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Lufkin Dump Trailer Owner's Manual

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DUMP TRAILER
OWNER'S MANUAL
LUFKIN INDUSTRIES, INC.
P.O. BOX 849
LUFKIN, TX 75902-0849
800-324-3812

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  • Page 1 DUMP TRAILER OWNER’S MANUAL LUFKIN INDUSTRIES, INC. P.O. BOX 849 LUFKIN, TX 75902-0849 800-324-3812...
  • Page 2 INTRODUCTION This manual is provided to every user of a newly manufactured LUFKIN trailer to acquaint you with the importance of maintenance and safety in the operation of your trailer. The life of a trailer can be increased with adequate regular service and an organized Trailer Preventative Maintenance program (TPM).
  • Page 3 Upon request we will furnish any additional or more detailed maintenance and operational instructions including any non-standard make of equipment that was specified and installed. The following numbers are in Lufkin, Texas at the main office and manufacturing plant. Please contact your factory branch or dealer first:...
  • Page 4 OWNERS MANUAL FOR DUMP TRAILERS INTRODUCTION PAGE 2 REPORTING SAFETY DEFECTS PAGE 3 SECTION 1 PAGE 8 SUSPENSIONS 1.1.1 TORQUE VALUES 1.1.1.1 SINGLE POINTS 1.1.1.2 AIR SPRING 1.1.1.3 MECHANICAL SPRING 1.1.2 AIR SPRING SUSPENSION INFORMATION 1.1.2.1 LIFT AXLE OPERATION 1.1.2.2 DUMP VALVE OPERATION 1.1.2.3 GENERAL ADJUSTMENT PROCEDURE FOR SETTING RIDE HEIGHT...

  • Page 5: Table Of Contents

    AIR SYSTEM MAINTENANCE 3.2.1 BRAKE AIR ACTUATION MAINTENANCE ANTILOCK BRAKE SYSTEM—(ABS) SECTION 4 PAGE 21 ELECTRICAL/LIGHTING SYSTEM SECTION 5 PAGE 22 TIRES 5.1.1 GENERAL INFORMATION 5.1.2 SAFETY RECOMMENDATIONS FOR TRAILER TIRES SECTION 6 PAGE 24 WHEELS AND RIMS 6.1.1 HUB-PILOTED MOUNTING 6.1.2 STUD-PILOTED MOUNTING 6.1.3...

  • Page 6: Section

    SECTION 9 PAGE 31 END DUMP TRAILER OPERATING INSTRUCTIONS LOADING PROCEDURES AND METHODS 9.2.1 HOPPER 9.2.2 END LOADER 9.2.3 CROWN LOADING TARPING COMMODITIES UNLOADING 9.5.1 STOCK PILE 9.5.2 HOPPER 9.5.3 WINDROW 9.5.4 SPREAD OPERATION TAIL GATE OPERATION 9.6.1 OPEN TAILGATE 9.6.2...
  • Page 7 9.8.5 TIRES 9.8.6 HUMPING 9.8.6 STAY AT CONTROLS 9.8.7 OVERLOADING 9.8.8 SUSPENSION MAXIMUM HEIGHT AND DUMP ANGLE SECTION 10 PAGE 37 10.1 END DUMP MAINTENANCE 10.1.1 TAILGATE LATCHES AND ASSEMBLY 10.1.2 FIFTH WHEEL ASSEMBLY 10.1.3 HYDRAULIC CYLINDERS 10.1.4 FLOORS AND WALLS 10.2 BOTTOM DUMP MAINTENANCE 10.2.1 DOOR HINGE PIVOT PINS 10.2.2 FIFTH WHEEL ASSEMBLY...
  • Page 8 All fasteners on the suspension of your new LUFKIN Trailer were torqued before delivery to the proper torque values. Due to vibration and shock loads it is necessary after a break-in period of 1000 miles or three months, and every six (6) months thereafter, to tighten all nuts and bolts to the recommended torque.
  • Page 9 HUTCH 900/440 SERIES LINK TO VENDOR FILE 1.1.1.2 AIR SPRING LINK TO VENDOR FILE NEWAY RL SERIES HENDRICKSON INTRAAX SERIES LINK TO VENDOR FILE Page 9...
  • Page 10 HENDRICKSON NHT SERIES LINK TO VENDOR FILE 1.1.1.3 MECHANICAL SPRING LINK TO VENDOR FILE HUTCH 9700 SERIES 1.1.2 AIR SPRING SUSPENSION INFORMATION Regular preventive maintenance checks on air spring suspensions are the same as on leaf spring suspensions with the addition of the air bags and air components. With the air pressure above 65 psi, the height between axle and frame should be within 1/4”...
  • Page 11 be disconnected and the lever arm be rotated to a vertical down position. This will exhaust air from the bags, allowing load to be carried on internal rubber stops within the bags. This procedure is intended for temporary operation only. See Figure 1. Figure 1 - AIR SPRING LEVELING VALVE Air spring suspensions are equipped with an air brake protection valve.
  • Page 12 1.1.3.1 SPRING HUTCH Your new LUFKIN Trailer was aligned at the factory before delivery. For safe and efficient operation and to prevent excessive tire wear, off tracking and hard pulling it is recommended that after a short break-in period you have a qualified trailer mechanic check the alignment.
  • Page 13 To align a four (4) spring suspension there is one adjustable torque arm on each axle. Release the clamps at each end of the adjusting screw. Align front axle with the king pin and adjust each axle thereafter parallel to the front axle. Be sure to secure the clamps on the adjustable torque arm after alignment.
  • Page 14 1.1.3.3.4 Measure distances A and B from the king pin to the front axle. Refer to Figure 4. These must be equal within 1/8 inch of each other. Measure distances C and D between axles using gauge as shown in Figure 5. Note that all currently available trailer axles have dimples or recesses at the center of the axle spindle ends.
  • Page 15 1.1.4 ADDITIONAL SUSPENSION MAINTENANCE CHECKS FAILURE TO TAKE THE PREVENTIVE MAINTENANCE PRO- CEDURES ABOVE CAN RESULT IN ACCELERATED WEAR AND LEAD TO MALFUNCTION AND POSSIBLE VEHICLE CRASH! Check leaf springs for broken leaves. Replace broken leaves immediately to prevent the other leaves from being overloaded.
  • Page 16 To correctly check and adjust wheel bearings, the axle must be supported so wheels are clear of the front and free to roll. As standard equipment, LUFKIN employs the use of a one-piece spindle nut. Procedures for installation and wheel bearing adjustment may be found by clicking on the links below.
  • Page 17 2.1.3.1.3 Look for leaks on inside of wheels or hub, or as swirls on tire. 2.1.3.1.4 Check for abnormal tire wear. 2.1.3.2 During operation, bearing failure can result in: - Wheel vibration - Wheel wobble - Wheel noise - Smoke from wheel end - Wheel lock-up and skidding 2.1.3 OIL SEALS...
  • Page 18 SECTION 3 AUTOMATIC SLACK ADJUSTERS (ASA) The brakes were properly adjusted on your LUFKIN Trailer before delivery. Automatic slack adjusters are required by law, effective on all trailers produced since December 1993. Depending on the brand of slack adjuster used, the operating, and adjusting procedures may vary.
  • Page 19 3.2.1.3 The relay valve should not have a continuous flow of air from the exhaust port except immediately after a brake release. If air continues to discharge, it could be a malfunction of the exhaust valve, or the “O” ring seal on the push rod of the spring brake chamber is bad and is allowing air to be discharged through the service chamber and out the relay valve exhaust port.
  • Page 20 Warning and caution notices should be followed as some components contain powerful springs and injury can result if not properly disassembled. THE BRAKE SYSTEM ON LUFKIN TRAILERS IS DESIGNED AND CONSTRUCTED TO MEET FMVSS 121 REQUIREMENTS. IN ADDITION, COMPONENTS ARE SELECTED THAT WILL PROMOTE BRAKE BALANCE BETWEEN TRACTOR AND TRAILER.
  • Page 21 Blue Wire #7 pin of the SAE 560 connector will provide constant power. Your LUFKIN Trailer, as manufactured, meets or exceeds the requirements set forth in FMVSS 108 which describes the various required lighting and reflectors The law also requires these trailers be equipped with reflective tape that is so placed as to describe the general outline of the trailer when viewed at night so that other motorists may be alerted as to its presence.
  • Page 22 SECTION 5 TIRES 5.1.1 GENERAL INFORMATION Over and under inflation are the greatest causes of tire damage. Over inflation does not compensate for overloading. Rapid tire wear is the result of either condition and may be apparent at different places on the tire. Always keep tires inflated to proper pressure as stamped on the side of the tire.
  • Page 23 CHECK TIRES BEFORE EACH TRIP WHILE THEY ARE COOL. EXAMINE YOUR TIRES FOR BULGES, CUTS, CRACKS, OR PENETRATIONS. USE OF A DAMAGED TIRE COULD RESULT IN TIRE DESTRUCTION, PROPERTY DAMAGE, AND PERSONAL INJURY. REPORT TIRE DAMAGE TO YOUR DEALER AT ONCE. WHEEL ALIGNMENT IS RECOMMENDED AFTER TWO MONTHS.
  • Page 24 WHEELS AND RIMS 6.1.1 HUB-PILOTED MOUNTING Disc wheels are standard on LUFKIN trailers. These wheels may be either steel or aluminum. It is important that the wheel nuts be tightened independently to the recommended torque values. Hub piloted wheels are designed to center on the hub at the center hole or bore of the wheel (see Figures 7 and 8).
  • Page 25 You must never use the hub piloted wheels, which have straight holes, with ball seat or spherical chamfer nuts. These parts are not engineered to work together and can cause premature wheel failure. On heavy truck dual wheels, this condition would not allow the inner cap nut to fit into the inner wheel causing the inner cap nut to interfere with the outer wheel.
  • Page 26 Figure 9 Nuts must be kept tight by retorquing nuts on a routine basis and using the proper nut torque and tightening sequence. Loose nuts could result in loose wheels or premature wheel failure. This can result in an accident or injury. 6.1.2 STUD-PILOTED MOUNTING Wheels with the stud-piloted mounting system are called stud mount wheels.
  • Page 27 Slide the outer dual wheel over the inner cap nuts and repeat the entire procedure using the same nut tightening sequence in Figure 9. Not all nuts and studs can be used with all types o f wheels. The use of improper nuts and studs can cause nut loosening, stud failure or premature wheel failure, which could cause an accident or injury.
  • Page 28 For vendor information, click on the links below. LINK TO VENDOR FILE Accuride Wheels Conmet Hub/Drums Service Manual LINK TO VENDOR FILE KIC Hub/Drum Catalog LINK TO VENDOR FILE Webb Torque Specifications LINK TO VENDOR FILE Page 28...
  • Page 29 Jost International 7.1.2 EMPTY WEIGHT Your LUFKIN Dump trailer may be equipped with landing gear supports that are intended for empty weight only. Caution should be exercised to not drop a loaded trailer when these support legs are used. Page 29...
  • Page 30 SECTION 8 KING PIN AND UPPER COUPLER 8.1.1 Check king pin wear on the 2” diameter. Replace if worn down 1/8” or more. 8.1.2 Check bottom flange of king pin for cracks or broken pieces. Replace if necessary. INSPECTION CRITERIA 8.2.1 Check fasteners connecting upper coupler assembly to chassis rail on vans.
  • Page 31 OPERATOR SHOULD WARN ALL PERSONS TO STAND CLEAR AT LEAST 35 FEET FROM TRAILER WHILE DUMP IS BEING RAISED AND LOWERED. 9.1.9 SHOULD DUMP TRAILER START TO TILT, MOVE CONTROL IMMEDIATELY TO “LOWER” POSITION. 9.1.10 THE HOIST IS NOT DESIGNED FOR HOLDING BOX IN ELEVATED POSITION FOR ANY LENGTH OF TIME.
  • Page 32 9.2.1 HOPPER Hopper loading provides the opportunity to load a trailer more uniformly since the load is metered and flows from above the trailer. The end dump trailer may be slowly advanced forward during loading to accomplish this. 9.2.2 END LOADER The most common method of loading a trailer is with a front-end loader.
  • Page 33 9.5.1 STOCK PILE The most common method for unloading most commodities from an end dump trailer is to discharge the load onto a pile. A clean, compacted, level dump site is required. Any rapid tractor acceleration/deceleration should be avoided with the trailer body elevated to reduce dynamic tailgate impacts.
  • Page 34 SPREADING MUST BE RESTRICTED TO LEVEL, COMPACTED ROAD SURFACES AND TO MATERIALS WHICH ARE FREE FLOWING. THE BODY MUST BE RAISED IN INCREMENTS SO THAT THE LOAD IS KEPT TOWARD THE REAR. TAILGATE OPERATION 9.6.1 OPEN TAILGATE The tailgate must be unlocked prior to significantly elevating the body; otherwise, the load builds up against the tailgate, causing undue forces on the body structure and greatly increases the risk of tip-over.
  • Page 35 When the tractor and trailer are straight, the coupler bearings are apart, assisting in stabilizing the unit. When a frameless end dump trailer is coupled to a tractor fifth wheel, the fifth wheel must be “blocked”. Blocking restricts pivoting of the fifth wheel plate and draft arms. Lift the dump body only when the tractor and trailer are in a straight line.
  • Page 36 9.8.8 OVERLOADING Overloading is a very common occurrence that aggravates all of the above conditions that cause tip-overs. Lufkin Trailers are designed to carry and dump legal loads. 9.8.9 SUSPENSION Prior to dumping, the trailer suspension should be checked to make sure there are no broken springs, damaged air bags, loose U-bolts, etc.
  • Page 37 Slowing down pump speed will help both problems. Either a rigid mount or oscillating fifth wheel can be used for a dump trailer operation. If oscillating fifth wheel is used, it must be blocked so it will not oscillate.
  • Page 38 10.2.3 AIR LINE LUBRICATOR A bottom dump trailer is equipped with (2) air cylinders that control the operation of the doors. These cylinders are equipped with an air line lubricator. This lubricator is provided to ensure smooth operation of the cylinders.
  • Page 39 There are many important decals on your LUFKIN trailer. These decals serve several different purposes, including maintenance information, safety information, and information about compliance with state and federal regulations. If your trailer is missing any of the decals shown below, please contact LUFKIN for replacement information.
  • Page 40 These decals should be on the front of a LUFKIN model ULD and HRD end dumps only. Page 40...
  • Page 41 SIDE DECALS The serial plate will be on the front on a bottom dump (see picture on previous page), and as shown below on a model ULD and HRD. These are the decals you should see on the radius arms/landing gear on a model ULD and HRD. Page 41...
  • Page 42 These are the decals you should see on the bottom dump hopper and doors. These are the decals you may see in the suspension area. They may vary depending on suspension type. Page 42...
  • Page 43 Page 43...
  • Page 44 These decals may be seen at the rear of the trailer near the ABS light. REAR DECALS These are the decals you should see on the rear bolster on a ULD and rear end on a HRD. Page 44...
  • Page 45 SECTION 12 12.1 SUPPLIER SECTION The following names, addresses and phone numbers will provide a second source when there are questions: AXLES: ArvinMeritor Dana Corporation 2135 West Maple Road PO Box 4013 Troy, MI 48084 Kalamazoo, MI 49003 Phone: (800)-535-5560 Phone: (800)-826-4357 www.arvinmeritor.com www.roadranger.com...
  • Page 46 Parker Hydaulics (Commercial) West Craft Cylinders Mobile Cylinder Div. 100 Mill Pond Street P.O. Box 239 P.O. Box 596 Youngstown, OH 44501-0239 Alto, TX 75925 Phone: (330)-740-8670 Phone: (936)-858-4426 www.commercialhydraulics.com www.westcraftmfg.com HARNESS/LIGHTING: Peterson Manufacturing Co. Truck-lite Company, Inc. 4200 E. 135th Street 310 E.
  • Page 47 WHEEL END COMPONENTS: Accuride Corporation MacLean Vehicle Systems 7140 Office Circle 1000 Allanson Road P.O. Box 15600 Mundelein, IL 60060 Evansville, IN 44716-0600 Phone: (800) 323-4536 Phone: (888)-770-7282 www.mfmvs.com www.accuridewheels.com Stemco LP Alcoa Inc. Wheel Products 300 Industrial Blvd. 1600 Harvard Avenue P.O Box 1989 Cleveland, OH 44105 Longview, Texas 75606-1989...
  • Page 48 LAWS, REGULATIONS AND INDUSTRY STANDARDS Dept. of Transportation, National Highway Traffic Safety Administration Federal Motor Vehicle Safety Standards FMVSS Lights FMVSS V.I.N. FMVSS Brakes FMVSS Rear Impact Guard FMVSS Rear Impact Guard Recommended practices and tech bulletin: Truck Trailer Manufacturers Association Alexandria, VA 703-549-3010 www.ttmanet.org...
  • Page 49 (including, but not limited to, overhead doors, floors, brake linings, brake drums, oil seals, bearings, paint, lights and lamp bulbs, tarps, tires, and the like) LUFKIN extends no warranties of its own, specifically disclaiming any such warranties by LUFKIN, express or implied, as to such component parts, materials accessories or expendable parts.
  • Page 50 LUFKIN INDUSTRIES, INC. P.O. BOX 849 LUFKIN, TX 75902-0849 800-324-3812 Revised 11/06 Page 50...

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