BULK FEED BODIES & TRAILERS BULK NITRATE BODIES & TRAILERS

Transcription

1 BULK FEED BODIES & TRAILERS BULK NITRATE BODIES & TRAILERS 1. Introduction And Warranty Introduction Warranty Safety Safety Alert Symbol and Signal Words Towing Hazards Driving Too Fast Trailer Not Properly Coupled to Truck Overloading Improper Load Distribution Inappropriate Cargo Brakes and Lights Clearance Hydraulics Maintenance Loading and Unloading Hazards From Modifying equipment Safety Warning Labels Reporting Safety Defects Coupling Truck To Trailer Providing an Adequate Truck Trailer Information Before Attempting To Couple Truck To Trailer Couple Truck to Trailer Pretrip Inspection Towing Trailer Wheels and Tires Alignment Loading And Unloading Load Feed Load Feed Using Top Doors Load Feed Using The Vacuum Feed Retrieval System Unload Feed Using Discharge Auger Unload Feed Into A Pit Uncouple Truck Uncouple Truck from Trailer Inspections And Maintenance Every Day Pre Trip Inspections

2 7.1.2 Inspect Body, Chassis And Fasteners Every Week Inspect, Measure And Adjust Brakes Drain Trailer Air Tanks Lubrication Every Two Weeks Every Three Weeks Every Month Every Six Months As Necessary Hydraulic System Augers Overcenter Valve Adjustment Tires Wheels Disk Wheels Wheel Ends

3 1. INTRODUCTION AND WARRANTY 1.1 INTRODUCTION Read and understand this manual before using your trailer or truck body and follow all of the safety instructions. Keep all manuals provided with your trailer or truck body in a safe place inside your truck at all times. Some components may have separate instruction manuals. Where this manual indicates that you should read another manual, and you do not have that manual, contact your dealer or Warren manufacturing for assistance. Information provided in this manual was current as of the issue date. Warren Manufacturing reserves the right to make design changes without further notice or liability. 1.2 WARRANTY WARREN MANUFACTURING, INC., (hereinafter called Warren) warrants each new trailer, body and item of hydraulic equipment manufactured by it to be free from defects in material and workmanship under normal use and service with loads not exceeding the vehicle manufacturer's rated capacity for a period of 12 months after delivery to the original purchaser direct or by an authorized distributor. Exclusions from Warranty. This Warranty shall not apply to: (1) components manufactured by persons other than Warren (such as hydraulic pumps, motors, valve, bearings, etc.) beyond warranty, if any, which may be made by such manufacturer, (2) any unit which shall have been subject to misuse, negligence, alteration or accident or which shall have been repaired by anyone other than Warren or its authorized service distributor in any way so as in the judgment of Warren to affect adversely its performance or reliability, or (3) normal maintenance services. Purchaser's Exclusive Remedies. Warren's sole obligation under this warranty will be to repair or replace, at its option, any warranted unit or part as described above which shall be returned to Warren's factory or authorized service distributor and which examination shall disclose to Warren's satisfaction to have been defective. Freight or other transportation costs to and from the factory or authorized service distributor must be paid by the purchaser. Warren will not assume any charges for repairs made by anyone other than Warren or its authorized service distributor. Exclusion of other Warranties. No other warranty is made by Warren and in particular Warren makes NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. Warren neither assumes nor authorizes any person to assume for it any liability other than described herein. Limitations of Actions. Without extending the period of warranty stated above, any action for breach of warranty must be commenced within one year of the breached claimed or forever barred. Limitation of Damages. The purchaser's remedy stated above shall be exclusive for any and all claims against Warren whether based on contract, negligence, tort, or any other theory. In no event shall Warren be liable for any consequential damages which may result from any defect or failure of a unit or part. 3

4 2. SAFETY 2.1 SAFETY ALERT SYMBOL AND SIGNAL WORDS This Owner s Manual covers trailers and bodies produced by Warren Manufacturing. Before towing, operating or servicing a Warren Manufacturing trailer or body, you must read, understand and follow the instructions and safety warnings in this manual. Your trailer or truck body may not be equipped with some of the optional equipment shown in the illustrations in this manual. The safety information in this manual is denoted by the safety alert symbol: ^ The level of risk is indicated by the following signal words.! DANGER DANGER Indicates a hazardous situation, which, if not avoided, will result in death or serious injury. WARNING Indicates a hazardous situation, which, if not avoided, could result in death or serious injury.! CAUTION CAUTION Indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury. NOTICE NOTICE Indicates a situation that could result in damage to the equipment or other property. 2.2 TOWING HAZARDS Loss of control of the truck/trailer combination can result in death or serious injury. The most common causes for loss of control are: Driving too fast. Incorrect coupling. Overloading. Improper load distribution. Shifting cargo DRIVING TOO FAST If you drive too fast, the trailer is more likely to sway, thus increasing the possibility for loss of control. Collision hazard. Driving too fast for conditions can result in loss of control and may result death or serious injury. Adjust speed down when towing trailer. 4

5 Safety TRAILER NOT PROPERLY COUPLED TO TRUCK A secure coupling is vital. Uncoupling can result in death or serious injury. Collision hazard. An improperly coupled trailer can result in death or serious injury. Before towing trailer, verify that: The coupler is properly secured and locked. Trailer landing gear is fully retracted. Lights and air hoses connected. Perform pre-trip inspection OVERLOADING An overloaded trailer can result in loss of control, which may result in death or serious injury. Overloading may also result in tire, wheel, axle or structural failure, and also increased stopping distances. Collision hazard. Overloading can result in death or serious injury. Do not load a trailer or truck body so that the Gross Vehicle Weight Rating (GVWR) or Gross Axle Weight Rating (GAWR) is exceeded IMPROPER LOAD DISTRIBUTION Improper load distribution can result to poor stability and handling. Refer to Loading and Unloading for more information. Uneven load distribution can cause tire, wheel, axle or structural failure. Be sure your load is evenly distributed frontto-rear and side-to-side. Collision hazard. An improperly loaded trailer can result in failure or loss of control, leading to death or serious injury. Evenly distribute the load throughout the trailer. 5

6 Safety INAPPROPRIATE CARGO Carry only the cargo that your trailer or truck body was designed for. A trailer must not be used to carry certain items, such as people, containers of hazardous substances or containers of flammable substances. Never transport people in or on a trailer or truck body. Do not transport flammable, explosive, poisonous or other dangerous materials in or on your trailer or truck body unless specifically designed to do so. 2.3 BRAKES AND LIGHTS Be sure that the brakes and all of the lights are functioning properly. Collision hazard. Failure to connect the electrical connector and air hoses will result in inoperable trailer lights and brakes, and can lead to collision. Before each tow, verify that all lights and brakes work properly. 2.4 CLEARANCE Collision hazard. Know the height, width and length of the trailer or truck body. Always be aware of clearances. 2.5 HYDRAULICS Pressurized fluids can penetrate the skin. Hydraulic hoses can fail from age, damage and exposure. Do not search for hydraulic leaks without body and face protection. A tiny, almost invisible leak can penetrate the skin, thereby requiring immediate medical attention. Use wood or cardboard to detect hydraulic leaks, never your hands. 6

7 2.6 MAINTENANCE Crushing hazard. Safety Before performing inspections, service or maintenance: Park truck and/or trailer on firm, level surface. Set brakes, turn truck engine off and remove ignition key. Chock tires if brakes are to be released. Support trailer with properly rated and placed stands. 2.7 LOADING AND UNLOADING! DANGER Electrocution hazard. Contact with overhead will cause serious Electrocution can occur Turn the boom in Be sure there are no over or near the trailer electrical lines injury or death. without contact. lowest position. electrical lines or truck body. Falling hazard. Use caution while on ladder and catwalk. Keep off ladder and catwalk during wind, rain, lightening and snow conditions and if there is a possibility for ice or frost on ladder and catwalk. If catwalk is equipped with handrails, set them up before using catwalk. Crushing and severing hazard. Never enter the trailer while the augers or vacuum system are engaged. Keep away from moving parts. Never operate equipment with guards or shields removed. Remain at the controls while augers and vacuum system are in engaged. 7

8 Safety 2.8 HAZARDS FROM MODIFYING EQUIPMENT Before making any alteration to your Warren Manufacturing equipment, contact your dealer or Warren Manufacturing and describe the alteration you are contemplating. Altering may cause your equipment to be unsafe and may void the manufacturers warranty. 2.9 SAFETY WARNING LABELS Figure 2-1 Label On Vertical Auger Access Door Figure 2-2 Label On Pit Dump Door 8

9 Safety Figure 2-3 Label On Rear of Body and Trailer Figure 2-4 Label On Front Of Body And Trailer Figure 2-5 Labels On Fuel Tank And Hydraulic Oil Tank 9

10 Safety Figure 2-5 Labels On Rear Of Body And Trailer 10

11 Safety Figure 2-6 Labels On Hydraulic Control Box Figure 2-7 Labels On Vertical Auger To protect against death or serious injury, all labels must be on the trailer or truck body and must be legible. If any of these labels are missing or cannot be read, call Warren Manufacturing at for replacement labels REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Warren Manufacturing. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Warren Manufacturing. To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at (TTY: ), go to or write to: Administrator, NHTSA, 400 Seventh Street, SW., Washington, DC You can also obtain other information about motor vehicle safety from 11

12 3. COUPLING TRUCK TO TRAILER 3.1 PROVIDING AN ADEQUATE TRUCK The truck must be matched to the Gross Vehicle Weight Rating (GVWR) of your trailer. If you already have a truck, know your trucks tow rating and make certain the trailer s rated capacity is less than or equal to the truck s rated towing capacity.! DANGER Loss of control hazard. Use of an under-rated truck could result in loss of control, and can lead to death or serious injury. Be sure your truck is rated for the Gross Vehicle Weight Rating (GVWR) of your trailer. 3.2 TRAILER INFORMATION The Certification / VIN tag is located on the left side of the trailer, near the landing gear. See figure 3-1. Figure Certification / VIN Tag Location The trailer Certification / VIN tag contains the following information: MANUFACTURER: Warren Manufacturing, Inc. DATE: Month and year the trailer was manufactured. GVWR: The Gross Vehicle Weight Rating is the maximum allowable gross weight of the trailer and its contents with the listed wheel rims. FRONT GAWR: The Gross Axle Weight Rating is the maximum gross weight that the front axle can support. 1 st INTERM. GAWR: The Gross Axle Weight Rating is the maximum gross weight that the 1 st intermediate axle can support. 2 nd INTERM. GAWR: The Gross Axle Weight Rating is the maximum gross weight that the 2 nd intermediate axle can support. REAR GAWR: The Gross Axle(s) Weight Rating is the maximum gross weight that the rear axle(s) can support. TIRE: The tire size recommended for your trailer and load range. RIMS: The rim size recommended for your trailer. 12

13 Coupling Trailer To Truck COLD INFLATION PRESSURE: The pounds per square inch is the tire pressure (Kilopascals / Pounds per Square Inch) measured when cold. VIN: The Vehicle Identification Number. TYPE: Type of trailer. CERTIFICATION STATEMENT: This vehicle conforms to all applicable U.S. Federal Motor Vehicle Safety Standards in effect on the date of manufacture shown above. 3.3 BEFORE ATTEMPTING TO COUPLE TRUCK TO TRAILER 1. Check the condition of the kingpin and mounting plate. Wipe the kingpin clean and inspect it for flat spots, cracks and pits. Uncoupling hazard. A worn, bent or damaged kingpin can fail while towing, which can result in death or serious injury. Inspect the kingpin and kingpin plate for wear and damage. Replace a worn or damaged kingpin or kingpin plate before towing trailer. 2. Verify that the kingpin plate and fifth wheel fasteners are tight and welds are sound. Uncoupling hazard. A loose kingpin or fifth wheel can result in the trailer uncoupling, which can result in death or serious injury. Verify the kingpin and fifth wheel are tight. 3. Lubricate the fifth wheel lock mechanism and verify it will move freely. 4. Clear all hoses and electrical cables from the coupling area. 5. Verify the fifth wheel locks are open. Crushing hazard. Death or serious injury may occur if the trailer drops. Keep bystanders away from trailer while coupling. 3.4 COUPLE TRUCK TO TRAILER 1. Place wheel chocks behind the trailer tires. 2. Place the truck directly in front of the trailer in a straight line. See figure 3-2. NEVER back under the trailer at an angle. 13

14 Coupling Trailer To Truck 3. Back the truck until close to the trailer. Figure 3-2 Align Truck With Trailer For Coupling 4. Apply the truck parking brakes and place transmission in neutral. 5. Release air from truck suspension (if equipped). 6. Inspect the height of the trailer vs the fifth wheel. The kingpin plate on the front of the trailer should first contact the fifth wheel 4-6 inches rearward of the fifth wheel centerline. See figure 3-3. The trailer should rise slightly when the truck is backed under it. If the trailer is too low, the truck may strike and damage the front of the trailer. If the trailer is too high, it will not couple correctly. Adjust the landing gear as needed to achieve the correct trailer height. Uncoupling hazard. Trailer must be at the correct height to couple to truck. Verify trailer is at the proper height before coupling. 7. Verify that the kingpin and fifth wheel are aligned. Figure 3-3 Coupling Truck To Trailer 8. Slowly back the truck keeping the kingpin aligned with the fifth wheel. Continue backing until the fifth wheel locks firmly on the kingpin. Attempt to pull forward as a test to verify the fifth wheel is locked. Do not attempt to move the truck and trailer at this time. 9. Apply the truck parking brake, place transmission in neutral, stop truck engine and remove ignition key. 10. Inspect the coupling. See figure 3-4. Verify there is no space between the kingpin plate and the fifth wheel. If there is space, the kingpin may be on top of the fifth wheel jaws. Raise the trailer with the landing gear, pull the fifth wheel release lever and pull the truck ahead. Repeat steps 6-10 again to couple the trailer correctly. 14

15 Coupling Trailer To Truck Figure 3-4 Fifth Wheel Checks 10. Go under the trailer with a flashlight and look into the back of the fifth wheel. Verify the fifth wheel jaws (A) have closed around the shank of the kingpin and the fifth wheel lock lever is in the locked position. See figure Inflate the truck suspension (if equipped). Figure 3-5 Fifth Wheel Jaws Closed Around Kingpin Shank 12. Connect the 7-pin electrical connector (1), service hose to glad hand (2) and supply hose to glad hand (3). DO NOT connect the 7-pin electrical cable from the truck to connector (4)! Connector (4) is for the unloading system remote pendent. Figure 3-6 Connect Hoses And Electrical Connector Risk of unintended unloading system functions. The trailer unloading system may unintentionally activate if the truck electrical light cable is plugged into connector (4). Do not plug truck electrical cable into remote pendent connector (4). 15

16 Coupling Trailer To Truck 13. Connect the pressure and return hydraulic hoses to the couplers on the truck. See figure 3-7. Pressurized fluids can penetrate the skin. Hydraulic hoses can fail from age, damage and exposure. Do not search for hydraulic leaks without body and face protection. A tiny, almost invisible leak can penetrate the skin, thereby requiring immediate medical attention. Use wood or cardboard to detect hydraulic leaks, never your hands. Figure 3-7 Connect Hydraulic Hoses 14. Raise the landing gear. Warren Manufacturing. uses a two speed landing gear from several different manufacturers. High speed may be in on some models and out on others. Engage the crank handle (1) to the shaft and turn to retract the landing gear. Return the landing gear crank handle to the storage position. See figure 3-8. Figure Two Speed Landing Gear 15. Press the trailer air supply valve in the truck to fill the trailer air tanks. Do not release parking brakes. 16

17 16. Perform pretrip inspection. See section PRETRIP INSPECTION Perform the inspections and checks before towing trailer: Coupling Trailer To Truck Check all lights for proper operation. Check that ABS light on street side rear corner of the trailer is not illuminated. If lamp is illuminated, see the axle and brake manufacturers manual. Check that all safety decals are in place and in good, readable condition. Check that all reflectors are in place and in good condition. Check air pressure on all tires. Air pressure is listed on the Certification/VIN tag. Check and inspect all tires. If a tire has a bald spot, bulge, cut or cords showing, replace the tire(s) before towing trailer. Check wheel lug torque. See Section Check the wheel hub fluid level and also for signs of lubricant leakage. Check for broken or missing leaf springs or verify that air suspension springs are inflated. Check electrical harness and air hoses from truck for damage. Listen for air leaks in hoses and air suspension (if equipped). Check brakes for wear and verify the brakes function properly. Repair or replace any worn, damaged, leaking, broken or non-functioning items before towing the trailer. 17

18 4. TOWING TRAILER 4.1 WHEELS AND TIRES Uneven tread wear can be caused by tire imbalance, axle misalignment or improper inflation. If you observe uneven tread wear, take the trailer to an authorized truck/trailer service center for diagnosis. Trailer wheels and lugs are subjected to high side loads. This can cause the wheel lugs to become loose. Check to be certain wheel lugs are tightened to lb ft of torque. Refer to the maintenance section for the proper tightening procedure. Failure to perform this check may result in a wheel parting from the trailer, and a crash leading to death or serious injury. You must use a torque wrench to obtain the proper tightening of the lug nuts. 4.2 ALIGNMENT Properly aligned trailer axles optimize fuel economy and drivability, and help prevent excessive tire wear. A perfect alignment scenario has all trailer wheels parallel to one another and perpendicular to the centerline of the trailer. However due to uncontrollable factors, this perfect scenario is often an unreasonable expectation. A more likely alignment scenario has the trailer wheels parallel within a very small tolerance range to one another and perpendicular within a very small tolerance range to the centerline of the trailer. There are two important trailer axle angles that must be kept within recommended tolerance ranges: thrust angle and scrub angle. These angles, when out of tolerance, can lead to increased rolling resistance, excessive tire wear and can contribute to trailer dog tracking. Dog tracking is a condition where the trailer does not follow or track directly behind the truck as the vehicle is being operated in a straight line and is influenced by body rail alignment, king pin location, axle side-to-side location, and other things. If realignment is necessary, take the trailer to your dealer or an authorized trailer service center. 18

19 5. LOADING AND UNLOADING Improper trailer loading causes many accidents and deaths. To safely load a trailer, you must consider the overall load weight and load distribution. The load distribution must be such that no component part of the trailer is loaded beyond its rating. You must be sure that the load distribution does not exceed the rating of the tires, wheels and axles. Collision hazard. An overloaded trailer may result in death or serious injury. Do not load a trailer so that the Gross Vehicle Weight Rating (GVWR) or Gross Axle Weight Rating (GAWR) is exceeded. 5.1 LOAD FEED LOAD FEED USING TOP DOORS Falling hazard. Use caution while on ladder and catwalk. Keep off ladder and catwalk during wind, rain, lightening and snow conditions and if there is a possibility for ice or frost on ladder and catwalk. If catwalk is equipped with handrails, set them up before using catwalk. 1. Close all compartment gates. Your compartment gates may be operated by a rack & pinion or a crank handle. For horizontal rack & pinion style gates, the gate is closed when the forward racks (1) are extended. Use the socket and ratchet provided to open and close the compartment gates. For inverted "V" style rack & pinion style gates, turn the crank handles (2) counter-clockwise to close the compartment gates. For drop style gates, turn the handle counterclockwise. Figure 5-1 Compartment Gate Controls 2. Open top doors. Your top doors may be air or manually operated. The air valve (3) is located on the forward street side fender. The crank handles (4) are located on the forward street side and rear curb side. To open the air operated top doors, pull valve (3) out to the center (exhaust) position until all pressurized air is exhausted from the 19

20 Loading And Unloading cylinders and then pull valve to the full out position. For manually operated doors, rotate crank handles (4) to open the top doors. For manually operated individual doors, pull up on the rubber hold-down and slide the door away from you. Figure 5-2 Top Door Controls 3. Load the feed onto the trailer, distributing the feed evenly throughout the trailer. 4. Weigh the trailer to be sure you have not exceeded the weight capacity of the trailer, tires, axles and wheels. 5. Close top doors. To close the air operated top doors, push valve (3) in to the center (exhaust) position until all pressurized air is exhausted from the cylinders and then push valve to the full in position. For manually operated doors, rotate crank handles (4) to close top doors. For manually operated individual doors, pull the door towards you and fasten the rubber latch. See figure Verify that top doors are fully closed LOAD FEED USING THE VACUUM FEED RETRIEVAL SYSTEM 1. Park the truck or trailer in a desirable position accessible to the feed bin and set the parking brakes. Crushing hazard. Never enter the trailer while the augers or vacuum system are engaged. Keep away from moving parts. Remain at the controls while augers and vacuum system are in engaged. 3. Verify that all hydraulic controls are in the neutral position. 20

21 Loading And Unloading Figure 5-3 Hydraulic Controls 4. If equipped with a remote pendent, connect pendent to 7-pin connector (1). See figure 5-4. Figure 5-4 Remote Pendent Connector 5. Connect vacuum hoses (2) on front of trailer to tractor vacuum and pressure couplers. See figure 5-5. Figure

22 Loading And Unloading 6. Connect vacuum pickup hoses (3) to coupler (4) on rear of trailer. See figure 5-6. Connect retrieval tip to vacuum pickup hose. 7. Place retrieval hose tip under feed bin. Figure 5-6 Feed Retrieval Hose Connector 8. Select bin for feed and remove lock pin from lever. Move lever (5) down to place feed into selected bin. See figure 5-7. Depending on the amount of feed you will be loading, it is a good idea to open the next forward bin also. Figure 5-7 Open Feed Bin 9. Engage PTO. During cold weather, let the hydraulic system run a few minutes to warm up. 10. Set the engine speed so that the PTO is running at 1200 RPM. 11. Engage vacuum system by pushing floor auger control valve (6) inward. See figure

23 Loading And Unloading Figure 5-8 Engage Vacuum System 12. Set the airlock shaft speed at RPM with the flow control valve (8). See figure 5-9. Figure 5-9 Auger and Flow Control 13. Vacuum the feed into the selected bin. If the bin is full, close the bin by pushing the lever (5) up and lock into position with lock pin. Closing this bin will direct the feed onto the next open bin. See figure Figure 5-10 Feed Bin Closed 14. After feed has been retrieved, shut off the vacuum system by pulling floor auger control valve (6) outward. 23

24 Loading And Unloading Figure 5-11 Disengage Vacuum System 15. Disengage the discharge and vertical augers using control valve (7). See figure Figure 5-12 Discharge and Vertical Auger Control 16. Disconnect and stow vacuum hoses and feed retrieval hoses. 5.2 UNLOAD FEED USING DISCHARGE AUGER 1. Park the truck or trailer in a desirable position accessible to the feed bin and set the parking brakes. 2. Get out and verify that there is no electrical wire near the trailer, truck body or within reach of the auger.! DANGER Electrocution hazard. Contact with overhead electrical lines will cause serious injury or death. Electrocution can occur without contact. Turn the boom in lowest position. Be sure there are no electrical lines over or near the trailer or truck body. 24

25 Loading And Unloading Crushing and severing hazard. Never enter the trailer while the augers are engaged. Keep away from moving parts. Remain at the controls while augers are in engaged. 3. Verify that all hydraulic controls are in the neutral position. See figure Figure 5-13 Hydraulic Controls 4. If equipped with a remote pendent, connect pendent to 7-pin connector (1). See figure Figure 5-14 Remote Pendent Connector 5. Engage PTO. During cold weather, let the hydraulic system run a few minutes to warm up. 6. Set the engine speed so that the PTO is running at 1200 RPM. 25

26 Loading And Unloading Note: Your trailer or truck body is equipped with the standard hydraulic control levers and may be equipped with a wireless remote or a remote pendent to control the boom lift, boom swing and augers. Use the steps and illustrations below for operating the boom and augers. 7. If using a wireless remote or remote pendent, turn power switch (2) to ON. See figure Figure 5-15 Wireless and Remote Pendent 8. Move the Boom Lift switch (3) to UP or pull the Raise/Lower valve (4) to raise the boom off the boom supports. 9. Using the Boom Swing (5) and Boom Lift (3) switches, or the Raise/Lower (4) and Swivel (6) valves, raise and turn the boom to its unloading position. See figure Figure 5-16 Auger Controls 26

27 Loading And Unloading 10. Engage the boom lock by moving valve handle (7) horizontal as shown in figure This will prevent the boom from settling while unloading the feed. Figure 5-17 Engage Boom Lock 11. If using a wireless remote or remote pendent, select ALL AUGERS on switch (8). If using the hydraulic controls, engage the discharge and vertical augers using control valve (9). See figure If using the hydraulic controls, engage the floor auger using control valve (10). See figure Figure 5-18 Auger Controls NOTE: Warren Manufacturing hydraulic systems are equipped with a balance sensor valve (overcenter valve) between the floor auger hydraulic circuit and the vertical and discharge hydraulic circuit. This balance sensor valve eliminates the need to manually control the speed of the floor auger. The purpose of this valve is to automatically control the flow of feed from the floor auger to the vertical and discharge auger. If the floor auger should overfill the vertical auger and cause a jam, this valve will open and bypass the hydraulic oil which in turn allows the vertical to cleanout. As soon as the vertical auger has been relieved, the floor auger will return to normal speed. 27

28 Loading And Unloading 13. Warren Manufacturing recommends that you open only one compartment at a time and that you open the rear feed compartment gate first. For horizontal rack & pinion style gates, use the socket and ratchet (11) provided to open and the compartment gates. The gate is open when the rearward rack is extended. For inverted "V" style rack & pinion style gates, turn the crank handles (12) clockwise to open the compartment gates. For drop style gates, turn the handle clockwise. See figure Figure 5-19 Open Feed Gate NOTE: If you need to stop the unloading, it is recommended that you close the compartment door and allow the floor, vertical and discharge augers to empty. NOTE: The crank handle style gates are pre-drilled with holes for use with the pins to control the flow of feed. Some heavier or wetter feeds may require a pin setting short of the completely open position. Simply place pin in desired hole prior to opening the gate. 14. After the rear compartment is empty, leave the rear gate open and open the compartment at the front of the trailer or body. After the front compartment is empty, open the second and so on working toward the rear. 15. When all compartments, floor auger, vertical and discharge augers are empty, stop the augers by returning the control valves and switches to the OFF or neutral position. 16. Disengage the boom lock by moving valve handle (7) vertical as shown in figure NOTICE Discharge auger may lower if boom lock handle is disengaged while auger is full of feed. Be certain auger is empty before disengaging boom lock. Figure 5-20 Disengage Boom Lock 28

29 Loading And Unloading 17. Using the Boom Swing (5) and Boom Lift (3) switches, or the Raise/Lower (4) and Swivel (6) valves, turn and lower the boom to its travel position on the trailer/body support. See figure Figure 5-21 Auger Controls 18. Turn wireless remote or remote pendent to OFF and disengage PTO. 5.3 UNLOAD FEED INTO A PIT 1. Park the truck or trailer with one of the floor auger doors in position over the pit and set the parking brakes. Crushing hazard. Never enter the trailer while the augers are engaged. Keep away from moving parts. Remain at the controls while augers are in engaged. 2. Verify that all hydraulic controls are in the neutral position. See figure Figure 5-22 Hydraulic Controls 29

30 Crushing and severing hazard. Loading And Unloading Never open a floor auger access door while the auger is engaged. Keep away from moving parts. Remain at the controls while augers are in engaged. 5. Open latches on auger pit dump door and swing door downward. See figure Figure 5-23 Floor Auger Pit Dump Door 6. Engage PTO. During cold weather, let the hydraulic system run a few minutes to warm up. 7. Set the engine speed so that the PTO is running at 1200 RPM. 8. Move hydraulic control lever (10) to engage the floor auger. See figure The wireless remote or remote pendants do not have the capability to select the floor auger separately. Figure 5-24 Floor Auger Control Warren Manufacturing recommends that you open only one compartment at a time and that you open the rear feed compartment gate first. For horizontal rack & pinion style gates, use the socket and ratchet (11) provided to open and 30

31 Loading And Unloading the compartment gates. The gate is open when the rearward rack is extended. For inverted "V" style rack & pinion style gates, turn the crank handles (12) clockwise to open the compartment gates. For drop style gates, turn the handle clockwise. See figure Figure 5-25 Open Feed Gate NOTE: If you need to stop the unloading, it is recommended that you close the compartment door and allow the floor, vertical and discharge augers to empty. NOTE: The crank handle style gates are pre-drilled with holes for use with the pins to control the flow of feed. Some heavier or wetter feeds may require a pin setting short of the completely open position. Simply place pin in desired hole prior to opening the gate. 9. After the rear compartment is empty, leave the rear gate open and open the compartment at the front of the trailer or body. After the front compartment is empty, open the second and so on working toward the rear. 10. When all compartments and the floor auger are empty, stop the auger by moving the control valve to the neutral position. Crushing and severing hazard. Never open a floor auger access door while the auger is engaged. Keep away from moving parts. Remain at the controls while augers are in engaged. 11. Close and latch auger pit dump door. Be certain latches (1) are engaged to secure door. See figure Figure 5-26 Floor Auger Pit Dump Door 31

32 6. UNCOUPLE TRUCK 6.1 UNCOUPLE TRUCK FROM TRAILER 1. Park the trailer on a firm level surface. 2. Set the parking brakes and pull trailer air supply valve out. 3. If trailer is loaded, place blocks or pads under landing gear legs to prevent settling. 4. Lower the landing gear. Warren Manufacturing uses a two speed landing gear from several different manufacturers. High speed may be in on some models and out on others. Engage the crank handle (1) to the shaft and turn to extend the landing gear until it makes firm contact with the pavement, blocks or pads. Switch to low gear and crank an additional 4-8 turns. Return the landing gear crank handle to the storage position. See figure 6-1. Figure 6-1 Extend Landing Gear Legs 5. Disconnect the electrical connector (1), service hose (2) and supply hose (3). Disconnect pendent remote from connector (4) if equipped. See figure 6-2. Figure 6-2 Disconnect Hoses and Electrical Connector 32

33 Uncouple Truck 6. Disconnect the hydraulic hoses from the couplers on the truck. See figure Pull the fifth wheel release lever. Figure 6-3 Disconnect Hydraulic Hoses 8. Release air in truck suspension (if equipped) and pull truck forward until fifth wheel comes out from under the trailer. 9. Stop with truck frame under trailer. This will prevent the trailer from falling to the ground if the landing gear should collapse or sink. 10. Apply parking brake and place transmission in neutral. 11. Make sure ground is supporting the trailer. Make sure landing gear is not damaged. 12. Check the area and drive truck forward until clear of trailer. 33

34 7. INSPECTIONS AND MAINTENANCE Warren Manufacturing uses components on their trailers such as landing gear, axle assemblies, tires and rims which are produced by other manufacturers. Refer to the OEM manufacturer s information for specific maintenance instructions. If you do not have the manufacturers information, contact Warren Manufacturing or your dealer for assistance. Routine inspections, maintenance and service must be performed on a regular basis to insure safe and reliable operation. Inspections can be performed by a person trained in spotting potential problems. Service and repairs must be performed by a trained, qualified technician. The lubrication schedule is based on normal service of one shift per day. If unit is operated more or under sever service, we recommend more frequent service. Note: In addition to this manual, also check the relevant component manufacturer's manual. Crushing hazard. Before performing trailer Inspections, service or maintenance: Park trailer on firm, level surface. Set parking brakes, turn truck engine off and remove ignition key. Chock tires if brakes are to be released. If raising trailer, support trailer with properly rated and placed stands. 7.1 EVERY DAY PRE TRIP INSPECTIONS Perform the following inspections and checks before towing trailer. This list is also covered in the pre-trip inspection: Check all lights for proper operation. Check that ABS light on street side rear corner of the trailer is not illuminated. If lamp is illuminated, see the axle and brake manufacturers manual. Check that all safety decals are in place and in good, readable condition. Check that all reflectors are in place and in good condition. Check air pressure on all tires. Air pressure is listed on the Certification/VIN tag. Check and inspect all tires. If a tire has a bald spot, bulge, cut or cords showing, replace the tire(s) before towing trailer. Check wheel lug torque. See Section Check the wheel hub fluid level and also for signs of lubricant leakage. Check for broken or missing leaf springs or verify that air suspension springs are inflated. Check electrical harness and air hoses from truck for damage. Listen for air leaks in hoses and air suspension (if equipped). Check brakes for wear and verify the brakes function properly. Repair or replace any worn, damaged, leaking, broken or non-functioning items before towing the trailer INSPECT BODY, CHASSIS AND FASTENERS 1. Inspect the trailer body and chassis for damage daily. 2. Inspect all of the fasteners, welds and structural frame members for bending and other damage, cracks, or failure. Repair or replace any damaged fastener and repair the frame member. If you have any questions about the condition or method of repair of fasteners or frame members, get the recommendation of, or have the repair done by Warren Manufacturing or your dealer. Welds must be repaired by a qualified technician. 34

35 Inspections And Maintenance Broken or damaged fasteners or welds can cause injury and/or damage to trailer and contents. Inspect for and repair all damaged parts. 7.2 EVERY WEEK INSPECT, MEASURE AND ADJUST BRAKES Inspect and measure the brake linings. Replace with a quality shoe and lining if contaminated, cracked or if the lining is worn to less than ¼ inch thickness at any point. See figure 8-6. Figure 7-1 Measure Brake Lining Chock tires and release brakes. Measure the distance (A) with brakes released. See figure 7-2. Use a lever to move slack adjuster until brakes contact the drum and measure the distance (B). Subtract distance A from distance B. The result is the free stroke. Adjust slack adjuster so the free stroke is 3/8 5/8 inch on each slack adjuster. Figure 7-2 Adjust Slack Adjusters 35

36 7.2.2 DRAIN TRAILER AIR TANKS Inspections And Maintenance Drain moisture from trailer air tanks by opening petcock on the bottom of each air tank. See figure 8-5. Close petcocks after draining LUBRICATION Lubricate the following grease fittings at least once per week with a high quality lithium grease. Figure 7-3 Lubricate Vertical Auger Bearings Figure 7-4 Lubricate Discharge Auger Bearings Figure 7-5 Lubricate Split Ring Bearings 36

37 Inspections And Maintenance 7.3 EVERY TWO WEEKS Figure 7-6 Lubricate Vertical Auger Swivel Bearings Lubricate the following grease fittings at least once every two weeks with a high quality lithium grease. 7.4 EVERY THREE WEEKS Figure 7-7 Lubricate Floor Auger Bearings Lubricate the following grease fittings at least once every three weeks with a high quality lithium grease. Figure 7-8 Lubricate Gate Bearings Note: Do not lubricate the horizontal rack & pinion style gates. Lubrication will cause a buildup of feed dust and road grime. 7.5 EVERY MONTH Lubricate the following grease fittings at least once every month with a high quality lithium grease. 37

38 Inspections And Maintenance Figure 7-9 Lubricate Manual Top Door Bearings Figure 7-10 Lubricate Air Operated Top Door Bearings Lubricate all chains with a non-petroleum based chain lubricant. Petroleum based lubricants will cause a buildup of feed dust and road grime on the chains. 38

39 Inspections And Maintenance 7.6 EVERY SIX MONTHS Figure 7-11 Lubricate All Chains Disengage the turn device chain and rotate the gearbox shaft 1/3 revolution for more even wear of the internal cast gear. 7.7 AS NECESSARY Lubricate the king pin wear plate as necessary with a quality lithium grease. 7.8 HYDRAULIC SYSTEM Use an oil viscosity based on the expected air temperature range during the period between oil changes. Use of a good quality hydraulic oil and oil filter is critical to the performance and life of the hydraulic system. Check the hydraulic pump and filter information for service and maintenance intervals, recommended oil viscosity and oil additives. Oil should be changed 2-3 times per year for units operating in double shifts. Do not adjust pump pressure or relief valve settings. If the hydraulic system is not functioning properly, contact a qualified hydraulics technician. 7.9 AUGERS Adjusting pump pressure and/or relief valve settings can cause the hydraulic system to malfunction. Never adjust the pump pressure and/or relief valve settings. Contact a qualified hydraulics technician. Check augers periodically for metal-to-metal contact. If there is contact, align auger replace any worn nylon wear strips on auger flighting If the auger is damaged, it should be straightened or replaced. 39

40 Inspections And Maintenance 7.10 OVERCENTER VALVE ADJUSTMENT Pressurized fluids can penetrate the skin. Relieve pressure in the hydraulic system before opening a hose, line or fitting. Do not search for hydraulic leaks without body and face protection. A tiny, almost invisible leak can penetrate the skin, thereby requiring immediate medical attention. Use wood or cardboard to detect hydraulic leaks, never your hands. All truck mount and trailer bulk feed units equipped with standard auger systems come with an adjustable overcenter valve (part # ). The overcenter valve is provided to control the flow of feed from the floor auger to the vertical and discharge auger automatically. This valve also serves to minimize "fines" in palletized feeds since the transition from the floor auger to the vertical auger is regulated. By keeping all of the augers full but not packed, the unit unloads at the best rate with a minimum of material breakage. To secure the adjustment it will be necessary to install a hydraulic pressure gauge with a capacity to measure from 0 to 3,000 PSI in the inlet line at the 3-bank hydraulic control valve (part # ). The gauge may be installed in either a "T" ahead of the valve or by removing the onequarter inch Allen pipe plug in the inlet section of the 3-bank valve. For a more precise adjustment, we recommend installation of a Warren Hydraulic System Analyzer (part # ). Although the overcenter valve comes preset, it may require in-field adjustment for proper operation. To adjust using the 0 to 3,000 PSI Pressure Gauge, proceed as follows: 1. Raise discharge auger to the height of the highest bin normally delivered to, using the material that is most difficult to unload. 2. Operate engine at unloading speed. Engage valve controlling vertical and discharge augers. Engage the floor auger. 3. Open feed compartment gate. Always open and unload one compartment at a time. 4. Using a 3/16" Allen screw wrench, adjust the overcenter valve so the pressure gauge reads approximately 2,000 PSI. By turning the screw in (clockwise), you will increase the pressure reading. By turning the screw out (counter-clockwise), you will decrease the pressure reading. 5. If using the Warren Hydraulic System Analyzer, use the instruction sheet provided with it. 6. If there is no variation in pressure, or if there are erratic fluctuations in pressure, the overcenter valve probably need to be replaced. NOTE: By keeping the auger speed and material flow in balance we have minimized hydraulic temperatures and have increased the life of augers, auger bearings, nylon on augers, and hydraulic system components TIRES Before each tow, be sure the tire pressure is at the value indicated on the Certification / VIN label. Tire pressure must be checked while the tires are cold. Do not check the tire pressure immediately after towing the trailer. Allow at least three hours for a tire to cool, if the trailer has been towed for as much as one mile. Replace tires that have the wear bands showing before towing trailer. A bubble, cut or bulge in a side wall can result in a tire blowout. Inspect both side walls of each tire for any bubble, cut or bulge; and replace a damaged tire before towing the trailer. 40

41 Inspections And Maintenance 7.12 WHEELS Collision hazard. Worn, damaged or under-inflated tires can cause loss of control, injury and damage. Check tires before towing trailer. Whenever tires/wheels are removed, check the condition of the wheel, wheel lugs, hubs and studs. Replace any damaged, corroded or worn parts. Use the correct wheel lugs and wedges (if equipped) for your trailer. Wheel failure hazard. Never weld on wheel or hub for any reason Never install aluminum wheels on an axle designed for steel wheels. The stud length is greater for aluminum wheels than steel wheels. Always use the correct lugs and wedges (if equipped) DISK WHEELS Lug nuts are prone to loosen right after a wheel is mounted to a hub. When driving on a remounted wheel, check to see if the lug nuts are tight after the first miles of driving and weekly thereafter. Lug nuts are prone to loosen after being first assembled. Death or serious injury can result. Check lug nuts for tightness on a new trailer, and after re-mounting a wheel after the first miles and weekly thereafter. 1. Place two drops of oil to a point between the nut and flange and two drops to the two or three threads at the end of each wheel stud. 2. Tighten to 50 lb/ft of torque in the sequence shown in figure Tighten to lb/ft of torque in the sequence shown in figure

42 Inspections And Maintenance WHEEL ENDS Figure 7-12 Wheel Lug Torque Sequence Your trailer is equipped with oil bath wheel ends. See figure Figure 7-13 Wheel End Lubrication Refer to your axle manufacturers manual for the recommended lubricant. Remove the rubber plug (1). Add lubricant to the bottom full line on hub cap. Install rubber plug. 42