CONTAINS IMPORTANT INFORMATION PLEASE READ BEFORE LEAVING YOUR DEALER

Transcription

1 DO NOT FORGET TO RETURN WARRANTY CARD ON PAGE 7 Owners Handbook DO NOT FORGET T RETURN WARRANTY CARD ON PAGE 7 CONTAINS IMPORTANT INFORMATION PLEASE READ BEFORE LEAVING YOUR DEALER MERSEA COMMERCIAL & LEISURE TRAILERS LTD 6 COMMERCE WAY, WHITEHALL INDUSTRIAL ESTATE COLCHESTER, ESSEX. CO2 8HH Tel Fax sales@merseatrailers.com Product Information (place label or write in) SERIAL NO: TRAILER MODEL: ISSUE 6 12/08/09

2 ISSUE 1. 16/01/06 0

3 CONTENTS Pre-Delivery Checklist page 2 Basic Legal Requirements page 3 Regular Checks & Maintenance page 4 Drum Brake Operating & Maintenance Instructions page 5-6 Rapide 3 Year Warranty page 7-8 Service Centre Network page 9 Service Check List page 10 Warranty Service Inspection page 11 Repair/Replacements page 12 Disc Brake Operating, Maintenance & Repair Instructions page 13 How the System Works page14 Assembly & Setting Instructions page 15 Regular & Periodical Maintenance Instructions page 16 Fault Findings page 17 List of Spare Parts page Detailed Instructions For Service Centres page 29 ISSUE 6 12/08/09 1

4 Dear Customer, Congratulations!! You have purchased one of the finest Boat Trailers available. This quality product will give you years of faithful service if you follow a few simple rules, set out below. Pre-Delivery Supplier Check Box 1. Your supplier should have fitted the boat on the trailer to give a positive nose weight of approximately 7% of the trailers kerb weight. Check that this weight does not exceed the lowest S-Value of your towing vehicle, tow-bar and coupling. 2. The winch post height is correct when the strap is pulling the bow of the boat to the snubber horizontally or slightly downwards. 3. All side steadies or hull rollers should have been adjusted to hold the hull level on the trailer. Plastic covered side steadies should only touch the hull with the weight taken on keel rollers. The bilge rollers must all make contact with the hull. 4. Tyre pressures must be as recommended on the rating plate fixed in the near side front of the trailer frame. If you are unsure contact your local Trailer Centre. 5. Lighting if supplied must be plugged into your towing vehicle to ensure that the wiring is compatible and that all lights are in working order. 6. On all types of braked trailers the AUTO-REVERSE brakes must be checked and adjusted if necessary, in accordance with the manufacturers instructions via the Dealer or competent Trailer Centre. Optional 7. It is always a good idea to have tie down straps fitted these are an inexpensive extra. All boxes checked? Now read page 3 of this document ISSUE 6 12/08/09 2

5 Legal REMEMBER THAT A ROAD TRAILER IS A VEHICLE SUBJECT TO THE LAW WHO HAVE POWERS TO INSPECT IT AT ANY TIME ON THE ROAD AND MAY PROSECUTE A USER WHERE THE TRAILER IS NOT IN CONFORMITY WITH THE LAW OR WHERE IT IS NOT IN A ROADWORTHY CONDITION. IT IS THE OWNERS RESPONSIBILITY TO CHECK AND MAINTAIN THE TRAILER TO ENSURE IT IS ROADWORTHY. FAILURE TO DO SO CAN RESULT IN EXPENSIVE REPAIRS OR PROSECUTION. Safety With both braked and un-braked trailers the use of secondary couplings between the car towing bracket and the trailer frame is a legal requirement. In the case of braked trailers the breakaway cable will activate the trailer handbrake in the event of the trailer becoming uncoupled. If the trailer tends to snake at speed the problem could well be insufficient nose weight, low tyre pressures, incorrect weight distribution of the boat and contents, or a combination of all. Do not proceed to tow until the problem has been recognised and rectified. Speed The maximum towing limit in the UK is 60 m.p.h. on Dual Carriageways and Motorways but remains at 50 m.p.h. on Single Carriageways (Provided that no lower speed limit is in force). Trailer Weight Un-braked Trailers Maximum gross weight allowed is 750 Kg. However the gross trailer weight should NOT exceed 50% of the Kerb weight of the Towing Vehicle. Always check the rating plate on the trailer and check your vehicle handbook to ensure you do not exceed its towing capacity. Braked Trailers may be towed up to the maximum weight recommended by the manufacturer of the Towing Vehicle. Please note that the weights on the type label are adhered to and not the actual weight! YOU AND YOUR OUTFIT ARE BOTH NOW READY TO TOW AWAY SAFELY HAPPY TRAILING! ISSUE 6 12/08/09 3

6 Regular Checks & Maintenance 1) Check tyre pressures including spare and inflate if necessary to pressure shown on rating plate or side-wall of tyre. Examine tyres for damage i.e. cuts, porosity and tread wear, replace with equivalent size and type of tyre where necessary. This should be checked on a monthly basis. 2) Apply grease to tow ball and cup of coupling head after cleaning each item. Grease the moving parts of an un-braked coupling. Apply grease via the Grease nipples on a braked. This should be undertaken on a monthly basis. 3) Your trailer is fitted with an Alko Kober axle(s), which feature Waterproof bearings. If you re trailer is UN-BRAKED then you have the benefit of a 5-year warranty on the waterproof bearings. To validate the warranty the bearings MUST be serviced once a year using Renolit CL X2 grease. It is recommended that you carry out regular checks on the bearings i.e. check for excessive play (loose). If you have a BRAKED trailer the Waterproof bearings have a 1-year warranty. It is recommended that you carry out regular checks on the bearings i.e. check for excessive play (loose). 4) Have the brakes, including the hand brake, checked, adjusted and maintained via a competent Trailer Centre. This should be checked on a monthly basis. 5) Check and tighten (if necessary) all wheel nuts and other fixing nuts and bolts. All fixing bolts are fitted with Nyloc nuts to prevent loosening from vibration. Please use a calibrated torque wrench & torque to following load (s): M Nm 3/8 UNF Wheel Studs/Nuts Nm M Nm ½ UNF Wheel Studs/Nuts Nm M Nm 5/8 UNF Wheel Studs/Nuts Nm M8 Wheel Studs/Nuts 40 Nm Alko one shot hub nut 290 Nm M10 Wheel Studs/Nuts 60 Nm M12 Wheel Studs/Nuts Nm M16 Wheel Studs/Nuts 210 Nm 6) Check that all lights are in working order. Check that the cable and plug are in working order and that the cable is not damaged or frayed. Replace with new if necessary. Important Note It is a condition of the warranty (page 6, ref. 6) to have your trailer inspected and serviced, at least once a year by a recognised Rapide Service Centre or a competent trailer centre for the first three years. Following the warranty period it is recommended to have the trailer professionally serviced at the end of each season. HIGH MILEAGE OR REGULAR SUBMERSION OF THE TRAILER REQUIRES AN INCREASE IN THE FREQUENCY OF CHECK AND MAINTENANCE! ISSUE 6 12/08/09 4

7 Drum Brake Operating & Maintenance Instructions ISSUE 6 12/08/09 5

8 1. Features Rapide Trailers features Alko Kober axles. The axles come with waterproof bearings and braked trailers feature stainless steel brake cables as standard. There is also al Deluxe Brake Flushing System fitted as standard. Snipe Trailers are fitted with Avonride axles which feature 2. Things to avoid!! After towing it is strongly advisable not to launch your boat until the drums of the axle have cooled down. Immersion with warm drums will allow water ingress via a vacuum effect and severely damage the bearings and solidify the grease. The hand or park brake should not be used if the axle(s) have ever been submerged in water as salt residue, sand and grit can combine and seize on the brake shoes. When the trailer is being stored wheel chocks should be used in lieu of the park brake. See our website for details on wheel chocks. 3. Deluxe Brake Flushing System If you have the brake drum flushing system fitted to your trailer (see image 1.0) it allows you to flush the brake mechanism out with fresh water via the skin fitting located on the rear mudguard step. You must flush out each drum every time the axle(s) have been submerged and as a rule of thumb you should flush each drum for at least five minutes. If you have used the flushing system we strongly advise you tow the trailer to dissipate any excess water that may remain in the brake drum. This is a retro fit product. 4. Stainless steel brake cables The use of stainless steel cable for the brake linkages dramatically reduces the chance of them seizing. However they should be checked on a regular basis to ensure optimum performance. 5. Waterproof Bearings Your trailer is fitted with an Alko Kober axle(s) which feature Waterproof bearings. If you re trailer is UN-BRAKED then you have the benefit of a 5-year warranty on the waterproof bearings. To validate the warranty the bearings MUST be serviced once a year using Renolit CL X2 grease. It is recommended that you carry out regular checks on the bearings i.e. check for excessive play (loose). If you have a BRAKED trailer the Waterproof bearings have a 1-year warranty. It is recommended that you carry out quarterly checks on the bearings i.e. check for excessive play (loose). Please note the bearings are sealed and cannot be inspected or maintained. If the bearing is showing signs of excessive play or is starting to grumble then the bearing must be replaced and should be undertaken by a competent trailer centre. 6. Brake adjustment Drum braked axles should have the brake performance checked after the first 100 miles. There is no set timescale for further checks and any subsequent adjustment but it is advisable to undertake regular checks to ensure safe and optimum performance of the braking system. If the braking system requires adjustment (the trailer banging into the towing vehicle is a clear indication) then we advise you take your trailer to the nearest trailer centre. If you are proficient in adjusting the brakes or are undertaking a visual inspection of the brake mechanism then please be aware the hub/drum nut is a one shot nut and should not be re-used under any circumstances. It requires a 32mm socket and should be tightened to 290Nm. Image 1.0 Deluxe brake flushing point ISSUE 6 12/08/09 6

9 3-YEAR WARRANTY FOR DRUM & DISC BRAKE TRAILERS. TERMS & CONDITIONS. 1 This warranty is given in addition to the standard 12 month guarantee, and does not affect your statutory rights. 2 Mersea Commercial & Trailers Ltd provides a 3-year warranty covering manufacturing defects for all Rapide Power Boat Trailers registered after 1 st January The warranty period begins from the Date of Purchase. Please cut out the registration form at the bottom of this page and post it to Mersea Commercial & Trailers Ltd. 4 The 3-year warranty includes manufacturing defects of the Trailer coupling, drum brake axle(s), and metal work construction. 5 The 3-year warranty excludes Disc Brakes, fair wear and tear, galvanising and defects deemed to have arisen from misuse or overloading of the trailer. (Full details of exclusions next page) 6 To validate and maintain the warranty over the 3 year period, the trailer must be inspected and serviced, at least once a year by a recognised Rapide Service Centre who must stamp the Service Record section of your Owner Handbook & Service Record. 7 The warranty will cease to be valid: - If spare parts and or accessories, not approved by Mersea Commercial & Trailers Ltd have been fitted to the Trailer. - If the Trailer has been modified in any way without written approval by Mersea Commercial & Trailers Ltd. - If the Trailer has not been serviced annually in accordance with our instructions. Note it is essential that each service be recorded in the Service Record. 8 The warranty covers free of charge repair or replacement of the defective items to bring them into conformity. We may, however, at our discretion offer alternative remedies. Any further costs will not be the responsibility of Mersea Commercial & Trailers Ltd. 9 Any outstanding portion of the 3 year warranty can be transferred to a new owner subject to there being in existence a valid warranty (see clause 7) and that details of the change are confirmed in writing to Mersea Commercial & Trailers Ltd within 7 days of the transfer taking place. 10 The warranty does not cover consequential loss or damage to the property or third party claims and is in addition to your statutory rights under current consumer protection legislation. 11 The warranty ceases in all respects if the trailer is used for an incorrect purpose or loaded beyond the gross weight specified on the Rating Label. Cut along this line NAME: ADDRESS: WARRANTY REGISTRATION DEALER: POSTCODE: Product Information (place label or write in) SERIAL NO: SERIAL NO: TRAILER MODEL: TRAILER MODEL: DATE OF PURCHASE: TODAY S DATE: MERSEA COMMERCIAL & LEISURE TRAILERS LTD SERIAL NO ISSUE 6 12/08/09 7

10 The following list details the items, which are included and excluded from the three-year trailer warranty. The exclusion list gives main parts; any associated components will also be excluded. INCLUDED WARRANTY ITEMS (in accordance with the component manufacturers warranty) Bradley Coupling Bradley jockey wheel Trailer Frame & Brackets Welded construction EXCLUDED WARRANTY ITEMS Trailer Frame Galvanised, Zinc Plated and Painted Finishes Wheels and Tyres Knott Jockey wheels Lighting Boards and Reflectors Bearings (Un-braked Al-Ko axles have 5 year warranty, Braked Al-Ko axles have 12 months) Disc Brakes axle(s) (Standard 12 month guarantee) Disc Brake Coupling (Standard 12 month guarantee) Drum Brake shoes, adjusters and springs All Brake Cables Winch and Strap / Rope Fixings Nuts, Bolts, Washers, Split Pins etc. Failure through excessive Wear and Tear Manufacturing defects arising from the incorrect use or overloading of the trailer. ISSUE 6 12/08/09 8

11 SERVICE CENTRE NETWORK WHAT TO EXPECT! Mersea Commercial & Trailers Ltd has established a nationwide Rapide Service Centre details of which are enclosed in this handbook. Each Service Centre has been carefully selected to offer the high level of service expected by a Rapide Trailer customer. These include: Handling all warranty work in respect of Rapide Trailers. Have adequate space to service trailers up to 9 metres in length. Have suitable secure storage facilities. Employ trained technicians. Have suitable servicing equipment. Be able to provide a written quotation prior to carrying out the work. Stock a range of suitable spares. Be able to provide or obtain answers to questions on towing law. Will ensure all service details are recorded in your Service Record. If for whatever reason your Rapide Service Centre fails to live up to your expectations we want to hear about it. The following section includes important information required to maintain your warranty. Please ensure your Rapide Service Centre provides the following information: Written quotation Service checklist either their own list or the Rapide List on page 10. Stamps and signs the warranty inspection boxes page 11. Provides details of the parts fitted -either their own list or the Rapide List on page 12. ISSUE 6 12/08/09 9

12 SERVICE CHECK LIST NAME: DATE: SERIAL NUMBER: DRUM BRAKES: 1.Inspect brake linings, expander, springs and adjuster 2.Inspect brake cables, operation, condition & security 3.Check wheel bearings and oil seal 4.Refit brake drum and adjust brakes DISC BRAKES: 1.Check brake pads 2.Check condition of disc 3.Check cantilever operation 4.Lubricate calliper 5.Adjust brakes where necessary 6.Check Bearing Saver and refill where applicable COUPLING: 1.Check head for wear & lubricate 2.Check bellows 3.Check breakaway cable 4.Test damper 5.Check for play in drawtube 6.Grease coupling at grease points 7.Check handbrake operation & lubricate 8.Check coupling mounting bolts WHEELS & TYRES: 1.Check tyre condition and compatibility 2.Check tyre pressure 3.Inspect rims 4.Check wheel nut torque SUSPENSION: 1.Inspect axle mounting BODY & FITTINGS: 1.Check condition & operation of jockey wheel 2.Check condition & operation of winch & strap 3.Check bodywork for damage or deterioration 4.Inspect fixing bolts on bodywork ELECTRICS: 1.Test lamps 2.Check lenses and reflectors 3.Check cable(s) and plug(s) 4.Check Break Auto Reverse Device. SERVICED BY: COMPANY STAMP ISSUE 6 12/08/09 10

13 WARRANTY SERVICE INSPECTION Service Agent Stamp DATE: Service Agent Stamp DATE: Service Agent Stamp DATE: ISSUE 6 12/08/09 11

14 REPAIRS/REPLACEMENTS DATE DESCRIPTION OF WORK / PARTS ISSUE 6 12/08/09 12

15 Disc Brake Operating, Maintenance & Repair Instructions ISSUE 6 12/08/09 13

16 Disc Brakes - Operating & Maintenance Instructions. Mechanical overrun brake system for Standard & GS Style Disc Brakes 1. Features The WAP disc brake system has been tested in accordance with EC Directive 71/320 (in its latest adaptation, Directive 98/12) and has been given type approval for driving speeds of up to 80 mph /130 km/h. However please check and adhere to your countries speed limits! The WAP disc brake system is the only purely mechanically operated disc brake with a mechanical overrun system. This makes it as easy to operate as the long-familiar drum brakes. 2. Components of the complete brake system The complete brake system consists of the overrun system (A), available either as a flange or tube bracket, the transmission unit (B) and the disc brakes (C). These components form a coordinated unit. Note: Numbers & letters in parenthesis refer to the image depicted on page How the Disc Brake system works 3.1 Forward motion When the towing vehicle brakes, the trailer continues to move toward the vehicle. This pushes the thrust rod (1) on the overrun system into the housing (2). The back end of the pull rod, which is held in the housing by two bushes, then pushes against the reversing lever (3), which is also contained in the housing. The resulting displacement of the reversing lever causes the pressure to be transmitted via the transmission unit (generally a linkage) connected to the lower end of the reversing lever as tractive power to the compensator (4) on the disc brakes. From there, the overrun force is transmitted via the disc brake actuating cable (5) to the opposed brake application levers (6). These application levers act on the energy store (7), which applies the inner brake pad (8) to the brake disc (9). The outer brake pad (10) is applied to the brake disc via the floating calliper at the same time. 3.2 Reverse motion Pushing the pull rods into the overrun unit when moving in reverse causes forces to be transmitted as described under 3.1 above. The opposing rotation, caused by the direction of the wheel motion, pushes away the brake pads that were applied to the brake disc. The swivel arm (11) that forms the connection between the slider and the inner brake pad, tips to the side over its eccentric supporting point. This cancels the brake application stroke and thus also the braking action itself. When the vehicle moves forward again, the brake pads are returned to their starting position by the return spring (12). 3.3 Parking brake / breakaway brake The relatively large application stroke of the parking brake (13) compared to the service brake means that the inner brake pad is kept against the brake disk even when reversing. To this end, the handbrake lever (13) has to be pulled to its fullest extent. This applies the braking action as described under 3.1 above. Operating the handbrake lever also tensions the energy store (14) located in the brake linkage to prevent the braking system from unintentionally being released on a gradient. When the handbrake is released the energy store re-adjusts the braking power. Before moving off, the loop of the breakaway cable (15) connected to the handbrake lever must be connected to an integral and permanent part of the towing vehicle. If the trailer unit becomes separated from the towing vehicle, the parking brake will be applied via the breakaway cable. ISSUE 5 01/04/08 14

17 4. Assembly and setting instructions Fitting the brake unit to the trailer (Aftermarket fit only) a. Fit the overrun device and axle(s) to the chassis. b. Screw the brake cable assemblies to the abutment on the axles (welded to the axle tube). c. Fit the compensator in the transmission linkage to the fork ends of the brake cables. d. Connect the transmission linkage to the reversing lever on the overrun system using the fork ends. e. Draw the handbrake up to the second tooth. f. Tighten the turnbuckle on the transmission linkage until there is a maximum 2 mm play in the braking system. The energy store (14) must not be pre-tensioned under any circumstances. Secure the turnbuckle against coming loose using hexagon nuts. NOTE: Ensure that the compensator is at right angles to the transmission linkage, particularly in the case of tandem transmissions between the first and second axles. Correct by setting the turnbuckles on the long and short linkages if necessary. 4.1 Setting / adjusting the disc brakes When setting or adjusting the disc brakes, it is important that the pull rod on the overrun unit is fully drawn out and that the handbrake lever is in the release position. Use wheel chocks to prevent the vehicle from rolling away. Loosen the transmission unit by releasing the turnbuckle. Turn the adjusting nut (16) clockwise, with the wheel in constant forward motion, until the wheel stops tight. This will centre both brake pads on the brake disc. Then loosen the adjusting nut again until the wheel just runs free again. Repeat this process on all wheels. Only once all disc brakes on the trailer have been set or adjusted in this way is the transmission linkage tensioned again until there is a maximum 2 mm play. WARNING! Setting or adjusting the disc brakes and/or the transmission linkage and/or the energy store too closely will restrict the free movement of the brakes when moving backwards. It can result in increased wear & tear could lead to damage of the braking system 4.2 Brake testing For a final check of the brake unit settings, a few stopping motions should be carried out with a loaded trailer. With factory-new trailers and after changing the brake pads, short runs should be driven with the handbrake lightly applied. This will reseat the brake linings and adapt them to the brake disc surfaces. The brake unit is set correctly when the pull rods on the overrun unit are pushed in about half of the maximum overrun distance under heavy braking. ISSUE 5 01/04/08 15

18 REGULAR MAINTENANCE INSTRUCTIONS! a. Check ALL moving parts on the calliper to ensure good levels of lubrication are apparent before and after use. If re-application of grease or oil is required, please refer to figures 2-6. b. The brake calliper and disc should be thoroughly rinsed with fresh water after every immersion in salt water. Check ALL moving parts on the calliper and if re-application of grease or oil is required, please refer to figures 2-6. c. The disc brake system must NOT be cleaned using high-pressure cleaning devices. If highpressure devices should happen to be used, all moving parts on the calliper MUST be re-greased or re-oiled. See figures 2-6. d. If you have any queries regarding servicing or maintenance then you should consult your Owners Handbook and either contact us or visit your nearest Service Centre. PERIODICAL MAINTENANCE INSTRUCTIONS! There is no exact timescale for checking and servicing the various trailer components, as the amount and degree of use will vary from user to user. Below is a guide to how to ensure the prolonged and reliable use of the trailer. 5.1 After about 30 miles /50 km a. Check and tighten (if necessary) all wheel nuts. The torque setting for the wheel nut is 95Nm. b. Check the setting of the brake unit. Overrun distance? Do the disc brakes move freely when reversing? WARNING! Never adjust the brake unit via the brake linkages only. In every instance, adjust the disc brakes first and then re-tension the transmission point as described. 5.2 After about 300 miles / 500 km a. Check the wheel bearing for lateral play and adjust if necessary. b. Check the brake unit settings and adjust if necessary. 5.3 Every 2000 miles / 3000 km a. Lubricate the pull rod mountings on the overrun unit and the oscillating lever mountings on the torsion-bar axles using the grease nipples provided. b. Check all moving parts to ensure free movement and grease or oil as necessary as described in section 4.1 c. Check wheel bearing for lateral play and brake settings and adjust as necessary. d. Check the brake linings for wear. The brake pads can be clearly seen from outside. The pads should be changed when the pad is not less than 3mm thick (new pads are 13mm thick). e. Check the brake discs for wear. The discs should be changed when the disc is a minimum of 8mm thick (new discs are 10mm thick). 5.4 Setting wheel bearing play a. Tighten the castellated nut until the wheel begins to drag. Unscrew the nut until the split pin can be inserted. Ensure the wheel turns freely. WARNING: If the bearings are adjusted too tightly then this will lead to bearing failure! ISSUE 5 01/04/08 16

19 Alterations to any part of the trailer is not permissible without the permission of Mersea Commercial & Trailers Ltd and only in accordance with our i nfault Finding: s t r u c t i o n s. Problem Cause Rectification Jerky braking and driving Slack in the braking system, enabling the pull rod to be pushed too far in. Insufficient braking action Uneven braking action Difficult or impossible to push trailer backward Pull rod can be moved in and out by hand with no resistance; shock absorber faulty. Slack in the braking system. Transmission system too tight; linkage stuck and/or jammed. Disc brake actuating cables stuck or broken. Pull rod in the overrun system too tight. Brake pads worn, oily or greasy. Wheels brake unevenly. Brake actuating cable too tight or damaged. Disc brake pad oily or greasy. Transmission linkage, energy store and/or disc brake set too tight. Brake actuating cable jammed or broken, and does not return to the release position. Slider jammed in brake calliper, and does not return to the release position. Adjust the entire braking system in accordance with the assembly and setting instructions. Replace shock absorber in accordance with manufacturer s instructions. Adjust the entire braking system. Free up linkage, grease or oil brake actuating cables or replace broken cables. Lubricate pull rod as per maintenance instructions. Replace brake pads; if the pads are oily or greasy, check whether the wheel bearing seal is still sound. Adjust the disc brakes and the compensator in the transmission unit in accordance with the assembly and setting instructions. Grease / oil cable or replace it. Change pads in both disc brakes. Release turnbuckle on the transmission linkage and/or adjust the disc brakes in accordance with the assembly and setting instructions. Grease / oil cable, or replace it. Free the slider and grease or oil as appropriate. ISSUE 5 01/04/08 17

20 List of spare parts for Standard Disc Brake type WS 245 (Standard 1500kg axle): Kit Part No Qty. Description Brake Pad Kit Brake Disc Brake Mechanism Bowden Cable Compact bearing ISSUE 5 01/04/08 18

21 Detailed Instructions for Service Centres: 1. Brake-Pad change: You are most likely asked to change the Brake pads during a routine service or identify yourself the need to change them. The recommended minimum Brake-pad-lining thickness is 5 mm. The brake-pad kit (P/N: ISSUE 5 01/04/08 19

22 80152 (1500 kg axle) or P/N: (1800 kg axle)) supplied by Mersea Commercial & Trailers Ltd. contains four Brake-pads, four Brake-pad Pins, two compression springs, two tension springs and four safety clips. This is sufficient for one axle. Always replace all break-pads at the same time. 1.a Raise the trailer until all wheels are off the ground. Ensure the trailer is secure to work on. 1.b Take all wheels off and disconnect brakes at the compensator(s). You may leave the Bowden cables connected to the callipers. See Fig. 1 for item details. 1.c Release the Breakwear Adjustment nut (16) if necessary until the Nut is flush with the threaded bar. See Fig. 1, Item detail C. 1.d Take off the Safety Clips 1 and remove the Brake-pad Pins 2. The brake-pads 3 can now be removed. Note: The brake-pads have a recess and sit on a tab. You may need to slide the saddle to one side in order to remove the pads. See Fig. 2 for number details. 1.e Check the saddle 4 and levers 5 for movement. Make sure all moving parts are clean and re-grease if necessary. Use WD40 to free off linkages Fig.4, cylinders Fig.5 and floating saddle Fig.6. Clean joints and surfaces if necessary. Use Molybdenum grease to re-lubricate. Caution: Ensure no lubricant is deposited on the Disc. Use grease remover/cleaner to remove any lubricant from discs. See Fig. 3 for number details. 1.f Re-assemble the unit now in reverse order and check the break-pads are sitting correctly on the tab, the springs are mounted the right way, everything is moving where it should and all is secured as original. Repeat steps 1. c. to 1. f. for the remaining brake assemblies. 1.g Fasten the wheels onto the hubs and turn in a forward motion while tightening the Breakwear Adjustment nut (16) until you are unable to turn the wheel. Caution: Do NOT turn the wheel in a rearward motion! 1.h Slowly undo the Breakwear Adjustment nut (16) while trying to turn the wheel in a FORWARD motion until it just rotates freely. Caution: Do NOT turn the wheel in a rearward motion! 1.i Connect the brake linkages and adjust the compensator (Turnbuckle) at the coupling so that the wheels will not turn in a forward motion when the handbrake is pulled to the third or fourth notch. Make sure the wheels turn freely or slightly drag when the handbrake is off. Secure all locknuts. 1.j Check that all wheels brake evenly by notching the handbrake lever up one at a time and checking the tightness of each wheel in a forward motion accordingly. Adjust at the Breakwear Adjustment nut (16) accordingly. Caution: Do NOT turn the wheels in a rearward motion. 1.k Place Trailer on ground and torque all fasteners to the recommended setting. Check brakes are working properly. ISSUE 5 01/04/08 20

23 Fig. 2 Lubrication Information: Fig. 3 Lubrication Information: ISSUE 5 01/04/08 21

24 Fig. 4 Lubrication Information: Fig. 5 Lubrication Information: ISSUE 5 01/04/08 22

25 Fig. 6 Lubrication Information: NOTE: Do NOT use excessive force to free items. Let the parts soak in WD40 should they have seized. Never apply a force that could warp the disc. Check the Disc has the minimum thickness. The thickness is stamped onto the Disc perimeter. Only use a soft material mallet, i.e. copper or wood, should you need to apply a tapping force. REMEMBER: Should you have any queries please do not hesitate to contact us. You must contact the Technical Department should you have any doubt about the maintenance, rework, assembly or the workings of the product. Do NOT carry out any work if you don t understand it fully. SPARES: Due to the design of the system, use ONLY genuine replacement parts. Do NOT try to adapt non-genuine components and try to fit them. Functionality will be compromised if you do. ISSUE 5 01/04/08 23

26 2. Brake Calliper change: In the unlikely event where the callipers have ceased to function properly, after cleaning and re-lubrication attempts, you may need to change the Brake calliper(s). Should the Brake calliper(s) have been damaged to the extend, where their functionality is compromised you will need to change the Brake calliper(s). 2.a Follow Instructions 1. a to 1. d. to remove the brake pads. 2.b Should you be unable to remove the brake pads, release the Breakwear Adjustment nut and proceed to point 2. c. 2.c Assuming that you disconnected the brakes at the compensator, you need to remove the Bowden cable from the calliper now. Flip the safety clip of the outer Brake Lever over the end of the Bowden cable. Close the Brake lever sufficiently to pull the end of the Bowden cable out of the Outer Brake lever recess and to one side. Pull the end out of the Inner Brake lever block. Check the Bowden cable can move freely and was not the cause of the system not functioning. Replace all Bowden cables if necessary. See Fig. 1 Item Detail C for parts identification. 2.d Remove the screws (see Item 13 in Fig. 7) and lift the calliper straight off the disc. Depending on the arrangements, either dispose of the calliper, including the brake pads or return the entire assembly to us. Repeat points 2. a to 2. d above for the other side of the axle(s). 2.e Assemble the calliper if necessary so you have the floating saddle (Item 2, Fig. 7), the saddle (Item 3, Fig. 7) and the Brake pad kit assembled as illustrated in Fig. 7. You may need to turn the Breakwear Adjustment nut out until flush with the threaded bar. 2.f Slide the calliper assembly onto the disc. Note that the callipers are handed. Ensure that the disc is located BETWEEN the brake pads. 2.g Tighten the screws (see Item 13 in Fig. 7) hand tight and check that the disc is approximately central between the brake pads. Make sure the brake pads are pushed to the extreme outsides of the saddle. You may need to undo the screws and insert washers between the saddle and the attachment flange. Repeat this step until correct position is achieved. Torque the screws to Nm. 2.h Once you have completed the procedure for all callipers, re-connect the Bowden cable and follow steps 1. g. to 1. k. Please observe the NOTE, REMEMBER and SPARES advice at the end of the brake pad change procedure. ISSUE 5 01/04/08 24

27 Fig. 7: ISSUE 5 01/04/08 25

28 3. Disc change: Should the discs be excessively warped, corroded or below the minimum recommended thickness, you will need to change them. Although every effort is made that this is not required, undue side forces on the disc will cause them to warp. These may have been induced by forcing the brake pads apart using a screwdriver or similar tool or through the excessive use of a hammer/mallet. Note also that hammer marks in the form of indentations on the side face(s) call for a disc change as brake characteristics are negatively influenced. In the marine environment some corrosion will occur naturally. In most cases this is only superficial and the discs will clean up after a few miles. Should the brake pads remain bound to the disc, you may need to change the brake pads and discs. This is usually caused by the fact that the trailer was parked with the brakes ON. Advise the customer to NEVER park the trailer for prolonged periods (i.e. 24hrs +) with the brakes ON. The minimum disc thickness is marked on the perimeter. Take the wheel off and look through the callipers onto the disc to see the stamp marking. You may need to scrap some corrosion off and turn the disc to see the details. Measure the thickness and in the event that the disc is reduced below that figure, the disc(s) need to be changed. It is recommended that you change the discs and brake pads at the same time and in pairs. 3.a Follow Instructions 2. a. to 2. d. to remove the calliper(s). Do not dispose off the callipers if they are in working order. 3.b Soak/spray the inside disc-hub interface in WD40 or other corrosion solvent. Use a disc extractor tool to pull the disc(s) off the hub. Should you not have access to such a tool, you need to walk the disc off the hub by tapping the inside of the disc while turning it through 90 degrees in between gentle mallet blows. 3.c Once the disc is off, you need to clean the disc-hub interface using a wire-brush or similar utensil. Do NOT use an angle grinder or similar tool to clean the surfaces. 3.d Check the new disc(s) can be put onto the hub without the use of a hammer/mallet. It is advisable to use the wheel bolts to line up the holes of the hub and disc. Hand-tighten these and proceed to clean the disc(s) with alcohol-based liquid on the brake pad contact surfaces as they may have a protective wax layer. Observe the Health and Safety guidelines of the product when working with cleaning agents. 3.e You can now assemble and set up the brake system by following steps 2. e. to 2. h. Note point 3. f. below before placing the trailer back onto the ground. 3.f Check the wheel bearing play while the trailer is still off the ground and readjust if necessary. Once everything is assembled, fasteners torqued to their specified setting, lubricated if and where necessary and checked for completeness/correctness, can you check the brakes are working properly. Please observe the NOTE, REMEMBER and SPARES advice at the end of the brake pad change procedure. ISSUE 5 01/04/08 26

29 4. Coupling Push rod change: Changing the Push rod of a WAP coupling. The coupling illustrated in Fig. 8 is for reference. Method and sequence are the same for Delta and Box-section couplings. Removing the pushrod: 4.1. Disconnect the break system at the Turnbuckle (1) Pull Handbrake lever (2) fully back. Attention: The Handbrake lever (2) will be pushed back by the Gas-strut (4) Undo Bolt and Safety Clip (3) and swing Gas-strut (4) down out of the way Pull bellow (5) off the Hitch (6) Undo and remove Bolts (7) and (8) Pull Reversing lever (9) downward out of the Housing (10) Pull out Pushrod (11) from front. Assemble the coupling in reverse order. Note, you may only be able to insert the Bolt (3) by pre-tensioning the Gas-strut (4), using the Handbrake lever (2). Attention: Check the Push-rod (11) and Reversing lever (9) can move sufficiently after tightening Bolts (7) and (8). Fig. 8: ISSUE 5 01/04/08 27

30 5. Coupling Damper change: Changing the damper of a WAP coupling. The Push rod illustrated in Fig. 9 is for reference. Method and sequence are the same for Delta and Box-section couplings Remove Push rod as described in section Undo and remove Bolts (1) and (2). 5.3 Pull Hitch (3) off the Push rod Remove Pin (5) using a hammer or mallet and drift/pin Remove Damper (6) by pulling it out of Push rod (4) from the front. Assemble Push rod in reverse order. Fig. 9: ISSUE 5 01/04/08 28

31 ISSUE 5 01/04/08 29

32 Accredited Service Centres Maps and Contact Details ISSUE 5 01/04/08 30

33 ISSUE 5 01/04/08 MERSEA COMMERCIAL & LEISURE TRAILERS LTD 6 COMMERCE WAY, WHITEHALL INDUSTRIAL ESTATE COLCHESTER, ESSEX. CO2 8HH Tel Fax sales@merseatrailers.com