when all otherproblem causes have been eliminated. Abushing removal/installation tool is availablefrom Hendrickson Turner when replacing thebushing and can be borrowed from yourdealer or distributor. A 10 ton portable hydrau-lic press must be supplied by the customer.Purchase the bushing replacement kit thatincludes a new bushing, pivot bolt kit andlubricant.

When replacing the bushing, follow thisprocedure:

a. Use a torch to "cut off" the Huck fastenersfrom the clamping bolt.

b. Press out the old bushing and press in thenew one.

c. Install the clamping bolt and tighten thefastener to 800 ft. lbs. (1080 N.m).

d. Tack weld the nut to the bolt to preventloosening.

Typical repairs include but are not limited to:

1. Air Spring Replacement:Air springs are designed to be virtuallytrouble-free throughout their life. Problemsseldom occur unless they are cut, punctured,abraded, pinched or torn and then they mustbe replaced.

a. Block the wheels to prevent trailermovement.

b. Exhaust air from the suspension system.

c. Raise and support the frame on safetystands.

NOTE

Do not raise frame too highunless shock absorbers areinstalled to prevent over-extend-ing the air spring.

d. Disconnect the air lines to the airspring(s).

e. Loosen mounting bolts and remove airspring(s).

f. Install new air spring(s).

g. Tighten mounting bolts to their specifiedtorque of 50 ft. lbs. (68 N.m).

h. Install air lines and tighten to their speci-fied torque.

i. Repeat on other air springs.

j. Remove stands from under frame.

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Valve Schematic

System Schematic

Fig. 8-30 RIDE HEIGHT CONTROL

Valve

8.11 SUSPENSION SYSTEM (cont'd)

8.11.1 AIR RIDE SUSPENSION (cont'd)

4. Air Control (Ride Height Control):An air ride suspension system uses theair from the tractor to pressurize the airsprings. A single height control valve isused to monitor the height of the frameabove the axle and add/exhaust air fromthe system as required to maintain thisdimension. Normally this dimension isset for your trailer and never changes.

The height control valve is located onthe rear axle of the axle assembly areaon the trailer and controls the adding/exhausting of air to the air springs. Asthe dimension between the frame andaxle increases, the control lever movesdown and air is exhausted from thesystem. As the dimension decreases,air is added to raise the frame. Allvalves incorporate a 5 to 15 second timedelay to minimize jerking or cycling.Replace valve if not functioning properly.

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5. Dump Valve:All air control systems are equipped with adump valve that allows the operator to exhaustthe air from the system as required.

a. Always dump the air when parking thetrailer and before unhooking.

b. Dumping the air is optional when:

i. Loading: The rapid orsudden addition of load tothe trailer can cause thecontrol valve to search forneutral. Exhausting the airrests the frame on theinterval bumper and pre-vents the valve fromsearching. When theloading is completed, closethe valve to repressurizethe system.

105

Fig. 8-31 DUMP VALVE

ii. Unloading: Dumping rapidly can alsorequire the valve to search for neutral.Close the valve when the unloading iscompleted to repressurize the system.

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8.11 SUSPENSION SYSTEM (cont'd)

8.11.2 MECHANICAL SUSPENSION

Two types of mechanical suspensions are avail-able on the trailer and must be specified andordered from the factory. Both work well andprovide the customer with a choice.

The standard suspension for the tandem andtriaxle models are the Reyco 21B 8 leaf and theHutch 9700 3 leaf. Both are designed to requireminimal service and maintenance on a trailer.However, these service intervals and maintenanceprocedures must be followed:

Service Intervals:1. Follow the break-in procedure specified in

Section 4.3.

2. Visually inspect the suspension at the start ofthe day or trip for bent, broken or loose com-ponents. Always correct these conditions andperform a complete check-out of the suspen-sion before placing the trailer back in service.

3. After each additional 25,000 miles (40,000km), or every 3 months, retorque all thefasteners to their specified torque per thefollowing table. Always use an accuratetorque wrench when retorquing fasteners andattach to the nut.

4. 25,000 miles (40,000 km) or every 3 months,inspect the following:

a. Check position of clamp if moveableclamps used. Clamping legs must becentered over slot in end tube.

b. Check fit and function of all bushings.

106

Description Size Torque

Ft. Lbs. N.m

Equalizer Shaft (All Spread)49" Spread54"-65-1/2" Spread72"-109" Spread

U-Bolt Nuts

Torque Arm Bolt Nuts

Torque Arm Clamping Nuts

Spring Retainer Nuts

1-1/4" Nut3/4" Capscrew

2-1/2" Nut1-1/2" Nut

1"

1/2"3/4"

1/2"

575-625200-225300-325200-225

300-325

160-200

80175-200

80

780-850270-305410-445270-305

410-445

216-270

110236-270

110

Table 7 Suspension Fastener Torque Requirements

c. Check all hanger and hanger bracingwelds for cracks.

d. Check all other welds for signs of cracksor distortion.

e. Check fit of springs in hangers andequalizers.

f. Check equalizers for excessive wear atspring ends.

g. Check suspension system alignment.

5. In addition to checking the alignment at therecommended intervals, axle alignment shouldbe checked when any of the followingconditions occur:

a. Discovery of loose fasteners or compo-nents.

b. Discovery of elongated holes in a suspen-IMPORTANT

A loose fastener is defined as onewhose torque has dropped belowits specified level.

sion system component.

c. Whenever bushings are replaced.

d. Whenever excessive or abnormal tirewear is observed.

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8.11 SUSPENSION SYSTEM (cont'd)

8.11.3 SUSPENSION SYSTEM SCHEMATICS

107

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8.12 TIRE WEAR PATTERNS

The way your tires wear is a good indicator ofother parts of the suspension. Abnormal wearpatterns are often caused by the need for simplemaintenance or axle alignment.

a. Over-Inflation:Excessive wear at the center of the tireindicates the air pressure in the tire is consist-ently too high. The tire is riding on the centerof the tread and wearing it prematurely.Occasionally, this wear pattern can result fromoutrageously wide tires on narrow rims. Thecure for this is to replace either the tires of thewheels.

Fig. 8-32 OVER-INFLATED

Fig. 8-33 UNDER-INFLATED

b. Under-Inflation:This type of wear usually results from consist-ent under-inflation. When a tire is under-inflated, there is too much contact with theroad by the outer treads, which wear prema-turely. When this type of wear occurs, and thetire pressure is known to be consistentlycorrect or the need for axle alignment could beindicated.

Fig. 8-34 FEATHERING

c. Feathering:Feathering is a condition when the edge ofeach tread rib develops a slightly roundededge on one side and a sharp edge on theother. By running your hand over the tire, youcan usually feel the sharper edges before youwill be able to see them. The most commoncauses of feathering are incorrect toe-insetting, deteriorated bushing in the suspensionor misalignment.

Over-Inflation

Under-Inflation

Feathering

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Fig. 8-35 ONE-SIDE WEAR

Fig. 8-36 CUPPING

Fig. 8-37 SECOND RIB WEAR

e. Cupping:Cups or scalloped dips appearing around theedge of the tread almost always indicate worn(sometimes bent) suspension parts. Adjust-ment of axle alignment alone will seldom curethe problem. Any worn component thatconnects the wheel to the suspension cancause this type of wear. Occasionally, wheelsthat are out of balance will wear like this, butwheel imbalance usually shows up as baldspots between the outside edges and centerof the tread.

f. Second Rib Wear:Second rib wear is usually found only in radialtires, and appears where the steel belts end inrelation to the tread. It can be kept to aminimum by paying careful attention to tirepressure and frequently rotating the tires. Thisis often considered normal wear but excessiveamounts indicate that the tires are too wide forthe wheels.

d. One-Side Wear:When an inner or outer rib wears faster thanthe rest of the tire, the need for axle alignmentis indicated. There is excessive camber in theaxle causing the wheel to lean too muchexcessive load on the one side of the tire.Misalignment could also be due to saggingsprings, or worn suspension system compo-nents.

One side wear

Cupping

Second-rib wear

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8.13 AIR SYSTEM

Trailers are equipped with an air system, that ispressurized by a compressor on the tractor, foroperating the discharge gates, brakes and airsuspension (if so equipped). All components mustbe in good condition for the system to function andperform as intended. The air system must beinspected to be kept in good condition and func-tional checks performed to be sure it is operatingas required.

8.13.1 AIR SYSTEM INSPECTION

The pre-trip or pre-start inspection include severalair system related checks, inspections or tasksincluding but not limited to:

Daily1. Check that the glad hands are clean and in

good condition. Check seals in glad handClean, repair or replace as required.

2. Check that the air hoses between the tractorand the trailer are routed to prevent rubbing,chaffing or pinching. Reroute to correctcondition if required.

3. Drain moisture from all air tanks. Pull on thecable attached to drain valve on the bottom ofeach tank until the water or spray no longercan be seen.

IMPORTANT

Tanks must be drained daily in high humidityand cold temperature conditions to preventgetting water or ice in the system.

4. Check that all the lines and hoses conveyingair along the frame are tied up and secured toprevent dragging, scuffing or snagging. Tieup or protect as required to correct the condi-tion. Damaging an air system component cancause a sudden loss of pressure and result ina loss of service brakes.

110

8.13.2 AIR SYSTEM FUNCTIONAL

A vehicle air system is a combination of the componentson the tractor and the trailer. All must be maintained ingood condition for the entire system to function asrequired. Although a visual check will indicate the outercondition of the components, it does not indicate theleaks or responsiveness of the system. To evaluate theintegrity and responsiveness of the system, performthese functional checks:

1. Attach the trailer to a tractor and connect all the airand electrical lines.

2. Block wheels.

3. Stop tractor engine and exhaust air from all tanks.

4. Start engine and run at fast idle (1200-1500 RPM) tocharge the air system.

Verify that:a. Low pressure alarm goes off when the system

pressure exceeds 50 psi.

b. Increasing the system pressure between 50 psiand 80 psi takes less than 3 minutes.

c. The compressor cuts out when the systempressure exceeds 120 psi.

d. Fan brakes to use air. Compressor mustengage when system pressure drops below 105psi.

NOTE

Release spring brakes beforefanning service brakes.

5. Push emergency valve to charge trailer system. Applyand release service brakes.

6. Build system above 120 psi and stop engine.

Verify that:a. Main tank pressure does not drop more than 18

psi when brakes are fully applied using brakepedal. If pressure drop exceeds 18 psi, adjustbrakes and recheck.

b. System pressure should not drop more than 4 psiper minute. Listen for audible leaks.

c. Release foot valve, fan treadle to drop mainreservoir pressure. Brakes should dynamiteautomatically when the pressure drops below 60psi.

Adjust or repair system until these conditions are met.

IMPORTANT

New FMVSS-121 regulations mandatehigher pressures in the supply line toinsure proper brake operation. Set thecompressor pressure for cut-in to 105psi and cut-out to 120 psi. Do not useadditives in the air systems.

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8.13.3 AIR SYSTEM SCHEMATICS

111

Tandem Axles - 2 Tank 2 Valve

Triaxle - Tridem W/FF2

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Trailers can be equipped with a system thatcontrols the brakes on a vehicle to prevent wheellock-up when braking. The system consists of anECU (Electronic Control Unit), Modulator (ABSmodulator valve), tooth wheel, wheel speed sensorand wiring harness. The system configuration isdetermined by the number of wheel sensors andrelay valves in the system. The system isdesigned with a self-diagnostic feature thatmonitors the condition of the system and canindicate system faults through a series of cooledflashing lights. Each operator and/or servicemanshould have a copy of the Service Booklet fromRockwell that explains the Blink Code DiagnosticsSystem. Use the ECU/Valve serial number andconfiguration to specify the applicable booklet foryour system.

1. Power:The system can be powered by tapping intothe "live" wiring harness or through the brakelight circuit. With the former, the system is ONwhenever the ignition key is turned on. Withthe latter, the system is ON when the brakesare applied.

2. Function:Sensors on each wheel monitor wheel speedand transmit a signal to the ECU. Duringheavy, severe and emergency braking orhazardous road conditions, the ECU monitorsand compares the speed of each wheel todetermine if any are slowing too rapidly. If awheel is slowing too rapidly, the ECU workswith the modulator valve to relieve the airpressure to the brake son that wheel toprevent lock-up. By preventing wheel lock-up,each wheel provides maximum braking forceand eliminates trailer instability.

3. Warning Lamp:Each system is equipped with a warning lampto display the condition of ABS system to thedriver/operator. Be familiar with the meaningof the warning lamp codes before using thetrailer.

8.14 ABS VEHICLE CONTROL SYSTEM

a. On a stoplight activated system, thewarning lamp comes ON when you applythe brakes and goes OFF when yourelease the brakes on a stationary vehicle.

b. On a constant-power system, the warn-

Brakes

Released

Applied

Applied

Applied

WarningLamp

Off

On

Flashes once, thenstays off for

remainder of stop.

On for duration ofstop.

Fault inSystem

N.A.

N.A.*

No

Yes

VehicleSpeed

N.A.

< 4 mph

> 4 mph

N.A.*

Warning Lamp With Stoplight Power

* At less than 4 mph, you cannot tell whether thelight indicates a fault or an incomplete self-check.To tell if there is a fault, you must apply the brakeswhile driving faster than 4 mph to see if the lightstays on during the application.

Ignition

Off

On

On

On

Warning Lamps(on Trailer and

Dash)

Off

On**

Off

On

Fault inSystem

N.A.

N.A.**

No

Yes

VehicleSpeed

N.A.

< 4 mph

> 4 mph

N.A.**

Warning Lamp With Constant Power

* The light comes on at the initial activation of theECU, not each time the vehicle slows down below4 mph. Until the vehicle initially exceeds 4 mph,you cannot tell if the light indicates a fault or anincomplete self-check. To tell if there is a fault,you must drive faster than 4 mph and see if thelight stays on. Once vehicle speed exceeds 4mph, the light remains off unless a fault occurs orthe ignition is turned off and then turned on again.

ing lamp comes ON when you turn theignition ON and goes OFF when thevehicle exceeds 4 mph (6 km/h).

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4. Faults:Whenever there is a fault/problem with thesystem or any of its components, thewarning lamp will not come ON per thetables listed on the previous page. Thesystem is designed with an internal self-diagnostic and memory system to tellservice personnel the cause and location/site of the fault/problem through theirdiagnostic blink code system.

5. Blink Code Diagnostics:A system can be accessed using a specialdiagnostic tool to plug into the ECU toidentify the faults/problems and locations.Purchase the appropriate tool and Mainte-nance Booklet for your system to keep it ingood operating condition. Each system isdesigned with blink code diagnostic code toidentify fault cause and location as definedin Maintenance booklet. Always correct anyfaults as they are identified to maintain theunit in top operating conditions.

Fig. 8-38 ABS CONFIGURATION4S/2M

2S/2M

2S/1M

Sensor Locations

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8.15 ABS SCHEMATICS

114

4S/2M

2S/1M

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8.16 ELECTRICAL SYSTEM

All trailers are equipped with an electricalsystem for providing power for lights andelectrical controls. All components are de-signed to minimize the effects of foul weatherand adverse operating conditions. However, itis the responsibility of the operator to checkand verify that all components are in goodcondition and functioning as intended.

During the daily or pre-trip inspection, alwaysverify that each light functions as required. Itmay be helpful to work with another individualto verify the function of the brake or turn signallights. A properly functioning electrical systemis the only way an operator can communicatehis intentions to other drivers. Checking theelectrical system includes but is not limited to:

1. Replace any bulb that is burned out.

2. Clean all reflective lenses. Replace anythat are cracked or broken.

3. Clean all connections and terminals to alight that is flickering.

4. Reroute and secure any wires or cablesthat are dangling or have snagged onsomething.

5. Check the integrity of the seal aroundeach light. Replace any seal that iscracked or damaged.

115

Rear

Terminal Box

Electrical Connectors

Fig. 8-39 LIGHTING

Function

Table 8 Trailer Light Requirements

Size(Watts)

8

27

27

8

5

P/N

4" Tail Lamp

Signal/Brake

Side Signal

Clearance

Marker

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8.16.1 ELECTRICAL SCHEMATICS

116

Light Schematic

Remote Switch Schematic

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8.17 HYDRAULIC SCHEMATICS

117

Tandem Pump - Tractor Wetline

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118

Hopper Auger

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8.17 HYDRAULIC SCHEMATICS (cont'd)

119

Hopper Blower

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120

Hopper Stinger

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8.17 HYDRAULIC SCHEMATICS (cont'd)

121

Hopper Auger Blower

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122

Hopper Auger Stuffer

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8.17 HYDRAULIC SCHEMATICS (cont'd)

123

Hopper Auger Stuffer Blower

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Each compartment is equipped with a gatethat controls the flow of material into thetrough conveyor. Each gate is opened andclosed manually with a crank or with an aircylinder.

For units built prior to 1999, (see figure 8-40)the tracking chain must be positioned snuglyagainst the sprocket to prevent tooth jumpingor jamming. To adjust the tracking chain,follow this procedure:

1. Stop engine and remove ignition key.

2. Enter compartment and remove coverover tower.

3. Loosen jam nut on tracking chain positionbolt.

4. Use the position nut to properly locate thetracking chain against the sprocket.

5. Tighten jam nut to its specified torque.

124

8.18 GATE TOWER - MANUAL

Tower

Tracking Chain Position Bolt

Fig. 8-40 MANUAL GATE

Machine is shown with guard removed oraccess door opened for illustrative pur-poses only. Do not operate machine withguard removed or access door opened.

WARNING

Fig. 8-40A NEW STYLE MANUALGATE (ON UNITSBUILT AFTER

1999)

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9 BOOM ROTATION DRIVE SYSTEMEach unit is equipped with a boom thatcan be rotated into position for unloading.A dual stage roller chain drive systemprovides an infinitely variable system forpositioning the boom to any feed storagefacility. For the system to function asrequired, the roller chain must be lubri-cated monthly and the chain tensionmaintained at the proper level.

To set chain tension, follow this proce-dure:

1. Place all controls in neutral, disen-gage PTO clutch, stop engine, setpark brake, remove ignition key andwait for all moving parts to stop.

2. Remove guards over boom rotationdrive system.

3. Check tension of each chain. Withthe proper tension, the chain candeflect 1/8 inch (3 mm) at the centreof the span.

4. To adjust chain tension:a. Use the nut on the sprocket

position bolt to set the position ofthe sprocket assembly.

Hydraulic Motor Assembly

Fig. 9-1 BOOM ROTATION DRIVE SYSTEM

125

NOTE

Always set the sprocket positionfirst.

Drive System

Sprocket Position Boltb. Loosen the hydraulic motorassembly mounting bolts.

c. Slide or tap the motor assemblyinto the desired position.

d. Tighten motor assembly mount-ing bolts to their specified torque.

5. Install and secure the drive systemguards.

Machine is shown with guard removedor access door opened for illustrativepurposes only. Do not operate ma-chine with guard removed or accessdoor opened.

WARNING

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10 TROUBLE SHOOTINGThe Walinga Bulk Feed Unit uses an auger, air or a dual system for unloading material as required. It is asimple and reliable system that requires minimal maintenance.

In the following section, we have listed many of the problems, causes and solutions to the problems thatyou may encounter.

If you encounter a problem that is difficult to solve, even after having read through this trouble shootingsection, please call your local Walinga dealer or distributor. Before you call, please have this Operator'sManual and the serial numbers from your trailer ready.

PROBLEM CAUSE SOLUTION

1. Air Ride Suspension

Suspension beams installed outof parallel.

Axle welds missing or broken.

Failed pivot bushing (rare).

Trailer out of alignment.

Missing or broken alignmentcollar welds.

Suspension not square to axle.

Air springs misaligned.

Failed pivot bushing (rare).

Determine which beam is out ofparallel, cut from axle, repositionand re-weld.

Clear away old welds, repositionthe beams to be parallel and re-weld to axle.

Contact Hendrickson TurnerTechnical Service Department.

Remove weld from the alignmentcollars on those axles requiringadjustment. Realign per procedureprovided by Hendrickson Turner.

Clear away failed welds and realignper procedure provided byHendrickson Turner.

Contact the Hendrickson TurnerTechnical Service Department.

Compare the installation to thesuspension drawing and repositionmountings as required.

Contact the Hendrickson TurnerTechnical Service Department.

Trailer leans......constantly in one direction

...varies from side to side.

...varies in one direction.

Trailer "Dog-Tracks"......constantly to one side.

...from side to side.

...to one side under load.

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PROBLEM CAUSE SOLUTION

1. Air Ride Suspension (cont'd)

Incorrect alignment.

Suspension beams out of parallel(vertically or longitudinally).

Frame bracket centers do notmatch the suspension beamcenters.

Use of improper bushing lubri-cant.

Faulty or worn bushing.

Failed bushing.

Re-bush the suspension and re-align as per Hendrickson Turnerinstructions.

Determine which beam(s) is out ofposition, cut from axle, repositionand weld. Re-bush both suspen-sion pivots.

Compare the installation dimen-sions to the suspension assemblydrawing. Reposition the incorrectcomponents and re-bush bothsuspension pivots.

Re-bush using lubricant supplied byHendrickson Turner.

Replace bushing.

Rubber protruding from both endsof the bushing tube is normal.Excess rubber protruding from oneend can indicate a bushing walkcondition.

Bushing WalkThe suspension beams haveshifted from the center of thepivot bushings).

Pivot can be moved vertically.

Bushing protrudes from thebushing tube.

PROBLEM CAUSE SOLUTION

2. Mechanical Suspension

Improper suspension spring Broken or cracked spring leaves. Replace complete spring.action.

Uneven load distribution. Rearrange load for proper distribution.

Weak spring. Replace spring.

Springs out of alignment in Align springs and tighten U-bolts tohangers due to loose U-bolts. proper torque.

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PROBLEM CAUSE SOLUTION

3. Tires

Inflate to proper pressure.

Tighten wheel stud nuts or clamps.

Adjust bearings.

Straighten, align or replace axle.

Match tires.

Correct brakes as required.

Apply brakes slowly when ap-proaching stops.

Reduce speed.

Inflate to proper pressure.

Reduce speed.

Torque tighten all rim clamps.

Replace bearings.

Replace wheel or rim.

Replace or straighten axle.

Replace leaf or complete spring.

Replace or straighten axle.

Straighten frame or align axles.

Over or under inflation.

Loose wheel stud nuts or clamps.

Loose or tight wheel bearing.

Axle bent or out of alignment.

Tires not properly matched.

Improper acting brakes.

Rapid stopping.

High speed.

Over or under inflation.

Excessive speed on turns.

Tire wobble due to uneven rimclamping.

Worn or damaged wheel bear-ings.

Bent wheel or rim.

Bent axle.

Leaf spring broken.

Bent axle.

Frame or suspension (axles) outof alignment.

Loss of tire air pressure. Puncture in tire. Repair or replace tire.

Faulty valve or valve core. Replace valve assembly or core.

Wheel or rim damage. Replace wheel or rim.

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PROBLEM CAUSE SOLUTION

4. Electrical

Check electrical system circuits.

Repair as required.

Charge battery.

Repair or replace cable.

Repair as necessary.

Repair or replace.

Replace junction box.

Repair as required.

Repair or replace cable as required.

Repair or replace.

Repair or replace junction box.

Bad connection.

Frayed wires.

Battery on tractor not sufficientlycharged.

Damaged or disconnected wireon ground cable.

Poor ground at sockets.

Broken main harness.

Junction box failure.

Frayed wires.

Damaged or disconnectedground cable.

Loose or corroded connection inground lead between tractor andtrailer.

Internal short in junction box.

Lights flicker or do notcome on.

Complete loss of trailer lights.

Lights flash improperly orappear to be crossed.

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PROBLEM CAUSE SOLUTION

5. Air System

Excessive compressorcycling.

Trailer brakes slow andsluggish.

Air leak.

System or component failure.

Check air line fittings and hoseconnections on service or supplyline.

Check service chamber at clamphousing, push rod for damage.

Check service chamber diaphragm.

Check emergency chamber clampand vent holes for leakage.

Repair or replace air chamber asrequired.

Check FFVII brake valve if soequipped. Repair or replace asrequired.

Check slack adjuster and chamber/spring brake push rod alignment forinterference.

Assure slack adjuster and chamber/spring brake push rod angle 90°applied with proper adjustment.

Assure open lines - no kinks, bends,closed shut-off cocks, restrictions,excessive elbows.

Assure adequate tractor brakefunction.

Have authorized service centercheck for adequate pressure andtiming balance relative to tractor/trailer application.

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131

PROBLEM CAUSE SOLUTION

5. Air System (cont'd)

Trailer brakes drag.

Trailer brakes won't apply(service).

Park/emergency brakes won'trelease.

System or component failure

System or component failure.

System or component failure.

Assure emergency line exceeds 120psi pressure; check and maintaingovernor at max. cut-in.

Check slack adjuster and chamber/spring brake push rod alignment forinterference.

Assure slack adjuster and chamber/spring brake push rod angle 90°applied with proper adjustment.

Assure open lines - no kinks, bends,closed shut-off cocks, restrictions,excessive elbows.

Check for trapped service air pres-sure at trailer service/delivery hoses.If air pressure is noted, check for fullrelease of all application valves(tractor/truck/trailer).

Check air delivery to emergencysystem.

Check air delivery to servicegladhand.

Check air delivery to air chamber orspring brake.

Check air delivery to all reservoirs atsystem working pressure.

Check slack adjuster and chamber/spring brake push rod alignment forinterference.

Check slack adjuster and chamber/spring brake push rod angle 90°applied with proper adjustment.

Check air jumper hoses are notcrossed between tractor and trailer.

Check air delivery to emergencygladhands exceeds 120 psi.

Check air delivery to FFV valve.

Check air delivery to all reservoirs atsystem working pressure.

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PROBLEM CAUSE SOLUTION

5. Air System (cont'd)

Park/emergency brakeswon't release (cont'd).

Park/emergency brakeswon't hold.

Air reservoir leaks or loosemounting.

Semi-trailer "Runs-Up" ontractor.

Poor braking performance.

System or component failure(cont'd).

System or component failure.

System or component failure.

Check brake linkage.

Uneven brakes.

Check open lines - no kinks, bends,closed shut-off cocks, restrictions,excessive elbows.

Check that brake shoes are notfrozen to drums.

Check slack adjuster and chamber/spring brake push rod alignment forinterference.

Assure slack adjuster and chamber/spring brake push rod angle 90°applied with proper adjustment.

Replace/use rubber grommets withintegral brackets.

Assure slack adjuster and chamber/spring brake push rod angle 90°applied with proper adjustment.

Check gladhand connection.

Assure open lines - no kinks, bends,closed shut-off cocks, restrictions,excessive elbows.

Have authorized service centercheck for adequate pressure andtiming balance relative to tractor/trailer application.

Check slack adjuster and chamber/spring brake push rod angle 90°applied with proper adjustment.

Check open lines - no kinks, bends,closed shut-off cocks, restrictions,excessive elbows.

Check for leaks in system by apply-ing service brake and inspecting.

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PROBLEM CAUSE SOLUTION

5. Air System (cont'd)

Poor braking performance(cont'd).

Trailer brake lining wear exces-sive.

Trailer brakes slow to apply.

Trailer service brakes slow torelease.

Slack adjuster not auto-adjusting.

Cracked housing.

Worn clevis pin bushing.

Have authorized service centercheck for adequate pressure andtiming balance relative to tractor/trailer application.

Proceed per problem "trailer brakesdrag."

Check slack adjuster and chamber/spring brake push rod angle 90°applied with proper adjustment.

Check air delivery to all reservoirsat system working pressure.

Check open lines - no kinks, bends,closed shut-off cocks, restrictions,excessive elbows.

Have authorized use of "jumperhose analyser" and duplex gauge topin-point brake imbalance.

Check functional return spring inservice chamber or spring brake.

Check open lines - no kinks, bends,closed shut-off cocks, restrictions,excessive elbows.

Have authorized use of "jumperhose analyser" and duplex gauge topin-point brake imbalance.

Check for damaged actuator rod.Replace as required.

Slack adjuster internal componentsseized. Replace.

Replace slack adjuster.

Replace bushing

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134

PROBLEM CAUSE SOLUTION

5. Air System (cont'd)

Poor braking performance(cont'd).

Full function valve (FFV) leaks atexhaust port with all brakesreleased.

Full function valve (FFV) leaks atexhaust port with service brakesapplied.

Spring parking brake (serviceonly service chamber side ofspring brake) drags or won'trelease.

Spring parking brake leaks whenpressurized for park brakerelease.

Replace FFV valve.

Replace FFV valve.

Check for:- Improper adjustment, restriction

or broken line.- Diaphragm failure.- System pressure too low (120 psi

min).- Replace entire unit or piggy-back

emergency section.

Check for:- Ruptured spring side diaphragm.- Hose leaks.- Repair hose leak or replace

spring brake chamber.

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135

PROBLEM CAUSE SOLUTION

6. Hydraulic System

No oil pressure.

Noisy pump.

Discharge auger will not raise.

Vertical, discharge and flooraugers running in reverse.

Auger does not turn whenmotor is running.

Auger will not swivel whenmotor is running.

Extreme pressure needed toswivel discharge.

Discharge and floor augerexceedingly noisy.

Evidence of oil in feed.

Hose hook up incorrect.

Loose coupling in driveline.

Loose connection.

Air in oil.

Bent drive shaft.

Low oil supply.

Air in oil.

See if boom lock is released.

Low oil pressure.

Wrong motor rotation afterbeing repaired.

Key in auger bushing is sheared.

Motor shaft is broken.

Broken chain.

Key in motor shaft is sheared.

Motor shaft is broken.

Lack of lubrication on pivot rings.

Nylon lining worn or damaged.

Loose hanger bearing.

Leaking oil seal on boom auger orvertical auger motor.

Reverse hoses on pump.

Check setscrews in driveline.

Check hose fittings.

Check hose fittings.

Check driveline.

Increase oil in reservoir.

Check hose fittings.

Check for air leaks.

PTO in jammed gear.

Check line pressure at suggestedRPM.

Switch oil lines.

Replace key.

Remove motor and check shaft.

Replace or repair chain.

Replace key.

Remove motor and check shaft.

Lubricate pivot rings.

Remove auger, check and repairworn nylon.

Tighten bearing.

Remove motor and replace seal.

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136

PROBLEM CAUSE SOLUTION

7. Orbit Motor

Slow operation.

Motor will not turn.

Motor runs without turningshaft.

Motor turns in wrong directionafter being replaced.

Leak at shaft.

Plugged filter.

Relief setting too low.

Worn pump.

Worn motor.

Extremely high fluid temperaturecausing pump and motor to slip(temp. increase as pump andmotor wear).

Inadequate size oil lines.

Pump cavitation.

Shaft seized in housing due toexcessive side load or misalign-ment (Note 500 lb. max. radialloading on shaft).

Large contaminating particles influid such as machining chips orsand - very dirty fluid.

Broken shaft from extreme sideloads or misalignment.

Broken shaft.

Hose connections wrong.

Worn or cut quad-ring.

Replace filter element or clean filter.

Set relief valve for proper PSI.

Repair or replace pump.

Replace worn parts or motor.

Increase reservoir size and use ahigh viscosity index such as20W40.

Increase oil lines.

Increase oil line size to pump, incold weather, use 5W20 oil.

Replace housing assembly set ifdamaged.

Flush new systems - use betterfiltration.

Correct and replace.

Replace shaft assembly - checkhousing for wear and replace ifnecessary.

Reverse connections.

Replace quad-ring, polish shaft atseal area with #600 wet or drysanding cloth.

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137

PROBLEM CAUSE SOLUTION

7. Orbit Motor (cont'd)

Leak between flange andhousing.

Leak between housing andwear plates or between wearplates and gerotor.

Leak between gerotor andend cap.

Cracked front flange.

Leak at oil ports.

Loose flange.

Damaged seal between housingflange.

Leak in body plug seal.

End cap bolts loose.

(Note: All motors are tested andrated of a maximum back pres-sure of 1000 PSI).

Dirt between surfaces.

Scratches or nicks on surfaces.

Use installation bolts which aretoo long and bottom againsthousing.

Poor fittings.

Damaged threads.

Tighten.

Replace seal. Check housingsurface at seal for sharp nicks ordeep scratches.

Replace faulty o-rings.

Tighten the cap screws at gerotorend of motor - if the threads areaccidentally stripped in the housing,the hole may be drilled and tappeddeeper and the motor reassembledw/longer bolts.

Reassemble - clean and dry parts.

Polish very carefully on a flat, hardsurface - use #600 or finer abrasivecloth and very little pressure - avoidrounding edges.

Replace flange and use proper sizebolts.

Replace fittings carefully.

Replace housing or use nut such astrue seal.

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138

PROBLEM CAUSE SOLUTION

8. Hydraulic Failures

a. Cavitation. Insufficient inlet flow. Wrong pump speed. Slow downengine RPM and pump speed.

System hoses too small. Replacehoses with larger size.

Tank below line inlet. Change inletto bottom of tank.

Pressure hose used as suctionhose. Intake hose too small.Increase size of intake line.

Detergent oil in hydraulic system.Drain and flush hydraulic system.Replace with specified (non-detergent) oil.

Air getting into system (aeration).Tighten all fittings and extend returnline outlet below fluid surface inreservoir.

Suction filters restricting flow.Replace all filters and clean allscreens.

Clogged or inadequate breather.Clean or replace breather.

Wrong oil for climatic conditions.Change to proper oil.

Poor tank construction. Replacewith better tank.

Abused by overspeeding. Replacepump and don't overspeed.

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139

PROBLEM CAUSE SOLUTION

8. Hydraulic Failures (cont'd)

a. Cavitation (cont'd). Contamination Condensation in system and tank.Drain and flush system. Fill withspecified oil. Increase frequency ofchanging oil.

Inclement weather. Allow system towarm before operating.

Poor tank construction. Replacewith better tank.

Incorrect material for piping (galva-nized). Replace all piping. Usesteel. Drain and flush system.Replace with clean oil.

Dirty environment. Change oil andfilters more frequently.

Poor handling of oil. Only use cleancontainers to store and transport oil.Filter oil before adding to system.

Clogged or by-passing filter. Re-place filter and change filters morefrequently.

Sabotage. Keep unit in locked andcontrolled environment.

Cavitation contaminants. Replacepump. Drain and flush system.Replace with specified oil.

Stuck relief valve. Clean or replace

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valve.

Running without oil. Do not runwithout oil or with low oil.

Requirements for cooler disre-garded. Install cooler.

Leaving PTO in gear. Alwaysdisengage PTO when there is nodemand for oil.

System operating at or above reliefsetting for extended period.Change operating procedure toreduce pressure requirements.Replace oil and damaged compo-nents.

Hoses have too many fittings andtoo many angles. Replumb systemto reduce fittings and angles.

Poor reservoir design, placement orpaint. Install new reservoir in a newplace.

Indirect line routing. Replumbsystem to improve routing.

Poor hose construction. Replacewith better hoses.

Improper hose selection. Replacewith better hoses.

Lack of proper maintenance.Improve and increase maintenancefrequency.

Restrictions in system from poordesign and/or improper componentselection. Review system designand change components as re-quired.

b. System exceeds pressure specifications over-heats.

Worn bearings: Cracks anddiscoloration.

Warped wear plates or pressurebalance plates.

Internal seal destruction: Var-nish deposits.

Extreme gear path cutout/raggedand rough edges.

Heat checked or discoloredgears.

Components seize.

Housing cracks.

PROBLEM CAUSE SOLUTION

8. Hydraulic Failures (cont'd)

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11 SPECIFICATIONS

141

Model No.

HA-20-UL

HA-24-UL

HA-28-UL

HA-32-UL

HA-34-UL

HA-36-UL

HA-36-UL

HA-38-UL

HA-38-UL

HA-40-UL

HA-40-UL

No. of CompartmentsSize of Compartments

Five (48")

Six (48")

Seven (48")

Eight (48")

Eight (51")

Eight (54")

Nine (48")

Eight (57")

Nine (48")

Ten (48")

Eight (60")

Base UnitWeight lbs/kg

10,611/4813

11,351/5149

12,091/5485

12,831/5823

13,161/5970

13,485/6117

13,571/6156

13,809/6264

13,895/6303

14,305/6489

14,133/6411

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

Cubic CapacityBased on 44 cu. ft./ft.

880

1056

1232

1408

1496

1584

1584

1672

1672

1760

1760

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11.2 BOLT TORQUE

CHECKING BOLT TORQUE

The tables shown below give correct torque values for various bolts and capscrews. Tighten all bolts tothe torques specified in chart unless otherwise noted. Check tightness of bolts periodically, using bolttorque chart as a guide. Replace hardware with the same strength bolt.

ENGLISH TORQUE SPECIFICATIONS

SAE 2(N.m) (lb-ft)

Bolt Torque*Bolt

Diameter"A"

SAE 5(N.m) (lb-ft)

SAE 8(N.m) (lb-ft)

1/4"5/16"3/8"7/16"1/2"9/16"5/8"3/4"7/8"1"

81327416195128225230345

6102030456095165170225

12254572110155215390570850

919335380115160290420630

1736631001552203055408801320

12274575115165220400650970

METRIC TORQUE SPECIFICATIONS

8.8(N.m) (lb-ft)

Bolt Torque*Bolt

Diameter"A"

10.9(N.m) (lb-ft)

M3M4M5M6M8M10M12M14M16M20M24M30M36

.5361025509014022543575014952600

.42.24718376610316632155311031917

1.84.59153570125200310610105021003675

1.33.371126529214822945077415502710

Torque figures indicated above are valid for non-greased or non-oiled threads and heads unless otherwisespecified. Therefore, do not grease or oil bolts or capscrews unless otherwise specified in this manual.When using locking elements, increase torque values by 5%.

* Torque value for bolts and capscrews are identified by their head markings.

142

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TIGHTENING FLARE TYPE TUBE FITTINGS *

11.3 HYDRAULIC FITTING TORQUE

1. Check flare and flare seat for defectsthat might cause leakage.

2. Align tube with fitting before tightening.

3. Lubricate connection and hand tightenswivel nut until snug.

4. To prevent twisting the tube(s), use twowrenches. Place one wrench on theconnector body and with the secondtighten the swivel nut to the torqueshown.

* The torque values shown are based onlubricated connections as inreassembly.

RecommendedTurns To Tighten

(After FingerTightening)

(Flats) (Turn)

TubeSizeOD

(in.)

Nut SizeAcrossFlats

(in.)

TorqueValue*

(N.m) (lb-ft)

69121834467590

7/169/165/8

11/167/81

1-1/41-3/8

3/161/45/163/81/25/83/47/8

81216244662102122

111111

3/43/4

1/61/61/61/61/61/61/81/8

TIGHTENING O-RING FITTINGS *

1. Inspect O-ring and seat for dirt orobvious defects.

2. On angle fittings, back the lock nut offuntil washer bottoms out at top ofgroove.

3. Hand tighten fitting until back-upwasher or washer face (if straightfitting) bottoms on face and O-ring isseated.

4. Position angle fittings by unscrewingno more than one turn.

5. Tighten straight fittings to torqueshown.

6. Tighten while holding body of fittingwith a wrench.

RecommendedTurns To Tighten

(After FingerTightening)

(Flats) (Turn)

TubeSizeOD

(in.)

Nut SizeAcrossFlats

(in.)

TorqueValue*

(N.m) (lb-ft)

69121834467590105140160

1/29/165/8

11/167/81

1-1/41-3/81-1/21-7/82-1/8

3/87/161/29/163/47/8

1-1/161-3/161-5/161-5/81-7/8

81216244662102122142190217

22222

1-1/211

3/43/41/2

1/31/31/31/31/31/41/61/61/81/81/12

* The torque values shown are based onlubricated connections as in reassembly.

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12 INDEX

PAGE

I

Introduction ..................................................... 9

PAGEP

Suspension System ............................... 102 Air Ride Suspension ......................... 102 Mechanical Suspension .................... 106 Suspension System Schematics ....... 107 Wheels ................................................... 85 Wheel Hubs/Bearings ............................. 81

P

Periodic Maintenance and Adjustments ........ 75 ABS Vehicle Control System ................. 112 ABS Schematics .................................... 114 Air Chamber/Spring Brake ..................... 101 Air System ............................................. 110 Air System Functional ........................ 110 Air System Inspection ........................ 110 Air System Schematic ........................ 111 Axle Alignment ......................................... 79 Brakes ..................................................... 89 Electrical System ................................... 115 Electrical Schematics........................ 116 Fifth Wheel .............................................. 78 Gate Tower Manual ............................... 124 Hydraulic Schematics ............................ 117 King Pin and Fifth Wheel Plate ................ 77 Slack Adjusters ......................................... 92 Rockwell Automatic ............................ 92 Manual and Automatic Maintenance ... 93 Tires ........................................................ 87 Tire Wear Patterns ................................ 108 Torque Specification Summary ................ 75

O

Operation Guidelines .................................... 21 Break-In ................................................... 23 Controls ................................................... 31 Hooking Up/Unhooking ............................ 28 Hooking Up ......................................... 28 Unhooking .......................................... 30 Machine Placement ................................. 36 Operation ................................................. 39 Optional Equipment ................................. 52 Pre-Operation Vehicle Inspection Procedure ........................................... 25 Terminology ............................................. 22 To the New Operator or Owner................ 21 Transporting ............................................ 49 Breaking Guidelines ............................ 50 Operating Instructions ......................... 49 Tires ................................................... 51

S

Safety ........................................................... 10 General Safety ......................................... 11 Hydraulic Safety ....................................... 13 Maintenance Safety ................................. 13 Operating Safety ...................................... 12 Safety Signs ............................................ 14 Sign-Off Form .......................................... 15 Tire Safety ............................................... 14 Travel Safety ........................................... 14 Unloading Safety ..................................... 12Safety Sign Locations ................................... 16Service and Maintenance ............................. 54Service ......................................................... 54 Fluids and Lubricants .......................... 54 Greasing ............................................. 54 Hydraulic System ................................ 55Specifications ............................................. 141 Bolt Torque ............................................ 142 Hydraulic Fitting Torque ......................... 143

T

Trailer Servicing Intervals ............................. 56 Servicing Record Summary (Lubrication) .. 67Trouble Shooting ........................................ 126

U

Unloading System Servicing ......................... 68 Service Intervals ...................................... 68 Service Record ........................................ 74

B

Boom Rotation Drive System ...................... 125

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MANUAL COMMENT FORM

We would appreciate your input in helping us to provide you the customer, with improved manuals. Pleaseuse this form to submit Comments, Errors, Omissions, and Suggestions on this Manual. We would likeyour comments on things you do not like about this manual, as well as things you do like about themanual.

Please send this form via mail/e-mail or fax to Walinga Inc., or forward it to the closest Walinga Dealer orSales Representative. Thank you for your comments.

MANUAL NO. 34-____________________-6.

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CUSTOMER INFORMATION:

COMPANY NAME: ______________________________________________________________

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STREET ADDRESS: ____________________________________________________________

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SEND TO: Walinga Inc. FAX TO: (519) 824-5651Marketing Department E-MAIL: [email protected]# 5 Guelph OntarioCanada, N1H 6J2

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Head Office:RR#5

Guelph, Ontario,N1H 6J2PHONE (888) 925-4642

FAX (519) 824-5651www.walinga.com

FACTORY DISTRIBUTION AND SERVICE CENTRES:

IN CANADA: 70 3rd Ave. N.E. Box 1790 Carman, Manitoba Canada R0G 0J0

Tel (204) 745-2951 Fax (204) 745-6309 220 Frontage Rd. Davidson, Saskatchewan Canada S0G 1AO

Tel: (306) 567-3031 Fax: (306) 567-3039

IN USA: 1190 Electric Ave. Wayland, MI. USA 49348

Tel (800) 466-1197 Fax (616) 877-3474 579 4th Street NW

Sioux Center, Iowa USA 51250 Tel (800) 845-5589 Fax (712) 722-1128

PRINTED IN CANADAISSUE DATE: June, 1998 Auger UnloadREPRINT: January, 2008 Operators Manual OM PART# 34-17696-6