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PRATT Industries TRUSS Owner's/Operator's Manual

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OWNER/OPERATOR MANUAL
Advanced Design Intermodal Equipment
* T
T
*
RUSS
RAILERS
* L
D
T
*
UMBER
UMPER
RAILERS
Service Notes:
This operations manual describes the basic operations and maintenance procedures for PRATT trailer/chassis.
The information contained in this manual was current at the time of printing and is subject to change without notice or liability.
You must follow your company safety procedures when you service or repair equipment. Be sure you understand all the procedures and
instructions before you begin work on the unit.
- 1 -

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Summary of Contents for PRATT Industries TRUSS

  • Page 1 OWNER/OPERATOR MANUAL Advanced Design Intermodal Equipment RUSS RAILERS UMBER UMPER RAILERS Service Notes: This operations manual describes the basic operations and maintenance procedures for PRATT trailer/chassis. The information contained in this manual was current at the time of printing and is subject to change without notice or liability. You must follow your company safety procedures when you service or repair equipment.

  • Page 2: Table Of Contents

    Table of Contents Operator Instructions ......................4 Normal Trailer Use ......................5 PRATT Warranty Coverage ....................6 Operation of Rollerbed Trailer ..................10 Hydraulic neck assembly ......................10 Hydraulic neck operation ......................10 Truck requirements for charging battery .................. 10 Expanding the trailer (Expandables only) ..................
  • Page 3 Air brake maintenance....................... 39 Hydraulic system maintenance ....................40 Lighting maintenance ........................ 40 Additional Maintenance requirements for Rollerbed Trailers ..........41 Lubrication........................42 Note on lubrication........................42 Wheel bearings and hubs ......................42 Landing gear [two speed) ......................42 Brake camshafts......................... 42 Brake shoes..........................

  • Page 4: Operator Instructions

    Princess Street, Alexandria, Virginia 22314. IMPORTANT Read this manual carefully. Should you have any questions contact Pratt Industries, Inc. immediately for the answers. 1·800·546·7728 This manual should be kept with the trailer at all times and should be left with the trailer when it is sold.

  • Page 5: Normal Trailer Use

    CAUTION! Operation of the trailer outside the limitations of this manual is against federal law and PRATT Industries, Inc, design criteria. Any operation exceeding the limitations stated will void any responsibility of PRATT Industries, Inc, for the results.

  • Page 6: Pratt Warranty Coverage

    PRATT Warranty Coverage Effective 01/01/2003 ALL WARRANTY CLAIMS ARE SUBJECT TO PRATT INSPECTION FOR FINAL APPROVAL EVEN THOUGH AUTHORIZATION NUMBER HAS BEEN ISSUED FOR SOME ITEMS. U.S. and CANADA Five (5) YEAR - 100% Fabricated Frame parts and Labor All container chassis, drop frames, drop decks, goosenecks, hydraulic chassis, platform and Single Drop, double drop, Eight (8) Axle, B-Trains, Log, Folding Pole, Telescopic, Low Boy and all special units rated for GVWR 63,000 to 100,000 pounds, the main beams, fabricated components, steel construction, workmanship are covered 100% for five (5) years.
  • Page 7 Truck Light L.E.D., Five (5) Years Parts only. All parts must be returned. NOTE: The light and harness suppliers during manufacturing protect the electrical system against corrosion and at time of assembly. Corrosion is not considered a warranty item. SUSPENSION AND COMPONENTS: Hendrickson Intraax all models: Air springs 0-12 months parts and labor, 13 - 24 months parts only.
  • Page 8 Synthetic lubricant: All bearings and seals are covered for 35 months parts and labor providing proper maintenance has been performed and no mixing of lubricant has occurred. All parts must be returned. Landing Gear: Binkley all models 0-12 months parts and labor. All parts must be returned unless otherwise instructed.
  • Page 9 SAMPLE WARRANTY This is to certify that PRATT INDUSTRIES, INC warrants to the first purchaser only, the described new trailer manufactured by it to be free from defects in materials and workmanship, when properly maintained, and under normal use and service, which means the loading, unloading and transportation of uniformly distributed legal loads of no corrosive cargo, adequately restrained and secured in a manner which does not subject the trailer to strains or impacts greater than are imposed by normal use.

  • Page 10: Operation Of Rollerbed Trailer

    Operation of Rollerbed Trailer These 68,000#GVWR, Panel and Truss Rollerbed Trailers have a flat profile, with a Hydraulic Neck Assembly, a sliding tandem, 6” air unlocking deck rollers, and 11R/22.5 tires. The deck rollers are spaced approximately 2 ft. apart. 3’ on the front deck portions.

  • Page 11: Unloading Procedures

    9. Lift the front of the trailer by sliding the hydraulic cable into position #1 and raise the front end to the desired height. NOTE: The operator should try to achieve an unloading angle that does not bend the truss package until it has touched the ground and is partially off the trailer.

  • Page 12: Bad Job Site Conditions

    side near the middle of the trailer. To operate; remove the pin on the lock bars. This will divide the lock bars. You may then use the roller lock valve to unlock the rear half of the rollers only. NOTE: The hydraulic neck can be used when split unloading to lift the front end of the trailer, thus transferring weight to the tractor to maintain traction.

  • Page 13: Self-Adjusting Slack Adjuster

    position in these conditions, because the slide bogey may start to slide back under the trailer when you pull forward picking up on the tractor. By locking the slide bogey in the forward position, you eliminate this from happening in bad conditions. Self-Adjusting Slack Adjuster Operation Upon brake application the slack adjuster rotates and moves the...

  • Page 14: Maintenance

    rotation easier to see). This rotation indicates that an excessive clearance condition has been determined by the slack adjuster, and it is making an adjustment to compensate. On each subsequent brake release the amount of adjustment and pushrod travel will be reduced until the desired clearance is achieved.

  • Page 15: Coupling And Uncoupling

    Coupling and Uncoupling Knowing how to couple and uncouple correctly is basic to safe operation of combination vehicles. General coupling and uncoupling steps are listed below. There are differences between different rigs. So learn the details of coupling and uncoupling the truck(s) you operate. CAUTION! INCORRECT COUPLING AND UNCOUPLING CAN RESULT IN SERIOUS INJURY OR DEATH.
  • Page 16 Step 8 Supply Air to Trailer • From cab, push in "air supply" knob or move tractor protection valve control from the "emergency" to the "normal" position to supply air to the trailer brake system. • Wait until the air pressure is normal. •...

  • Page 17: Uncoupling Tractor-Semitrailers

    • Check for enough clearance between rear of tractor frame and Landing gear. (When tractor turns sharply, it must not hit landing gear.) • Check that there is enough clearance between the top of the tractor tires and the nose of the trailer.
  • Page 18 Step 9: Pull Tractor Clear of Trailer • Release parking brakes. • Check the area and drive the tractor clear. - 18 -...

  • Page 19: Trailer Maintenance Procedures

    Trailer Maintenance Procedures THE IMPORTANCE OF FREQUENT INSPECTION AND PREVEN· TATIVE MAINTENANCE FOR ANY MACHINE CANNOT BE OVER EMPHASIZED: YOUR PRATT TRAILER IS NO EXCEPTION. PROPER CARE GREATLY REDUCES THE REPAIR COST AND THE AMOUNT OF DOWNTIME. Kingpin and Fifth Wheel Area Inspect the kingpin for excessive wear, rough edges, looseness, broken or chipped out areas and cracks.
  • Page 20 Recheck rim clamps after first 50 to 100 miles of service. BRAKE DRUM ASSEMBLY TORQUE FOR DRUM BOLTS (Grade 5 or 8 Fasteners) TORQUE REQUIRED THREAD SIZE FT-LBS MIN FT-LBS MAX 1/2- 20 Rotate Belt 5/8-18 Rotate Belt (Tapped Holes) 5/8-18 Rotate Nut (Thru Holes)

  • Page 21: Hub Installation & Maintenance

    TORQUE FOR RIM NUTS Torque for rim nuts or capnuts is expressed in foot pounds, and is the force exerted in pounds multiplied by the lever arm or wrench length in feet. Example - 200 pounds x 2.25 ft.= 450 Foot Pounds. 200 Pounds Hub installation &...
  • Page 22 7. After the first 50 to 100 miles of service the capnut torque should be rechecked. a. Loosen the outer capnuts. b. Check the torque of the inner capnuts in the tightening direction. 8. Tighten the outer capnuts to 50 FT. LBS. in the sequence shown in Step 4. Tighten to full torque using the same sequence.
  • Page 23 BROKEN STUDS STRIPPED THREADS CAUSE Loose cap nuts overloading CAUSE Loose wheel assembly WHAT TO DO WHAT TO DO Replace stud. Follow Proper torque procedure. See page 16 Replace stud. Follow proper torque procedure. See Page 16 or 17 or 17 WORN MOUNTING WORN STUD GROOVE FACE ON HUB...
  • Page 24 2. Collapsed Rim Spacer 2. Caused by excessive torque. Replace spacer. II. HUBS Broken Studs 1. Loose Capnuts 1. Replace broken stud plus the Stud. On either side. If more Than two studs are broken, 2. Overloading Replace entire set. 2.

  • Page 25: Tire Maintenance

    Tire Maintenance Inflation Pressure The most critical factor in tire maintenance is proper inflation. No tire or tube is completely impervious to loss of air pressure. To avoid the hazards of under inflation, lost air must be replaced. Driving on any tire that does not have the correct inflation pressure is dangerous and will cause tire damage. Any under inflated tire builds up excessive heat that may result in sudden tire destruction.
  • Page 26 Always examine your tires for bulges, cracks, cuts or penetrations. If any such damage is found, the tire must be inspected by a Tire dealer at once. Use of a damaged tire could result in tire destruction, property damage and personal injury. Drive carefully All times wear our faster when subjected to high speeds as well as hard cornering, rapid starts, sudden stops and frequent driving on surfaces, which are in poor condition.
  • Page 27 that surfaces which could deteriorate the rubber. TIRES EXPOSED TO THESE SUBSTANCES COULD BE SUBJECT TO SUDDEN FAILURE. Recommendations for the use of dynamometers Severe damage can result in the crown area of radial truck tires when run on dynamometers for extended periods.

  • Page 28: Trailer Axle Maintenance

    Trailer axle maintenance TYPICAL AXLE ILLUSTRATIONS OF AXLE PARTS WITH PARTS LIST TYPICAL 16.5" X 7" BRAKE INSTALLATION ITEM DESCRIPTION ITEM DESCRIPTION Brake shoe and lining assembly Pin-anchor Spring-brake shoe retaining Beam-axle Dust shield Bracket -chamber Lock washer Camshaft Cap screw Washer-camshaft Spring-brake shoe return "O"...
  • Page 29 Disassemble wheel end components CAUTION! Do Not Work under the Trailer When the Vehicle is supported only by Jacks. Jacks Can Slip or Tip Over and Cause Injury. 1. Jack up the vehicle under the axle being serviced. 2. Install jack stands under each corner of the vehicle to hold it in position. 3.
  • Page 30 11. If necessary, use a cold chisel to remove the wheel bearing seal wiper from the spindle. Put two or three notches around the wiper sleeve to expand the sleeve so that it can be easily removed. Discard the seal and wiper.
  • Page 31 b. Cover all openings in the axle before cleaning to prevent water from entering the assembly. 4. Drying Cleaned Parts: a. Parts must be dried immediately after cleaning. b. Dry parts with soft, clean paper or cloth rags. Except for bearings, parts also can be dried with compressed air. IMPORTANT: Bearings MUST NOT be dried by rotating with compressed air.
  • Page 32 3. If necessary, install a new seal wiper on the spindle. Assemble the widest edge of the wiper evenly over the wiper journal and use a seal driver or installation sleeve of the correct dimension to install the wiper. The outer edge of the wiper must be installed level with the bearing journal. (See Figure above) 4.
  • Page 33 14. Install the wheels or tires and rims. Follow the torque specifications supplied by the wheel manufacturer. 15. Adjust the brakes. (See Brake Adjustments.) Wheel bearing adjustment Bearing wear can cause the adjustment of the wheel bearing to loosen. The adjustment of used wheel bearings can be checked with a dial indicator using the following procedures: 1.
  • Page 34 2. On wheel ends with double nuts (See Figure Above), use the following procedures: a. Remove the hubcap and gasket. NOTE: On oil lubricated wheel ends, put an empty container under the hubcap to receive the leaking oil when the hubcap is removed. b.
  • Page 35 2. Rotate the hub and check the oil level again. Replace the plug for the filler hole. (See Figure Previous Page) Grease: 1. Only NLGI 000-00 semi-fluid (per TMC RP622) Axle alignment Use the following procedures to check the alignment of trailer axles: SINGLE AXLE TRAILERS 1.

  • Page 36: Care And Maintenance Of Springs

    Care and maintenance of springs The leaf springs are working, flexible components and the main supporting members of a trailer suspension. They cushion the trailer and its load from various road shocks and provide necessary stability. A reasonable amount of care and maintenance is required to provide satisfactory service life. The springs must be tightly clamped to the spring seat and the axle to prevent any movement between V-bolts, which results in misalignment of axles.
  • Page 37 3. Maintain pressure in the air system (figure 3). DESIGNED KINGPIN HEIGHT MEASUREMENT 1. Check the ID tag on the front bulkhead or contact the trailer manufacturer for the designed kingpin height. Measure the trailer's kingpin height. The trailer mayor may not be connected to a tractor during the measurement.
  • Page 38 Intraax: AA230TBA.1 I4A1A01... 3. Measure the ride height (figure 5). If necessary, adjust the height control valve. The designed ride height is the distance from the center of the axle to the mounting surface of the suspension. NOTE: To determine the ride height, add half of the axle's diameter to the measurement shown on the tape measure.

  • Page 39: Air Brake Maintenance

    6. If minor adjustment is necessary, loosen the 1/4" lock nut located on the control arm, which will allow the control arm to oscillate approximately +/-1". Retighten the 1/4" adjusting lock nut from 2 to 4 ft-lbs. Air brake maintenance Successful maintenance of the air brake system depends upon systematic inspection and repair at regular intervals.

  • Page 40: Hydraulic System Maintenance

    Hydraulic system maintenance Telescopic cylinder Check your cylinder periodically for oil leaks. A damp to light film of oil on the cylinder indicated good cylinder operation. After numerous cycles of the cylinder, a small accumulation of oil may be noticed and should not be mistaken for leakage around the stage packing.

  • Page 41: Additional Maintenance Requirements For Rollerbed Trailers

    or how to rewire your vehicles, you should contact the tractor manufacturer, auxiliary equipment manufactur- er, and/or Pratt at 800-546-7728 Turn signal and hazard flasher system The turn signal lever and hazard flasher switch are located in the truck tractor. To operate the turn signals, the ignition switch must be in the ON position.

  • Page 42: Lubrication

    Lubrication Note on lubrication Use a standard, LP-2 chassis grease for all for all lubrication points having fittings. Apply grease with a suitable pressure type grease gun that fits the lubrication fittings. The gun may need a flexible extension on it to enable you to reach certain fittings.

  • Page 43: Reservoir Level Check

    Reservoir level check Measure oil level with the trailer hoist cylinder in the center position. The trailer must be hooked up to the truck tractor. Remove the reservoir filler cap and inspect oil level. Use care in filling reservoir so that dirt or other foreign material does not get into the hydraulic system.
  • Page 44 Each 20,000-Miles or Four Months (Whichever comes first) • Inspect brake drums and wheels. • Inspect brake linkage and shoes. • Inspect brake lines and hoses for chafing, looseness and deterioration. • Test brakes for action, side pull, and synchronization. •...

  • Page 45: Troubleshooting

    Troubleshooting Analyzing & diagnosing trailer service To directly assist in keeping your trailer on the road and rolling, the following troubleshooting guide has been prepared for your convenience. You can avoid serious delay and downtime in servicing your trailer if the cause of the trouble can be diagnosed and corrected quickly by you.

  • Page 46: Brakes

    3. Spring brake not properly released manually. 4. Reduction of service system pressure causing spring brakes to partially apply. 5. Broken return spring in spring brake section (double diaphragm type). (F) SERVICE BRAKES APPLY WHEN SPRING BRAKES ARE RELEASED BY AIR 1.

  • Page 47: Wheels, Tires And Alignment

    1. Check air line connections & verify sufficient 1. Low Air Pressure air in tank 2. Brake shoes bound up at cams 2. Lubricate brake-operating parts. 3. Brake hoses restricted 3. Replace hoses. 4. Brake out of adjustment. 4. Adjust brakes. 5.

  • Page 48: Landing Gear; Difficulty In Turning Handcrank

    Probable Cause Remedy 1. Tire wobble due to uneven rim clamping 1. Torque tighten all rim clamps 2. Burnt, worn or damaged wheel bearings 2. Replace bearings 3. Bent wheel or rim 3. Replace wheel or rim 4. Bent axle 4.

  • Page 49: Complete Loss Of Trailer Lights

    Complete loss of trailer lights Probable Cause Remedy 1. Broken main harness 1. Repair or replace wire 2. Blown fuse or breaker 2. Replace fuse 3. Check, repair or replace jumper cable if 3. Broken ground lead between tractor and trailer equipped 4.

  • Page 50: Appendix A: Maintenance Record

    Appendix A: Maintenance Record Date Maintenance Performed - 50 -...
  • Page 51 Date Maintenance Performed - 51 -...
  • Page 52 Date Maintenance Performed - 52 -...
  • Page 53 Date Maintenance Performed - 53 -...
  • Page 54 Date Maintenance Performed - 54 -...

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