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MAINTENANCE
MANUAL
Part No. 42101401
®
Please route to the individual
responsible for trailer maintenance
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MAINTENANCE MANUAL VANS PLATFORMS CONTENTS CONTENTS Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . 2 Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . 2 Reporting Other Claims. . . . . . . . . . . . . . . . . . . . . . 2 Reporting Other Claims. . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance Tips . . .
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This safety alert symbol is used throughout this manual to indicate potential personal safety hazards. Failure to heed the warnings associated with the safety alert symbol can result in property damage, serious injury or death. REPORTING SAFETY DEFECTS AND OTHER CLAIMS Customer Service Phone Number: 877-369-3493 This vehicle was designed and quality inspected to If you believe that your vehicle has a defect which conform with all applicable National Highway Traffic could cause a crash or could c
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INTRODUCTION It is to your advantage to be able to show that regularly This manual has been prepared to assist you in retain- scheduled TPM inspection checks have been made on ing the safety, dependability, and performance that are every piece of equipment operated. A regular TPM built into Great Dane trailers. It is essential that this program will assure that you get the most from your trailer receives periodic inspections, maintenance, and Great Dane trailer. service parts replacement. You ca
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Also, at the first TPM, a trailer mechanic should take MAINTENANCE TIPS the time to verify that there are no obstructions to BREAKING-IN A NEW TRAILER movement of the suspension equalizers. The most critical time in a new trailer’s life is its initial in-service check and first month’s “shakedown.” When the mechanic has made sure all fasteners are Preventive maintenance mechanics should be alert for tight, he should use the 50-ft.-tape method, with axle under-inflated tires and threaded fastener
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Enclosed air systems for brakes and air-operated APPEARANCE MAINTENANCE equipment should be drained regularly of accumulated Appearance maintenance includes cleaning, polishing, moisture. The air tanks should be drained daily. The corrosion prevention and removal, and protective trailer air system should be treated through tractor coating. You must have a working knowledge of each equipment only. Use of additives can cause damage to for the complete and proper appearance maintenance the brake sy
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The electrical system on every Great Dane trailer ELECTRICAL SYSTEM meets or exceeds all federal and state requirements in effect at the time of manufacture. Wherever required by law, lamps and reflectors are marked by the CAUTION manufacturer to indicate the appropriate specification CONNECTOR WIRING CHANGE with which each complies. NOTICE TO ALL TRACTOR-TRAILER OWNERS AND USERS For optimum performance and long life from the trailer’s Federal Motor Vehicle Safety Standard No. 121, lamps and wir
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A warning decal, as shown on the previous page, is MAINTENANCE DURING MAJOR OVERHAUL located on the front of each trailer. You may trace OF BRAKES individual electrical circuits by the wire colors indicated. During a major overhaul, check the following parts and Refer to the schematic drawing and the decal for replace them with original equipment parts or equal, as conductor numbers and wire colors. required: 1. Spiders – for looseness or sheared fasteners. WARNING Do not exceed 21 candlepower f
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In a system employing spring brake control valves, the BRAKE CARE AND ADJUSTMENT spring brakes should function and apply the brakes. The trailer brake system will perform safely and In a system that does not employ spring brake control efficiently only as long as it is properly maintained valves, the relay emergency valve should function and and not abused. Trailer brakes should be inspected apply the brakes. frequently in connection with a Trailer Preventive Maintenance (TPM) Program. Out-of-ad
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OVERSIZE LINERS CAM PLATE SHIMS To compensate for material removed when refacing When standard liners are installed with worn or trued brake drums, X (1/16" oversize) and XX (1/8" oversize) drums, or when X or XX liners have been installed and liners are furnished by the lining manufacturers. When are approximately 50% worn, shims or a combination oversize liners are used the drums should be machined of shims should be installed under each of the cam in increments of 1/16" (radius increased 1/16
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PARKING BRAKES DANGER DO NOT operate your trailer with All axles (except some converter dolly axles) are parking brakes caged or in any other way equipped with air/spring actuators. Each actuator is disabled. Never attempt to open a brake separated into two units. The base unit applies the actuator. The internal spring is very dangerous. service brakes. The top unit contains a coil spring that Do not repair spring brakes. Discard only by must be compressed by air within the chamber to using prop
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This detailed check takes about two and one-half 7. Tighten adjusting nut to 50 lb-ft torque while you hours. It’s important to check a representative tractor rotate hub in both directions to be sure all bearing and trailer each time you order equipment. surfaces are in contact. Keeping an eye on your brake service records will also 8a. For axles that have single-nut construction, back flag imbalance problems. If you are seeing 300,000 off adjusting nut 1/8 to 1/6 turn. Cotter pin (or lock) mile
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INSPECTION Inspect the inner and outer wheel bearing cups, cones RECOMMENDED WHEEL BEARING and rollers for excessive wear or damage. GREASE SPECIFICATIONS Refer to bearing and axle manufacturer’s manuals for Soap Type – Lithium, 12-Hydroxy stearate inspection and replacement requirements. or equivalent. LUBRICATION Consistency – NLGI No. 2 or NLGI No. 1 For maximum bearing life, inspect wheel bearings and Corrosion and Oxidation Inhibitors lubricant periodically, change lubricant regularly, and
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Check the rocker beam to see if there is adequate Lubrication fill oil (static) clearance between the ends of the spring and the rocker beam hub when the axle is both loaded and unloaded. Check welds to see that no cracking has occurred between the spring seats and axles, and between the hangers and sub-frame. Threaded fasteners should be checked for proper Fill to tightness after an initial break-in period of 3,000 to oil level line 5,000 miles. Torque should be rechecked every on hub cap 25,00
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The shock absorbers should be replaced at the first RUNNING GEAR ASSEMBLY sign of leaking hydraulic fluid. Worn shocks will allow Inspection of upper running gear rail weld attachment tire hop and yield poor handling characteristics. to the trailer for weld fatigue cracks is a requirement of the annual FHWA inspection. All trailer structures Many air suspensions are equipped with air control should be inspected for weld fatigue cracks and/or kits. The air control kit allows the raising or loweri
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SINGLE-PIECE RIM WHEELS 2. Remove damaged rims or wheels. Illustrated, complete safe operating procedures are 3. Mark damaged or hazardous areas so that part will provided on the wall chart “Mounting and Demounting be removed from service. Procedures for Truck/Bus Tires” available from the Department of Transportation, and OSHA. WARNING Excessively corroded or cracked The following minimum steps are recommended to pro- rims or rings can be dangerous. Deflate tires vide maximum safety when servic
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TUBELESS RIM LEAKS. Circumferential crack at bead set. Caused by pitting and erosion by the tire bead. Circumferential crack in well radius. Caused by overload and over inflation. Circumferential crack at RIM/WHEEL PROBLEMS attachment weld. Caused by overload and RIM BASE CRACKS over inflation. Circumferential crack at back flange radius or bead set. Note: Wheels with well-welded discs may not be Causes: Overload and/or over inflation, damage due approved for use with radial tires. to tire tools
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STUD HOLE CRACKS WHEEL CRACKS Hub or outboard drum may be damaged or broken. Must provide flat backup. Handhole to handhole. Handhole to studhole. Handhole to rim. Causes: Overloading. Double-capnut wheel mounting Crack originating from preload is force applied to thin edge of bolt hole. the disc by torquing nuts. Cause: Damaged or Inner cap nut must be tightened worn out chamfers. Studhole to studhole. before tightening outer nut. Causes: Loose cap nuts.(Also see chamber problems). This surface
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Running a tire under inflated can have serious conse- TIRE BRANDING quences in addition to reducing tread life. Heat buildup Whenever possible, tire branding should be in the can cause the tire body to deteriorate, resulting in sep- branding panel on the sidewall of most truck tires. Use aration of the tread from the body or belt ply. A soft tire extreme caution to prevent branding too deeply. The overdeflects, causing fatigue breaks in the body cords. ideal branding depth is 1/32", and in no ca
