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Great Dane 42101401 - page 1
MAINTENANCE MANUAL ® Please route to the individual responsible for trailer maintenance Part No. 42101401 ...
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Great Dane 42101401 - page 2
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Great Dane 42101401 - page 3
MAINTENANCE MANUAL V AN S CONTENTS Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . 2 Reporting Other Claims . . . . . . . . . . . . . . . . . . . . . . 2 I n t r o d u c t i o n ...............................3 M a i n t e n a n c eT i p s ..........................4 Appearance Maintenance . . . . . . . . . . . . . . . . . . . . 5 ...
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Great Dane 42101401 - page 4
This vehicle was designed and quality inspected to conform with all applicable National Highway T raffic Safety Administration (NHTSA) safety standards. Great Dane Limited Partnership warrants this vehicle to be free from defects in materials and workmanship in accordance with its standard printed warranty (see Appendix). If you detect a defect tha ...
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Great Dane 42101401 - page 5
IN TR ODUC TI O N T his manual has been prepared to assist you in retain- ing the safety , dependability , and performance that are built into Great Dane trailers. It is essential that this trailer receives periodic inspections, maintenance, and service parts replacement. Maintenance should be performed by Great Dane branches and dealers, or other ...
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Great Dane 42101401 - page 6
MA IN TE NA NC E TI PS B REAKING-IN A NEW TRAILER The most critical time in a new trailer ’s life is its initial i n-service check and first month’s “shakedown.” Preventive maintenance mechanics should be alert for under-inflated tires and threaded fasteners that may have loosened from factory-torque settings. Fastener torque should be all- ...
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Great Dane 42101401 - page 7
AP PE AR AN CE M AI NT EN AN CE A ppearance maintenance includes cleaning, polishing, corrosion prevention and removal, and protective coating. Y ou must have a working knowledge of each for the complete and proper appearance maintenance of a Great Dane trailer . W ASHING AND CHEMICALS Improper use of chemical cleaners has caused many a newly deliv ...
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Great Dane 42101401 - page 8
EL EC TR IC AL S YS TE M The electrical system on every Great Dane trailer meets or exceeds all federal and state requirements in effect at the time of manufacture. Wherever required by law , lamps and reflectors are marked by the m anufacturer to indicate the appropriate specification with which each complies. For opt imum pe rform ance and l ong ...
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Great Dane 42101401 - page 9
A warning decal, as shown on the previous page, is located on the front of each trail er . Y ou may trace indiv idual e lectri cal cir cuits b y the wire c olors i ndica ted. Refer t o the sch ematic d rawin g and the d ecal for c ondu ctor nu mbers an d wire co lors. Use only a 12-volt DC battery for checking lamps or antilock brake systems. Never ...
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Great Dane 42101401 - page 10
BR A K E CA R E A ND A D J US T M EN T T he trailer brake system will perform safely and efficiently only as long as it is properly maintained and not abused. T railer brakes should be inspected frequently in connection with a T railer Preventive Maintenance (TPM) Program. Out-of-adjustment b rakes can cause increased stopping distance, shorter bra ...
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Great Dane 42101401 - page 11
O VERSIZE LINERS T o compensate for material removed when refacing brake drums, X (1/16" oversize) and XX (1/8" oversize) liners are furnished by the lining manufacturers. When overs ize lin ers are us ed the dr ums sho uld be mac hined in incr ement s of 1/16" ( radiu s incre ased 1/1 6"). BRAKE SHOE ROLLER CAM FOLLO WERS Rolle ...
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Great Dane 42101401 - page 12
P AR KI NG B RA KE S All axles (except some converter dolly axles) are e quipped with air/spring actuators. Each actuator is separated into two units. The base unit applies the service brakes. The top unit contains a coil spring that must be compressed by air within the chamber to release the parking brakes. Loss of air pressure in the s upply line ...
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Great Dane 42101401 - page 13
This detailed check takes about two and one-half hours. It’s important to check a representative tractor and trailer each time you order equipment. K eeping an eye on your brake service records will also flag imbalance problems. If you are seeing 300,000 miles on tractor linings and 70,000 miles on trailer linings, there’s obviously an imbalanc ...
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Great Dane 42101401 - page 14
INSPECTION I nspect the inner and outer wheel bearing cups, cones and rollers for excessive wear or damage. Refer to bearing and axle manufacturer ’s manuals for inspection and replacement requirements. LUBRICA TION For maximum bearing life, inspect wheel bearings and lubricant periodically , change lubricant regularly , and clean the hub assembl ...
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Great Dane 42101401 - page 15
SU SP EN SI ON S Check wear pads in hangers. If they are wearing thin, install new pads or the spring will cause permanent damage to the hanger . Do not operate with broken spring leaves. Check to see if all springs can make proper contact with wear pads. T wisted springs and cocked hangers can cause uneven spring contact with wear pads, and will r ...
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Great Dane 42101401 - page 16
The shock absorbers should be replaced at the first sign of leaking hydraulic fluid. Worn shocks will allow tire hop and yield poor handling characteristics. M any air suspensions are equipped with air control kits. The air control kit allows the raising or lowering of the vehicle bed by inflating or exhausting air from the air suspension. Do NOT o ...
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Great Dane 42101401 - page 17
15 SINGLE-PIECE RIM WHEELS I llustrated, complete safe operating procedures are provided on the wall chart “Mounting and Demounting Procedures for T ruck/Bus T ires” available from the Department of T ransportation, and OSHA. T he following minimum steps are recommended to pro- vide maximum safety when servicing single-piece wheels: • The tir ...
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Great Dane 42101401 - page 18
16 RI M/ WH EE L PR OBL EM S RIM B ASE CRA CKS Circu mfere ntial cr ack at ba ck flan ge radiu s or bead s et. Causes: Overload and/or over inflation, damage due to tire tools, tire bead deep pitting or corrosion. Circumferential cracks in middle of rim. Cause: Damage at valve slot or elsewhere. Disc weld problem. Cracks in rim gutter . Causes: Ove ...
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Great Dane 42101401 - page 19
STUD HOLE CRA CKS H ub or outboard drum may be damaged or broken. Must provide flat backup. Double-capnut wheel mounting preload is force applied to the disc by torquing nuts. Inner cap nut must be tightened before tightening outer nut. This surface should be convex, not concave. Cause: Loose cap nuts or insufficient preload due to damaged threads ...
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Great Dane 42101401 - page 20
Running a tire under inflated can have serious conse- quences in addition to reducing tread life. Heat buildup can cause the tire body to deteriorate, resulting in sep- aration of the tread from the body or belt ply . A soft tire o verdeflects, causing fatigue breaks in the body cords. Continued overdeflection causes breaks in the body cord constru ...
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Great Dane 42101401 - page 21
19 TIRE LO ADS G reat Dane T railers, as required by the safety regulations of the National Highway T raffic Safety Administration has assigned a Gross Axle Weight Rating (GA WR) for each axle on the undercarriage. (See example certification plate below .) The GA WR and tire information shown on the vehicle certification plate was applicable at the ...
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Great Dane 42101401 - page 22
20 5. Measure the distance, on each side, from the center of the end of the front axle to the center of the end of the rear axle (measurements C and D of the tandem-axles illustration). These measurements m ust be within 1/16" of each other . (Illustrated is a gauge that simplifies this measurement.) It can be made of drill rod or pipe fitting ...
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Great Dane 42101401 - page 23
21 PI NT LE H OO K 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 replacement c omponents. 3. Regularly lubricate the latch and lock pivots with a light-oil lubricant. On models equipped with a grease fitting, apply a small quantity of grease thr ...
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Great Dane 42101401 - page 24
SI DE A ND R OOF P ANEL S – V ANS S ide and roof panels are critical structural members of the trailer . Small holes can be patched using an over- lay panel with blind rivets. Large holes may require panel replacements. When repairing large holes or when replacing full panels, use solid rivets of 21 17-T4 a luminum for aluminum panels, or solid r ...
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Great Dane 42101401 - page 25
d. Check all rollers for smoothness of operations and have all sliding or otherwise damaged rollers 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 light lubricant (not grease) on rollers, counterb ...
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Great Dane 42101401 - page 26
E xteriors: Cleaning the outside of refrigerated trailers should be done the same way dry-freight vans are cleaned. Live steam does a good job of cleaning and brightening the exterior surfaces of van trailers. Application of a protective transparent coating may b e used to protect the exterior surface from further oxidation. Do not use brightener o ...
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Great Dane 42101401 - page 27
25 3. Should ignition or combustion of the urethane become evident (flame, smoke, charring, odor , etc.), hot work must be stopped immediately . All flames must be extinguished and additional urethane mate- r ials must be removed from the workpiece and/or workplace before hot work is continued. 4. A fire watcher equipped with a 15-pound CO 2 or dry ...
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Great Dane 42101401 - page 28
R U NN IN G GE AR A SS EM BL Y — PL A TFO RM A ND C UR T AIN SI DE TR AI LE RS MO VEABLE SUSPENSIONS 1 . Always check the condition of the locking holes in the main beam. Holes that are badly worn or elongated will result in undue slack in the slider unit, causing excessive wear and suspension misalignment. 2. Always check to see that the hold-do ...
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Great Dane 42101401 - page 29
This is to certify that GREA T DANE L IMITED P ARTNERS HIP warrants to the first purchaser only (hereinafter referred to as "Purchaser"), subject to the condi- tions stated herein, that the descr ibed new trailer shall be free from defects in materials and workmanship, when properl y maintained, and under normal use and ser vice which mea ...
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Great Dane 42101401 - page 30
Recommended Maintenance Practices Manual T echnology and Maintenance Council American T rucking Association 2 200 Mill Road A lexandria, Virginia 22314 T TMA T railer Maintenance Manual T ruck Trai ler Manufacturers Association 1 020 Princess Street Alexandria, V A 22314 T TMA T echnical Bulletins and Recommended Practices T ruck Trai ler Manufactu ...
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Great Dane 42101401 - page 31
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Great Dane 42101401 - page 32
® PO BOX 67 • LA THROP A VENUE • SA V ANNAH, GA 31402 0509DMD $2.00 USD ...
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