OPERATOR’S MANUAL€¦ · Conceive, build and sell high quality trailers keeping in constant...

OPERATOR’S MANUAL

Conceive, build and sell high quality trailers keeping in constant innovation and

giving priority to a close relationship with customers and employees.

Think ahead, move forward

1

ABS REMORQUES INC. LIMITED WARRANTY POLICY

ABS Remorques Inc. warrants, directly to the original purchaser only, that each new live bottom trailers will be free from defects in materials and

workmanship, provided that the equipment warranted hereunder is operated by the purchaser in accordance with the practices approved by ABS.

Loads are not exceeding the manufacturer’s rated capacities and are not corrosive in nature.

Trailer frame and all welded steel components assembled by ABS workers 1 year (100 %)

Conveyor chain, slats, drive shaft and rubber belt 1 year (100 %) Note 1

Hydraulic lines, hoses, fittings and aluminum bloc component 1 year (100 %) Note 2

Hydraulic motor (orbital motor) 1 year (100 %) Note 2

Planetary gearbox 1 year (100 %) Note 3

Tarp mechanism 1 year (100 %)

Airlines, air bags, leveling valves, paint, shock absorbers, bearings, brake valves

Pneumatic cylinder, electrical wiring or components 6 months

In the case of a material defect or workmanship covered by this warranty, ABS Remorques will correct it in its sole discretion by supplying a new

part or fixing it in an authorized service center or in his facility depending on the situation.

No warranty will be paid if ABS Remorques is not aware of a defect and no authorizations were given prior to it.

Note 1: If used in accordance with ABS Remorques approved practices, a pro-rated warranty will be applied to the belt, the chains, the slats and

the main drive shaft. 1 to 2 years (75%) – 2 to 3 years (50%) – 3 to 4 years (25%). The use of the trailer must be on a base of a maximum of 12

hours, 5 days a week. If trailer is use on a base of 24 hours per day this pro-rated warranty does not apply.

Note 2: Heat and dirt will damage the hydraulic components. Make sure that the connectors and the fluid cap reservoir are clean.

Note 3: The oil in the planetary gear box must be replaced as per manufacturer’s instructions.

Conceive, build and sell high quality trailers keeping in constant innovation and

giving priority to a close relationship with customers and employees.


2

COMPONENTS MANUFACTURER’S LIMITED WARRANTY POLICY

Here is a summary of our supplier’s warranty policies that will apply under normal use.

Axles

Suspension and lifting mechanism

Landing gear

Rims

Tires

Tarp motor

Lights (L.E.D.)

This warranty excludes such parts or accessories which are not defective, but may wear out and have to be replaced.

ABS Remorques shall not be liable to purchaser for any incidental or consequential damages suffered by the purchaser.

Conceive, build and sell high quality trailers keeping in constant innovation and giving

priority to a close relationship with customers and employees.


3

OPERATOR’S INSTRUCTIONS

Operating instructions must be given to everyone before operating our

live bottom trailer. This manual includes general safety and

maintenance information that will be helpful for the operation of the

semi-trailer.

CONNECTING THE TRACTOR TO THE TRAILER

Use the following procedure:

a) Slowly back up the tractor under the trailer until the 5th

wheel

king pin latches.

b) Connect the air service supply (red) and the air control (blue).

Make sure there are no leaks.

c) Connect the 7 way electrical harnesses to the SAE 7 pin

receptacle.

d) Connect the secondary harness if present. (This harness is

installed by the customer to operate the equipment like the

tailgate, the utility lights, the strobe lights, etc.)

e) Connect the hydraulic pressure hose to the upper wing nut

connector. (A pressure gauge is mounted on the trailer’s left

side on the pressure line.)

f) Connect the hydraulic return hose to the lower wing nut

connector.

g) Connect the tarp motor and the tarp control if equipped. (The

motor can be connected directly to the battery by using two 4

gauges wires and 30 amps breaker. The handheld control can

be connected to the control box located at the front or on the

front door)




4

ELECTRIC TARP OPERATION

To operate our ABS Remorques’ tarp mechanism you must have 2

wires, a positive and a negative, from the tractor’s battery to the quick

connectors located at the front.

When connected to the control box, the handheld switch will allow the

operator to open or close the tarp while looking at it.

To open or close the tarp, push and hold, up or down on the trigger.

When the tarp is completely closed over the trailer or completely

opens and firmly compressed at the front, release the trigger switch.

IMPORTANT DO NOT HOLD THE TRIGGER WHEN THE TARP REACHES THE END OF COURSE. THIS COULD MAKE THE MOTOR OVERHEAT AND DAMAGE IT.

The circuit breaker may open if it is overloaded but should reset itself

after a 1 minute.

Also a manual handle is attached to the arm of the chain case. In case

of breakdown, the motor will remove the bolt that is connected to the

motor shaft to the chain case and will attach the handle on. Then you

will be able to operate the tarp manually.




5

LANDING GEAR ABS Remorques live bottom trailers are equipped with adjustable

landing gear.

Use the crank to raise the landing gear up in full position and secure it

in the storage position.

If needed clean it from any stone from the footplate.

INSPECTION INSPECTION INSPECTION

Check all lights, auxiliary equipment, tires pressure, closed tailgate

and air leaks before leaving for a job.

The rear tailgate is operated by pneumatic cylinders. These will open

or close the tailgate and keep it firmly closed. In addition, two

secondary safety locks engage to provide a safe operation on closed

door.

The tailgate design is made to collapse if the operator forgets to open it

and starts the conveyor with a load in it. This is why it is important to

have these points inspected before starting to work.




6

LOADING INSTRUCTIONS First of all, it is recommended to weight the trailer to get the correct

load distribution, as per government regulations.

Do not exceed total load specifications for the trailer or gross vehicle

weight rating. Use the lower of the two.

Be careful on how the loader operator drops the load in the trailer to

prevent damage to the conveyor mechanism. Also, beware against

impacts of loader’s front to the trailer sides or to the aluminum

bucket’s top crown.

Be careful when you are loading materials containing large rocks or

big chunks. ABS live bottom should be use for aggregates and hot

asphalt. It is possible to carry stone up to 6’’. To do so, drop the

material slowly to make a bed of rock in the conveyer. Do not empty

the bucket suddenly at first.

UNLOADING INSTRUCTIONS

Back up the trailer to the unloading location or to the paving machine.

Do not get too close to the stockpile.

Open the tailgate by using your tractor’s switch, if installed, or by

using the override button located in the box on the trailer’s left hand

side.




7

The tailgate is equipped with a feature called open tailgate indicator.

Visible from each side, these indicators show to the operator if the

tailgate is open prior to starting the conveyor. If these flags are in

vertical position it means that the tailgate is closed.

It may happen that the tailgate doesn’t open freely because it is stuck

on the side wall.

PRECAUTION MUST BE TAKEN IF YOU APPROACH THE TAILGATE WHILE THE AIR PRESSURE IS ON. THE TAILGATE MAY OPEN ALL OF A SUDDEN WITHOUT WARNING SO IT IS BETTER TO STAY ASIDE.

Depending on how your tractor hydraulic pump is set (refer to tractor

manual) engage the PTO (power take off) to start the conveyor.

At this point you have 3 things to observe. First, does the tailgate

open? Second, does the hydraulic gauge show a pressure building in

the line? Third, is the conveyor rotation indicator moving?

IF THE ROTATING INDICATOR DOESN’T START IMMEDIATELY STOP THE HYDRAULIC PUMP.




8

It will take a couple of days to learn how to unload the trailer as fast as

possible.

As the pile builds up pull forward twice, with tractor, (4-5 feet) to keep

the suspension area clear of material that may be carried back and to

provide a faster and complete unload.

When unloading in an asphalt paving machine or a shuttle buggy, stop

approximately 1-2 feet in front of a paver and let the paver catch up

with the trailer. This will prevent the paver from being bumped and

creating a lump on the asphalt road surface.

Set your tractor RPM at 1000. If your tractor pump is set up properly,

the oil flow will be around 30 GPM. On the other hand if the

hydraulic GPM is under 30, the conveyor speed will be slower.

When finish unloading, move forward or move away from the job site

where you will be able to clean the trailer’s rear end safely.

Close the tailgate and make sure it is completely closed. Safety locks

will close themselves after one minute.

Keep the tarp closed while you go back to the next loading point.

Keep the tarp closed while you go back to the next loading point




9

TYPES OF MATERIAL THAT CAN BE TRANSPORTED Our ABS live bottom trailer is designed to transport aggregates materials, hot mix asphalt, concrete and other processed materials related to asphalt and concrete paving. It also can be used for sand, treated cement, dirt, cold mix or plant mix, coal and many other materials such as copper concentrate or nickel, sugar, steel chips, fly ash, top soil, wood chips, etc. Our ABS live bottom trailer is designed for Canadian transportation regulations. That means it will give many years of duty if loaded according to province limitations. It is designed for aggregates dimensions 2 ½ ‘’ and less, but it can be used from time to time, for bigger rocks of 6 ‘’ and less. Adding small material to it will help stop bridging inside tub.

GENERAL SAFETY INSTRUCTIONS Several safety precautions should be followed when operating any type of heavy equipment. Special attention should be given to follow safety procedures. Carefully read the owner/operator manual. While the belt is in motion, never climb inside the trailer for any reason. Extreme precautions should be taken when working on or observing a moving conveyor from underneath. Disconnect hydraulic lines when working on the conveyor.

Keep all shields, guards or cover in place or make sure its re-install after maintenance and, before operating the trailer. Always stand clear of discharge area when unloading. Never climb inside a trailer if you are alone. Make sure someone is aware of where you are. Keep brakes adjusted and trailer in good mechanical condition. Never go inside a trailer when loading it. Never walk between the loader and trailer on a job site. Never overload the trailer; it can affect stability and reliability. Never use a trailer that has a leaking or faulty air system, faulty brakes or structural damage. Remember you are responsible for a safe operation and maintenance of your equipment.




10

HYDRAULIC SPECIFICATIONS Followed are the specifications for the truck pump and components

needed to operate our live bottom trailer.

With the tractor engine at 1000 RPM, the conveyer linear speed should

be 275’’ per minute or 89 links of chain.

The conveyer speed is related to the gallons per minute flowing from

the tractor pump. A flow test should be done on the tractor’s pump to

know what the present set–up is.

TRUCK PUMP = MUNCIE (E OU EH 27 GALLONS)

3 LINES OR EQUIVALENT.

POWER TAKE-OFF = RATIO OF 130% TO 140%

RESERVOIR = 75 GALLONS CAPACITY

COUPLING = 51P-16 OR 6105-16 (ON TRAILER

PRESSURE LINE)

COUPLING = 51W-16 OR 6125-16 (ON TRAILER

RETURN LINE) FILTERS = IF PRESENT, SHOULD BE

INSTALLED CLOSE TO THE RESERVOIR ON THE

RETURN LINE

WE USE TWO HYDRAULIC MOTORS. COUPLINGS MAY BE REVERSED OR REPLACE ACCORDING TO YOUR NEEDS.

AN EMPTY TRAILER WILL SHOW AN OPERATING

PRESSURE BETWEEN 200 AND 400 PSI.

THE REQUIRED PRESSURE TO START THE

CONVEYOR WILL BE AROUND 1800 TO 2000 PSI. IT

DECREASES WHILE UNLOADING MATERIAL.




11

MAINTENANCE MANUAL




12

CONVEYOR CHAIN OILERS

OILERS FOR CONVEYOR CHAINS

Operating an ABS live bottom trailer is very easy compared to the conventional end dumps. The operator no longer has to

worry about overhead wires and obstructions such as trees and bridges. You can even unload inside buildings! Uneven

ground is no longer a problem making unloading faster than an end dumps. Yes, a properly maintained ABS live bottom will

give you many years of worry free service if you observe the following precautions.




13

1: You must maintain proper tension on the conveyor and chain system!

2: The chains must be properly oiled on a regular basis!

In addition to this, during regular service intervals, it is a good idea to douse the chains with oil to flush the chains.

Failure to observe these precautions will cause premature failure of the chains due to rust between the links.

Your ABS live bottom trailer is equipped with oiler pads at the rear of the trailer on both sides. These felt pads drip a small

amount of hydraulic oil from the driver system onto the chains as it operates. There is a main shut off valve on the driver’s

side of the trailer and a metering (needle) valve on each side of the trailer near the oiler pads.

These are installed at the ABS factory by technicians but due to different flow rates they should be checked on the initial

operation of the trailer. To do this, engage the PTO and set the engine to 1,000 rpm and open the needle valve until oil drips

from the felt brushes. You can observe the oil flow from the side as shown in the left picture or you may remove the

protection cover and observe it from the rear. After setting the needle valve it must be locked in place by the lock screw.

Inspect the drip pads daily for damage and replace if worn.

THERE MUST BE AN OIL FILM ON THE CHAIN AT ALL TIMES. TO STORE THE TRAILER, YOU SHOULD DOUSE THE CHAIN WITH OIL.




14

CONVEYOR CHAIN TENSION

2011 + 2010 -

CONVEYOR TENSION INDICATOR (LEFT SIDE)

Chain tension is as important as keeping the links oiled. Proper tension on the conveyor assembly will ensure many years

of trouble free service. A chain that is too loose will damage the conveyor, the main shaft and the trailer structure. When

the chain is not tensioned properly, the top side of the conveyor will be in a straight line when pulling a load but the bottom

side will be slack. This may cause floating links that may lock the sprockets and cause major damage to the drive system

within a very short period of time. On ABS live bottom trailers it is easy to maintain and adjust the chain tension. Proper

tension can be observed by the amount of SPRING COMPRESSION and the LEVEL OF THE CHAIN in the slot.

ALIGN THE CHAIN WITH THE SLOT




15

As shown in the picture, the way the chain leaves the bottom of the sprocket is directly affected by the tension on the

chain. If the chain is too loose, it will hang up on the teeth of the sprocket. This will cause failure and severe damage to

the conveyor system.




16

This will not occur if the chain is properly tensioned as follows;

A. Unlock the jam nut beside the coil spring.

B. Using two wrenches to hold the nut compressing the coil spring and turn the nut at the end of the threaded rod in a

clockwise direction.

C. Apply pressure until you see the coil spring almost completely compress and the chain in line with the indicator slot

in the trailer frame.

D. Repeat this step on the other side of the trailer.

E. Start the trailer and let it turn for 5 minutes while observing the chain in the indicator slot.

F. If the chain is level in the indicator slot, re-tighten the jam nuts on both sides.

It is normal for the chain to move up and down a little during the operation But you must re-adjust the chain if it moves below the indicator slot.




17

HYDRAULIC FLOW CONTROL BLOCK

On all ABS live bottoms, all of the hydraulic components are of the highest quality and easily accessible.




18

Specially designed for live bottom operation, the hydraulic block includes the following features;

A pressure gauge to indicate the operating pressures;

A pressure relief valve that is set at 2,500 PSI to protect the conveyor mechanism from overpressure during

operation;

A check valve to protect against incorrect connection to the tractor;

A flow control valve which allows the operator to slow down or even stop the conveyor completely;

This can be done in the colder months to warm up the hydraulic oil before engaging the conveyor.

A shut-off valve for the conveyor lubricators.

NOTE: The block is maintenance free but it is a good idea to grease the threaded rod of the flow control valve to keep it from seizing.




19

SECONDARY WIRING HARNESS

2015 + 2014 2013-

To help make the ABS live bottom conform to your tractor and fleet operations, ABS has installed a secondary wiring

harness. This harness contains the auxiliary equipment hook up as follows:

RED - TAILGATE RED – TAILGATE BROWN –LIFT AXLE #1

BLUE – BACK-UP LIGHT BLACK – BACK-UP LIGHT GREEN – LIFT AXLE #2

BROWN - STROBE LIGHT WHITE – STROBE LIGHT RED - TAILGATE

WHITE – GROUND GREY – BACK-UP LIGHT

YELLOW - STROBE LIGHT

WHITE – GROUND




20

LEVELING VALVE ADJUSTMENT

2012 ½ ET - 2012 ½ ET +

SUSPENSION RIDE HEIGTH MUST BE SET AT 17 INCHES OR 14.5 INCHES IF YOU USE TOP OF THE

AXLE TO THE TOP OF THE AIR SPRING AS REFERENCE.

THE LEVELING VALVE SHOULD LOOK LIKE THE LEFT HAND SIDE PICTURE OR A QUICK WAY TO

CHECK FOR PROPER RIDE HEIGTH IS TO USE THE CENTER OF THE TOP BOLT HEAD AS REFERENCE

AS IN THE RIGHT HAND SIDE PICTURE, YOU MUST BE ON A FLAT SURFACE.




21

CONVEYOR BELT SCRAPERS

To keep conveyor belt clean, a scraper is installed at the rear end on the return side.

We use the same rubber material as the conveyor belt.




22

CONTROL BOX FOR LIFT AXLE AND TAILGATE

In the control box you will find 2 solenoid-valves operating the tailgate (left side) and the lift axle (right

side). These allow operators to control the tailgate and the lift axle from the truck cab (if set-up) or from

trailer itself. Also, on ABS trailers a pressure switch is installed on the axle lifting mechanism. Factory set

at an operating pressure of 35 psi, it will keep the lift axle in up position when the trailer is empty. By

loading trailer, pressure will rise over 35 psi and the lift axle will be in the down position. Finally, a drop

valve allows suspension air to be released when trailer has parked in the parking lot for a while.




23

BEFORE 2013

On ABS Live bottoms, all electrical connections are done in a protective plastic junction box.

Easily accessible, located on trailer left side, mechanics will find trouble shooting or add accessories very easy.




24

SELF STEER AXLE WHAT NOT TO DO

On ABS live bottom trailers, when it is requested by provincial regulation, the trailer will be equipped with a

self-steer axle. We proudly use Canadian made IMT products for our axles. Here is an example of what not to

do. Tires must be the same size, designation and tread. Also the same type: all radial or all bias ply. Inflate to

recommended pressure for actual load.




25

CLEANING CONVEYOR MECHANISM

On ABS live bottom trailers, the conveyor slides on a plastic liner. A ¼ inches formed plate, called a skate, is

sliding on this plastic liner. Two skates, one on each end of the slats, make the connection to the conveyor chains.

This is a maintenance free system but it is suggested to clean it from time to time with water pressure. It will help

to keep plastic liners free of fine dust. It can be perform when washing the trailer by shooting water directly in

openings each side of trailer while conveyor is rotating.

OPERATOR’S MANUAL€¦ · Conceive, build and sell high quality trailers keeping in constant...

Documents

Transcript of OPERATOR’S MANUAL€¦ · Conceive, build and sell high quality trailers keeping in constant...