Bumper Pull Dump Trailer Owner’s Manual WARNING This Owner’s Manual contains safety information and instructions for your trailer. You must read this manual before loading or towing your trailer. You must follow all safety precautions and instructions. Carry-On Trailer, Inc.
Contents 1. Introduction............................................................................................. 5 2. Safety ..................................................................................................... 6 2.1 Safety Alert Symbols And Signal Words..........................................................6 2.2 Major Hazards......................................................................................................
Contents 4. Coupling To Tow Vehicle....................................................................... 27 4.1 Tow Vehicle And Hitch......................................................................................27 4.1.1 Trailer Information.......................................................................................................... 27 4.1.2 Tow Vehicle..................................................................................................................... 27 4.
Contents 7. Breaking In A New Trailer..................................................................... 46 7.1 Retighten Lugs At First 10, 25 & 50 Miles.......................................................46 7.2 Adjust Brake At First 200 Miles.......................................................................46 7.3 Synchronizing Brake Systems........................................................................46 8. Accessories....................................................................
Introduction 1. Introduction Congratulations on the purchase of your trailer. We believe you will be happy and completely satisfied with your purchase. Our goal is to provide a valued customer a quality trailer at a reasonable price. For your safety, read and understand this manual before operating your trailer. If there are any questions about information in this manual, please consult your dealer. When calling about your trailer, please have the VIN number available for the dealer.
Safety 2. Safety 2.1 Safety Alert Symbols And Signal Words An Owner’s Manual that provides general trailer information cannot cover all of the specific details necessary for the proper combination of every trailer, tow vehicle and hitch. You must read, understand and follow the instructions given by the tow vehicle and trailer hitch manufacturers, as well as the instructions in this manual. Our trailers are built with components produced by various manufacturers.
Safety 2.2.4 Trailer Not Properly Coupled To Hitch ^ WARNING It is critical that the trailer be securely coupled to the hitch, and that the safety chains and emergency breakaway brake lanyard are correctly attached. Uncoupling may result in death or serious injury to you and to others. Driving too fast for conditions can result in loss of control and cause death or serious injury. Adjust speed down when towing trailer. ^ WARNING 2.2.
Safety 2.2.5 Proper Use Of Safety Chains Safety chains are provided so that control of the trailer can be maintained if your trailer comes loose from the hitch. ^ WARNING 2.2.7 Matching Trailer And Hitch ^ DANGER Be sure hitch and tow vehicle are rated for the Gross Vehicle Weight Rating (GVWR) of your trailer. Improper rigging of the safety chains can result in loss of control of the trailer and tow vehicle, leading to death or serious injury, if the trailer uncouples from the tow vehicle.
Safety ^ WARNING Inflate tires to pressure stated on the Certification / VIN label. Improper tire pressure may cause unstable trailer. Blowout and loss of control may occur. Death or serious injury can result. Make sure of proper tire pressure before towing trailer. The tightness of the wheel nuts or bolts is very important in keeping the wheels properly seated to the hub. Before each tow, check to make sure they are tight.
Safety 2.2.10 Unsafe Load Distribution Improper front / rear load distribution can lead to an unstable trailer or poor tow vehicle handling. Poor trailer stability results from tongue weights that are too low, and poor tow vehicle stability results from tongue weights that are too high. Refer to the “Loading And Unloading” section for more information.
Safety 2.2.12 Inappropriate Cargo ^ WARNING The trailer may be designed for specific cargo. If your trailer is designed for specific cargo, only carry that cargo in the trailer. A trailer must not be used to carry certain items, such as people, containers of hazardous substances or containers of flammable substances. Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes, and can lead to collision.
Safety ^ DANGER NEVER alter or substitute any hydraulic system component. Death or serious injury may result. An altered or component substituted hydraulic system may malfunction, resulting in the dump body falling without warning. NEVER alter or substitute any hydraulic system component. ^ WARNING Electrocution hazard. Dump body coming near or contacting power lines can cause electrocution. Electrocution can occur without contact.
Safety Conversely, rotating the steering wheel clockwise with your hands at the bottom of the wheel will move the rear of the trailer to the left, while backing up. Be careful not to allow the trailer to turn too much, because it will hit the rear of the tow vehicle. To straighten the rig, either pull forward, or turn the steering wheel in the opposite direction. 2.2.17 Safe Trailer Towing Guidelines necessary. Instead, slow down before you enter the curve.
Safety 2.2.18 Safety Warning Labels On Trailer Depending on trailer configuration, your trailer may not be equipped with all safety labels shown.
Safety 15
Safety ^ WARNING To protect you and others against death or serious injury, all of the labels shown must be on the trailer and must be legible. If any of these labels are missing or cannot be read, contact your dealer for replacement labels.
Safety 2.2.19 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 Carry-On Trailer, Inc. 101 Joe Harvey St Lavonia, GA 30553 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.
Tire Safety 3. Tire Safety Information 3.1 Trailer Tire Information This portion of the User’s Manual contains tire safety information as required by 49 CFR 575.6. Trailer tires may be worn out even though they still have plenty of tread left. This is because trailer tires have to carry a lot of weight all the time, even when not in use. Section 3.1 contains “Trailer Tire Information”. Section 3.2 contains “Steps for Determining Correct Load Limit - Trailer”. Section 3.
Tire Safety after five years, trailer tires are considered worn out and should be replaced, even if they have had minimal or no use. This is such a general statement that it may not apply in all cases. It is best to have your tires inspected by a tire supplier to determine if your tires need to be replaced. If you are storing your trailer for an extended period, make sure the tires are fully inflated to the maximum rated pressure and that you store them in a cool, dry place, such as a garage.
Tire Safety 3.3 Steps For Determining Correct Load Limit - Tow Vehicle 1. Locate the statement, “The combined weight of 2. 3. 4. 5. 6. occupants and cargo should never exceed XXX lbs.,” on your vehicle’s placard. Determine the combined weight of the driver and passengers who will be riding in your vehicle. Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds. The resulting figure equals the available amount of cargo and luggage capacity.
Tire Safety is higher or deeper than the same molding on the other sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle. Light truck (LT) tire: A tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose passenger vehicles. May be used on trailers. Load rating: The maximum load that a tire is rated to carry for a given inflation pressure.
Tire Safety Rim diameter: This means the nominal diameter of the bead seat. Rim size designation: This means the rim diameter and width. Rim type designation: This means the industry of manufacturer’s designation for a rim by style or code. Rim width: This means the nominal distance between rim flanges. Section width: The linear distance between the exteriors of the sidewalls of an inflated tire, excluding elevations due to labeling, decoration, or protective bands.
Tire Safety • • • Uniform Tire Quality Grading System Fundamental characteristics of tires Tire safety tips. Use this information to make tire safety a regular part of your vehicle maintenance routine. Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure. 3.5.1 Safety First- Basic Tire Maintenance Properly maintained tires improve the steering, stopping, traction, and load-carrying capability of your vehicle.
Tire Safety tire pressure. These “missing” pounds of pressure are what you will need to add. 5. At a service station, add the missing pounds of air pressure to each tire that is under inflated. 6. Check all the tires to make sure they have the same air pressure except in cases in which the front and rear tires are supposed to have different amounts of pressure).
Tire Safety Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement. R: The “R” stands for radial. Radial ply construction of tires has been the industry standard for the past 20 years. Next number: This two-digit number is the wheel or rim diameter in inches. If you change your wheel size, you will have to purchase new tires to match the new wheel diameter. Next number: This two- or three-digit number is the tire’s load index.
Tire Safety ST: An “ST” is an indication the tire is for trailer use only. Max. Load Dual kg (lbs) at kPa (psi) Cold: This information indicates the maximum load and tire pressure when the tire is used as a dual, that is, when four tires are put on each rear axle (a total of six or more tires on the vehicle). Max. Load Single kg (lbs) at kPa (psi) Cold: This information indicates the maximum load and tire pressure when the tire is used as a single.
Coupling To Tow Vehicle 4. Coupling To Tow Vehicle Follow all of the safety precautions and instructions in this manual to ensure safety of persons, cargo, and satisfactory life of the trailer. 4.1 Tow Vehicle And Hitch If the vehicle and hitch are not properly selected and matched to the Gross Vehicle Weight Rating (GVWR) of your trailer, you can cause an accident that could lead to death or serious injury.
Coupling To Tow Vehicle Hitch: The connecting mechanism including the ball support platform and ball and those components that extend and are attached to the towing vehicle, including bumpers intended to serve as hitches. Safety chains: Chains permanently attached to the trailer such that if the coupler connection comes loose, the safety chains can keep the trailer attached to the tow vehicle.
Coupling To Tow Vehicle 4.3.1.1 Before Coupling Trailer To Tow Vehicle 1. Be sure the size and rating of hitch ball match the size and rating of the coupler. Hitch balls and couplers are marked with their size and rating. ^ WARNING Coupler-to-hitch mismatch can result in uncoupling, leading to death or serious injury. Be sure the LOAD RATING of the hitch ball is equal or greater than the load rating of the coupler. 6. Raise the bottom surface of the coupler to be above the top of the hitch ball. 4.3.1.
Coupling To Tow Vehicle 6. Lower the trailer so that its entire tongue weight is held by the hitch, and continue retracting the jack to its fully retraced position. ^ CAUTION ^ WARNING Ring-to-pintle mismatch can result in uncoupling, leading to death or serious injury. Drop leg jacks may be spring loaded and may rapidly return to the raise position when released. Be sure the LOAD RATING of the pintle is equal or greater than the load rating of the ring. Keep clear when releasing drop legs.
Coupling To Tow Vehicle 2. Remove the safety latch pin and open the pintle ^ CAUTION locking mechanism. 3. In the open position, the ring is able to drop fully onto the pintle. Drop leg jacks may be spring loaded and may rapidly return to the raise position when released. Keep clear when releasing drop legs. 7. Fully retract jack drop leg if equipped. Go to Section 4.3.3 “Connect Safety Chains” to continue connecting trailer to tow vehicle. 4.
Coupling To Tow Vehicle ^ WARNING Improper rigging of the safety chains can result in loss of control of the trailer and tow vehicle, leading to death or serious injury, if the trailer uncouples from the tow vehicle. Connect the lanyard to the tow vehicle so that the hydraulic actuator will engage or the electric brake pullpin will be pulled out before all of the slack in the safety chains is taken up. Do not connect the lanyard to a safety chain, hitch ball or hitch ball assembly.
Coupling To Tow Vehicle Most trailers are setup to charge the battery from the tow vehicle. If the electrical system on your tow vehicle does not provide power to the battery, you must periodically charge the battery with a commercial battery charger to keep the battery charged. ^ CAUTION ^ WARNING An ineffective breakaway brake system can result in a runaway trailer, leading to death or serious injury if the coupler fails. Test the function of the breakaway brake system before towing trailer.
Coupling To Tow Vehicle 4.3.5.3 Test Surge Brakes Hydraulic surge actuator systems provide automatic and smooth trailer braking without special application by the tow vehicle driver. While this is extremely convenient it can sometimes be difficult to determine if the surge setup is functioning properly. The following steps provide a quick field-test to confirm that the trailer brake system is operational.
Coupling To Tow Vehicle 4.5 Tongue Weight It is critical to have a portion of the trailer load carried by the tow vehicle. That is, the trailer tongue must exert a downward force on the hitch. This is necessary for two reasons. First, the proper amount of tongue weight is necessary for the tow vehicle to be able to maintain control of the tow vehicle/trailer system.
Coupling To Tow Vehicle 4.6 Adjust Hitch Height (If Equipped) The height of the hitch on the trailer must be adjusted so that the trailer, when loaded to rated capacity, is level while connected to the tow vehicle. A level trailer allows equal weight distribution on the axles. Your dealer or a trailer service center can perform this adjustment or you can use the following steps to adjust the hitch height yourself.
Loading And Unloading 5. Loading And Unloading Improper trailer loading causes many accidents and deaths. To safely load a trailer, you must consider: • Overall load weight. • Load weight distribution. • Proper tongue weight. • Securing the load properly. To determine that you have loaded the trailer within its rating, you must consider the distribution of weight, as well as the total weight of the trailer and its contents.
Loading And Unloading ^ WARNING Electrocution hazard. Dump body coming near or contacting power lines can cause electrocution. Electrocution can occur without contact. Verify there are no overhead power lines over or near the trailer before raising dump body. ^ WARNING A soft and/or uneven surface may cause tow vehicle and trailer to tip over when dump body is raised. Raise dump body ONLY if tow vehicle and trailer are both on a firm and level surface. 5.
Loading And Unloading NOTICE Ramps are not rated for load bearing capacity. They will NOT support the load bearing capacity of the trailer. Do not overload ramps. 4. Load equipment into trailer. 5.3 Loading And Unloading Bulk Material Check if the trailer has “payload” decals. If not, then determine the payload, or cargo capacity, by subtracting the empty weight of the trailer from the GVWR given on the Certification / VIN tag.
Loading And Unloading ^ WARNING Unsecured rear doors can cause a driving hazard. Do not operate trailer without properly securing rear door latches. 5.3.2 Loading Bulk Material 1. Tell the loader operator the payload of your trailer. 2. 3. 4. 5. The loader operator will have an approximate weight of the material to be loaded. Use common sense when loading. If you are uncertain of the weight of the material, load a small amount and weigh your trailer.
Loading And Unloading 6. Unlock spreader gate. ^ WARNING ^ WARNING Electrocution hazard. Loaded materials can exert pressure against the spreader gate. Dump body coming near or contacting power lines can cause electrocution. This may cause the spreader gate to swing out with force when unlocked, causing serious injury. Electrocution can occur without contact. Stand on the side of the trailer to unlock spreader gate. 7.
Loading And Unloading NOTICE Prevent trailer damage. Trailers equipped with a power down hydraulic system can be damaged if the down button is held after the dump body is fully lowered. Release down button when the dump body is fully lowered. ^ WARNING Risk of battery exploding. Battery box prop rod may contact battery terminals, which may result in the battery exploding. Place battery box lid prop rod in retaining clip.
Loading And Unloading 8. Discontinue pushing the up button and walk to the ^ DANGER A lowering or falling dump body can result in death or serious injury. NEVER enter the area under the dump body unless the empty dump body is supported by the body prop. 9. ^ DANGER 10. The body prop is designed to support an empty dump body only. 11. NEVER support a loaded dump body by the body prop. Unload the dump body before using body prop. 12. 13. ^ WARNING Electrocution hazard.
Loading And Unloading Failure to do so may result in the prop rod contacting the battery terminals, which can result in the battery exploding. 14. Close and latch rear gates before moving trailer. ^ WARNING Unsecured gate(s) can cause a driving hazard. Do not operate trailer without properly securing rear gate latches. 5.4 Hydraulic Components Do not alter or substitute and hydraulic components on the dump trailer.
Risk of battery exploding. Pre-Tow Checklist 6. Pre-Tow Checklist Battery box prop rod may contact battery terminals, which may result in the battery exploding. Place battery box lid prop rod in retaining clip. Tongue Mounted Battery Boxes Only: When closing the battery box lid, place the prop rod in the retaining clip on the side of the battery box. Failure to do so may result in the prop rod contacting the battery terminals, which can result in the battery exploding. 5.
Breaking In A New Trailer 7. Breaking In A New Trailer ^ WARNING 7.1 Retighten Lugs At First 10, 25 & 50 Miles Wheel lugs can shift and settle quickly after being first assembled, and must be checked after the first 10, 25 and 50 miles of driving. Failure to perform this check may result in a wheel coming loose from the trailer, causing a crash leading to death or serious injury. Improper tightening of the lug nuts or bolts voids the axle warranty.
Accessories 8. Accessories This chapter provides some basic information for the safe operation of accessories. You must read and follow these instructions before using the accessory. If you are uncertain whether you have all of the instructions, contact your dealer before operating the accessory. 8.1 Accessory Battery Your trailer is equipped with an accessory battery that operates the dump body.
Inspection, Service And Maintenance 9. Inspection, Service And Maintenance 9.1 Inspection, Service & Maintenance Summary Charts You must inspect, maintain and service your trailer regularly to insure safe and reliable operation. If you cannot or are unsure how to perform the items listed here, have your dealer do them. Note: In addition to this manual, also check the relevant component manufacturer’s manual.
Inspection, Service And Maintenance Inspection And Service Every Month Inspection / Service Manual Section Reference Lubricate door hinges and dump Section 9. body pivots. Item Lubrication Item Brakes, electric • Magnet • Inspection and Service Every 6 Months or 6,000 Miles Inspection/Service Manual Section Reference Controller (in tow vehicle) Tires Check wear and current draw. Section 9. Check power output (amperage) Section 9. and modulation. See Controller Mfr’s Inspect tread thoroughly.
Inspection, Service And Maintenance Item Brakes, all types • Shoes and Drums Inspection And Service Every Year or 12,000 Miles Inspection/Service Manual Section Reference Check for scoring and wear. Replace Section 9. per manufacturer’s specifications. See Brake Mfr’s Manual Jack, Drop-leg (if equipped) Structure • Frame Members • Welds Wheels • Wheel Bearings • Rims Structure • Axle Attachment Bolts Grease gears at top. See Jack Mfr’s Manual Inspect all frame members, bolts & Section 9.
Inspection, Service And Maintenance 9.2 Inspection And Service Instructions ^ WARNING ^ WARNING Broken or damaged fasteners can cause injury or damage to trailer and contents. Worn or broken suspension parts can cause loss of control and injury may result. Inspect for, and repair all damaged parts at least once a year. Have trailer professionally inspected annually and after any impact. 9.2.1.2 Welds To perform many of the inspection and maintenance activities, you must jack up the trailer.
Inspection, Service And Maintenance automatically adjust the brake shoes when the trailer is “hard braked” from a rearward direction. Trailer disc brakes are self-adjusting and do not need to be periodically adjusted. Using pads or shoes without enough brake lining material can result in brake damage, create excessive heat and potentially cause the loss of braking capacity. Read your axle and brake manual to see how to adjust your brakes. If you do not have this manual, contact your dealer for assistance.
Inspection, Service And Maintenance Check fluid level prior to towing the trailer. The master cylinder is normally located on the tongue of the trailer. The fluid level must maintained at the full mark on reservoir. Check with your dealer for the type of brake fluid used in the brake system. 9.2.3.2 Hydraulic Surge Brake Before each tow, perform the following steps: 1. Check that the brake master cylinder level as instructed above. Check for leaks and repair as required. 2.
Inspection, Service And Maintenance The coupler latch lever must be able to rotate freely and automatically snap into the latched position. Oil the pivot points, sliding surfaces, and spring ends with SAE 30W motor oil. Keep the ball pocket and latch mechanism clean. Dirt or contamination can prevent proper operation of the latching mechanism. To avoid risk of collisions, all lights must work. 9.2.7 Wheel Rims When replacing a ball, the load rating must match or exceed the GVWR of the trailer.
Inspection, Service And Maintenance ^ WARNING Never go under trailer unless it is on firm and level ground and resting on properly placed and secured jack stands. If your axle(s) are equipped with a grease zerk on the ends of the axle(s), the bearings must be greased every 6 months or 6,000 miles to ensure reliable and safe operation of your trailer. 1. Remove the rubber plug from the axle end. 2. Place grease gun on zerk. 3. Pump grease until new grease begins to appear.
Inspection, Service And Maintenance dump body is supported by the body prop. 1. Park the trailer on a firm and level surface. 2. Pump grease into the dump body hinge fittings and ^ WARNING 3. Raise the dump body and place the body prop in Metal creep between the wheel rim and lug nuts or bolts can cause rim to loosen. rear door hinges every month. the upright position. Lower the dump body onto the body prop. The body prop must engage the receiver. 4.
