Page 3 - VANS; PLATFORMS; CONTENTS
MAINTENANCEMANUAL VANS CONTENTS Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . 2Reporting Other Claims . . . . . . . . . . . . . . . . . . . . . . 2Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Maintenance Tips . . . . . . . . . . . . . . . . . . . . ...
Page 4 - REPORTING SAFETY DEFECTS AND OTHER CLAIMS
This vehicle was designed and quality inspected toconform with all applicable National Highway TrafficSafety Administration (NHTSA) safety standards. GreatDane Limited Partnership warrants this vehicle to befree from defects in materials and workmanship inaccordance with its standard printed warrant...
Page 5 - INTRODUCTION
INTRODUCTION This manual has been prepared to assist you in retain-ing the safety, dependability, and performance that arebuilt into Great Dane trailers. It is essential that thistrailer receives periodic inspections, maintenance, andservice parts replacement. Maintenance should be performed by Grea...
Page 6 - MAINTENANCE TIPS
MAINTENANCE TIPS BREAKING-IN A NEW TRAILER The most critical time in a new trailer’s life is its initialin-service check and first month’s “shakedown.”Preventive maintenance mechanics should be alert forunder-inflated tires and threaded fasteners that mayhave loosened from factory-torque settings. F...
Page 7 - APPEARANCE MAINTENANCE; WASHING AND CHEMICALS; FREEZING WEATHER MAINTENANCE; WINTER CORROSION MAINTENANCE
APPEARANCE MAINTENANCE Appearance maintenance includes cleaning, polishing,corrosion prevention and removal, and protectivecoating. You must have a working knowledge of eachfor the complete and proper appearance maintenanceof a Great Dane trailer. WASHING AND CHEMICALS Improper use of chemical clean...
Page 8 - ELECTRICAL SYSTEM; WARNING; CAUTION; WIRING DIAGRAM
ELECTRICAL SYSTEM The electrical system on every Great Dane trailermeets or exceeds all federal and state requirements ineffect at the time of manufacture. Wherever requiredby law, lamps and reflectors are marked by themanufacturer to indicate the appropriate specificationwith which each complies. F...
Page 9 - BRAKE MAINTENANCE; SCHEDULED MAINTENANCE
A warning decal, as shown on the previous page, islocated on the front of each trailer. You may traceindividual electrical circuits by the wire colors indicated.Refer to the schematic drawing and the decal forconductor numbers and wire colors. Use only a 12-volt DC battery for checking lamps orantil...
Page 10 - BRAKE CARE AND ADJUSTMENT; AIR SYSTEM AND BRAKE OPERATION
BRAKE CARE AND ADJUSTMENT The trailer brake system will perform safely andefficiently only as long as it is properly maintainedand not abused. Trailer brakes should be inspectedfrequently in connection with a Trailer PreventiveMaintenance (TPM) Program. Out-of-adjustmentbrakes can cause increased st...
Page 11 - BRAKE ADJUSTERS; AUTOMATIC ADJUSTERS
OVERSIZE LINERS To compensate for material removed when refacingbrake drums, X (1/16" oversize) and XX (1/8" oversize)liners are furnished by the lining manufacturers. Whenoversize liners are used the drums should be machinedin increments of 1/16" (radius increased 1/16"). BRAKE SHOE...
Page 12 - DANGER
PARKING BRAKES All axles (except some converter dolly axles) areequipped with air/spring actuators. Each actuator isseparated into two units. The base unit applies theservice brakes. The top unit contains a coil spring thatmust be compressed by air within the chamber torelease the parking brakes. Lo...
Page 15 - SUSPENSIONS; AIR-SPRING SUSPENSION
SUSPENSIONS Check wear pads in hangers. If they are wearing thin,install new pads or the spring will cause permanentdamage to the hanger. Do not operate with brokenspring leaves. Check to see if all springs can make proper contactwith wear pads. Twisted springs and cocked hangerscan cause uneven spr...
Page 16 - LEAF-SPRING SUSPENSION; RUNNING GEAR ASSEMBLY; FIXED SUSPENSION
The shock absorbers should be replaced at the firstsign of leaking hydraulic fluid. Worn shocks will allowtire hop and yield poor handling characteristics. Many air suspensions are equipped with air controlkits. The air control kit allows the raising or loweringof the vehicle bed by inflating or exh...
Page 18 - RIM BASE CRACKS; DISC FAILURES
16 RIM/WHEEL PROBLEMS RIM BASE CRACKS Circumferential crack at back flange radius or bead set. Causes: Overload and/or over inflation, damage dueto tire tools, tire bead deep pittingor corrosion. Circumferential cracks inmiddle of rim. Cause: Damage at valve slotor elsewhere. Discweld problem. Crack...
Page 19 - TIRE CARE; PROPER INFLATION
STUD HOLE CRACKS Hub or outboard drum may be damaged or broken.Must provide flat backup. Double-capnut wheel mountingpreload is force applied tothe disc by torquing nuts.Inner cap nut must be tightenedbefore tightening outer nut. This surface should beconvex, not concave. Cause: Loose cap nuts or in...
Page 21 - TIRE LOADS; AXLE ALIGNMENT; SINGLE-AXLE PROCEDURE; TANDEM-AXLES PROCEDURE
19 TIRE LOADS Great Dane Trailers, as required by the safetyregulations of the National Highway Traffic SafetyAdministration has assigned a Gross Axle WeightRating (GAWR) for each axle on the undercarriage.(See example certification plate below.) The GAWR and tire information shown on the vehiclecer...
Page 22 - UPPER COUPLER & KINGPIN; BOLT TORQUE REQUIREMENTS; BOLT SIZE
20 5. Measure the distance, on each side, from the center of the end of the front axle to the center of the endof the rear axle (measurements C and D of thetandem-axles illustration). These measurementsmust be within 1/16" of each other. (Illustrated is agauge that simplifies this measurement.) ...
Page 23 - SUPPORT GEAR LUBRICATION; REAR IMPACT GUARD; MAINTENANCE AND REPAIR
21 PINTLE HOOK 1. Clean and check for proper operation. This should be done at each TPM. 2. Inspect for worn, damaged or missing parts. Replace only with compatible replacementcomponents. 3. Regularly lubricate the latch and lock pivots with a light-oil lubricant. On models equipped with a greasefit...
Page 24 - SIDE AND ROOF PANELS – VANS; BONDED ROOF
SIDE AND ROOF PANELS – VANS Side and roof panels are critical structural members ofthe trailer. Small holes can be patched using an over-lay panel with blind rivets. Large holes may requirepanel replacements. When repairing large holes orwhen replacing full panels, use solid rivets of 2117-T4aluminu...
Page 25 - TOP FLOOR; INSULATED TRAILER MAINTENANCE; CLEANING
d. Check all rollers for smoothness of operations and have all sliding or otherwise damagedrollers replaced. e. Replace frayed, damaged or severely worn pull straps. f. Check the door lock to be sure that it is free, and fully operational. g. Replace broken or damaged hinges. h. Periodically use a l...
Page 27 - PLATFORM TRAILERS; MAIN BEAMS; CONVERTER DOLLY
25 3. Should ignition or combustion of the urethane become evident (flame, smoke, charring, odor, etc.),hot work must be stopped immediately. All flamesmust be extinguished and additional urethane mate-rials must be removed from the workpiece and/orworkplace before hot work is continued. 4. A fire w...
Page 28 - ALTERATIONS TO THE TRAILER; MINOR ALTERATIONS
RUNNING GEAR ASSEMBLY —PLATFORM AND CURTAINSIDETRAILERS MOVEABLE SUSPENSIONS 1. Always check the condition of the locking holes in the main beam. Holes that are badly worn orelongated will result in undue slack in the sliderunit, causing excessive wear and suspensionmisalignment. 2. Always check to ...
Page 29 - IL; MAINTENANCE MANUAL APPENDIX
T h is is to ce rt if y th at G R E A T D A N E L IM IT E D P A R T N E R S H IP w ar ra n ts to th e fi rs t p u rc h as er o n ly (h er ei n af te r re fe rr ed to as "P u rc h as er ") , su b je ct to th e co n d i- ti o n s st at ed h er ei n , th at th e d es cr ib ed n ew tr ai le r sh...
Page 30 - MAINTENANCE MANUAL BIBLIOGRAPHY
Recommended Maintenance Practices Manual Technology and Maintenance Council American Trucking Association2200 Mill RoadAlexandria, Virginia 22314 TTMA Trailer Maintenance Manual Truck Trailer Manufacturers Association1020 Princess StreetAlexandria, VA 22314 TTMA Technical Bulletins and RecommendedPr...
