Sauber 1521-PRC Manual

This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521-PRC Combination Trailer
05/2017
Page 1
Custom Engineered for Appalachian Power Company
Pole Reel & Cargo Trailer - S/N 1F9UZ2525HV048074
Preface
Thank you for choosing Sauber Mfg. Co.. You have purchased a trailer designed and built with care. With
minimal maintenance and by understanding its operation, your new trailer will provide you with years of excellent
service. We welcome your suggestions for improvement and stand willing to assist you if any questions arise during
its operation. If we can help in any way, please contact your account representative toll free:
Website: SauberMfg.com
Voice Communications: [phone]
Fax Communications: [phone]
The following manual provides important safety information and instruction. Please read this manual before oper-
ating your new trailer. It is important to follow safety instructions and cautions.
We acknowledge that not every situation or combination of tow vehicle and trailer can be addressed, therefore we
ask that you use sound judgment after reading the following outlines.
Some components may be produced by a third party. When available, separate service manuals and instructions
may apply.
Serious Hazards
Loss of control of the tow vehicle/trailer combination could result in serious injury or death. The most common
causes for loss of control include:
• Failure to adjust driving behavior when towing a trailer
• Immoderate speed – Driving too fast for the conditions
With ideal road conditions, the maximum recommended speed for safely towing a trailer is 60 mph. If you drive
too fast, the trailer is more likely to sway, increasing the possibility for loss of control. In addition, it is possible that
the tires may overheat, increasing the chance of a blow out.
Decrease your speed as road, weather, lighting, and other conditions decline.

This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521-PRC Combination Trailer
05/2017
Page 2
• Improper sizing of the tow vehicle for the trailer
Trailers that weigh too much for the tow vehicle can cause unsafe stability issues which can lead to loss of control
and a serious accident. Know your vehicle tow rating and Gross Combination Weight Rating (GCWR.) Vehicle
manufacturers will provide you with maximum towing capacities, as well as the GCWR. The additional strain put
on the engine and drive-train of the vehicle may also lead to serious maintenance problems. For these reasons,
the maximum towing capacity of your towing vehicle should not be exceeded. The towing capacity of your vehicle
can be found in the tow vehicle's Owner's Manual.
Use of a hitch with a load rating less than the load rating of the trailer can result in loss of control and may lead to
a serious accident. Ensure that your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating (GVWR)
and tongue weight of your trailer.
• Overloading and/or improper weight distribution
The total weight of the load you put in or on the trailer, plus the empty weight of the trailer itself, must not exceed
the trailer's Gross Vehicle Weight Rating (GVWR.) If you do not know the empty weight of the trailer plus the
cargo weight, you must weigh the loaded trailer at a commercial scale. In addition, you must distribute the load in
the trailer such that the load on any axle does not exceed the Gross Axle Weight Rating (GAWR.) The GVWR and
GAWR are located on the OEM certification and VIN label attached to the front frame of the trailer.
Never exceed the trailer Gross Vehicle Weight Rating or the Gross Axle Weight Rating. Do not load a trailer so
that the weight on any tire exceeds its rating.
Improper front/rear load distribution can lead to trailer sway and poor handling conditions. Undesirable trailer
sway results from tongue weights that are too low, while tow vehicle instability results from tongue weights that
are too high.
Uneven left/right load distribution can cause tire, wheel, axle or structural failure. To the extent possible, be sure
your trailer is evenly loaded left/right. Towing stability also depends on keeping the center of gravity as low as pos-
sible.
Make certain the tongue weight is within the allowable range. Keep the center of gravity as low as possible.
• Unsecured loads
Your trailer may be designed for specific cargo, such as reels, or poles. If your trailer is designed for specific
cargo, do not carry any other cargo such as people, hazardous substances or containers of flammable materials.
It is important to avoid shifting cargo. The trailer ride can be bumpy and rough. Securing cargo so that it does not
shift or bounce out of the trailer is imperative. Tie down all loads with proper sized fasteners. Always secure doors
or lids if present on your trailer by securing it's latch.
• Improper braking and steering under sway conditions
When towing a trailer, you will have decreased acceleration, increased stopping distance, and increased turning
radius. The trailer will change the handling characteristics of your towing vehicle, making it more sensitive to

This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521-PRC Combination Trailer
05/2017
Page 3
steering inputs and more likely to be have its stability affected in windy conditions or when passed by large vehi-
cles. You will also need to adjust driving accordingly, i.e. taking a longer distance to pass and allowing for in-
creased braking distances, etc.
Common sense measures may be necessary, such as; being alert for slippery conditions, anticipate trailer sway
and be ready to reduce speed, use small, trim-like steering adjustments to re-gain control, check rear view mirrors
frequently to evaluate trailer towing and traffic conditions, use a lower gear when driving downhill or on long
grades, be aware of your trailer height at all times, especially when approaching bridges and roofed areas.
• Improper or incorrect coupling of the trailer to the hitch
It is critical that the trailer be securely coupled to the hitch, and that the safety chains and emergency break-away
cable (electric brakes) and air hoses (air brakes) are correctly attached. Uncoupling of the trailer during transit can
lead to a serious accident or a fatality.
Ensure that the pintle hook capacity rating, including installation, is sufficient for the GVWR and the tongue weight
of the trailer being towed. Make sure that the pintle hook is physically compatible with the trailer drawbar. Compat-
ibility information is available from the pintle hook manufacturer.
Observe the drawbar and pintle hook for wear, corrosion and cracks before coupling. Replace worn, cracked or
corroded components per the manufacturer's recommendations.
Ensure the hitch drawbar and pintle hook are installed with grade-8 fasteners and are properly torqued before
coupling to the tow vehicle.
Do not move the trailer if any of the following conditions appear:
• The drawbar is not secured and locked to the pintle hook.
• The safety chains are not secured to the tow vehicle. If your trailer detaches from the pintle hook for
any reason, we have provided safety chains so that control of the trailer can still be maintained. Im-
proper rigging of the safety chains could result in loss of control. Fasten chains to the frame of the
towing vehicle. Do not fasten chains to any part of the hitch unless the hitch has special holes or
loops specifically designed for that purpose. Cross chains underneath hitch and coupler with enough
slack to permit turning and to suspend the trailer tongue should it become detached.
• The trailer jacks are not fully retracted.
Do not tow the trailer on the road until:
• The trailer breakaway system is operational
• The breakaway switch must be connected and verified. If equipped with electric brakes, your trailer
will be equipped with a breakaway system that can apply the brakes on your trailer if it becomes de-
tached from the tow vehicle for any reason. The breakaway system, including the battery, must be in
good condition and properly rigged to be effective. An inoperative breakaway can result in a runaway
trailer. The breakaway cable must be attached to the towing vehicle and not to any part of the hitch.

This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521-PRC Combination Trailer
05/2017
Page 4
Before towing the trailer, test the system. If the system is not working, do not tow the trailer. Have it
serviced or repaired.
• Tires and wheels are checked
Failure to maintain proper tire condition and pressure can lead to loss of control.
Just as with your tow vehicle tires, the trailer tires and wheels are important safety items. It is essential to inspect
them before each tow.
If a tire is found to include defects such as a bald spot, bulge, cut, cracks or is showing any cords, replace before
towing. Have the tires inspected by qualified persons. Check inflation pressure on all tires prior to towing.
Failure to keep lug nuts tightened properly may cause the wheels to be seated to the hub improperly. Before
each tow, check to make sure they are properly torqued. The proper torque for lug nuts is listed in this manual
and available from the manufacturer. Use a torque wrench to tighten the lug nuts, use a crisscross star pattern.
Lug nuts are also prone to loosen after first being assembled. When driving a new trailer (or after wheels have be
remounted,) check to make sure they are tight after the first 10, 25, and 50 miles of use and before each tow
thereafter.
• The trailer lights and brakes are connected and checked
Be sure the trailer brakes and all the lights on your trailer are functioning properly before towing your trailer.
Brakes and lights on a trailer are controlled via a connection to the tow vehicle.
Electric Brakes
Check the trailer brake lights by having someone operate the brake and turn signals on the tow vehicle
while you visually verify it is functioning. If your trailer has electric brakes, your tow vehicle will have an electric
brake controller that is required to be installed at the driver's position that sends power to the brakes. To check the
condition of the electrical brake system, pull the breakaway pin and check for the illumination of the green LED
indicator light. When fully lit, the battery is charged and the system wiring is correct. To test this system, operate
the brake controller while trying to pull the trailer at a speed of less than 5mph to verify they are operating and you
can feel them engage.
• Proper Tongue Weight is established
It is critical to have a portion of the trailer load carried by the tow vehicle. The trailer tongue should always exert a
downward force on the hitch. Proper tongue weight is essential to good trailer tracking and safe operation. If too
little weight is distributed to the tongue, towing will be erratic. Too much tongue weight may overload the towing
vehicle’s rear axle or the pintle hitch rating. Ten to twenty percent weight transfer is considered a normal range.
Smaller, single axle trailers can transfer weight on the high side of this range. Larger, multiple axle trailers are de-
signed to transfer less because of the limited capacity of the towing vehicle’s rear axle.

This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521-PRC Combination Trailer
05/2017
Page 5
When necessary, tongue weight can be controlled by distributing the load or by adjusting the pintle eye.
Even loading is ideal, but when this is not possible, place more weight toward the trailer front to provide a safe
tongue weight. Be aware that too much tongue weight from an uneven load can overload tow vehicle compo-
nents. It is incumbent upon the operator to provide a safe, towable tongue weight without excessive hitch weight
transfer that could place the tow vehicle in a non-compliant condition. If your trailer is equipped with an adjustable
eye, lowering it will generally increase tongue weight while raising it will decrease tongue weight - especially on
multi-axle models. Additional loading instructions may be included with your trailer, and should be followed.
Once the trailer pintle eye is secured in the towing vehicle hitch, cross the safety chains and connect
them to the rings provided at the towing vehicle bumper. Insert the electrical connection cord and check trailer
lighting. Connect the air glad hands if present and check brake operation. Ensure the trailer axle(s) do not ex-
ceed their GAWR and the entire trailer and load does not exceed the GVWR rating.
• Grounding
Your trailer is equipped with a bronze grounding lug. When the trailer is used near energized conduc-
tors the trailer must be grounded. A grounding lug is provided to help you follow your company’s
safety practices.
• Wheel Chocks
Set the chocks at each rear wheel in the direction of the expected load or grade.
• Do not modify your trailer
Your trailer is a custom engineered piece of equipment. Essential safety items can be damaged by altering your
trailer. The simplest modifications, such as driving a screw or punching a hole to install a hanger can inadvert-
ently damage an electrical wire or other hidden component. Before making any alteration to your trailer, contact
Sauber Mfg. Co. at [phone].
Pole Carrying
Your pole trailer is equipped with a telescoping tongue section which allows the operator to regulate rear pole
overhang and tongue weight. Optimal tongue weight is between ten and twenty percent of the total load. (5) ad-
justments are provided to help you achieve a safe weight distribution. A “cat-track” system is provided inside the
telescoping section which eliminates cumbersome front extension cords. Technical pole carrying recommenda-
tions follow:
General
Sauber Mfg. Co. builds standard extendible tongue pole trailers w/ multiple adjustment positions. This bulletin
serves as a guide in recommending what size poles should be carried in various positions. It is always assumed
that the pole will be carried with the butt end (heavy end) towards the front and that the pole front will be within 1’
of the hitch front. The calculations below assume 20% total weight transfer to the trailer tongue and are based on

This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521-PRC Combination Trailer
05/2017
Page 6
standard minimum butt and top circumference measurements for the class pole indicated. The pole trailer length
required for Sauber Extendible Tongue Pole and Combination Trailers can be calculated by the formula:
(TC / (TC + BC)) * 1.20 * PL + UB + 1 = Pole Trailer Length Required
Where:
TC = Top Circumference (IN)
BC = Butt Circumference (IN)
PL = Pole Length (FT)
UB = Undercarriage to Rear Bolster (FT)
UB = 4’ For Standard Pole Trailers
UB = 5’ For Model 1521-PRC Combination Trailers
This table provides representative pole data; consult your supplier for your most accurate information:
Wood Pole Data Chart
Class 1 2 3 4 5
Min Top Dia 8.6" 8.0" 7.3" 6.7" 6.0"
Length Min Dia 6' From Butt
Weight For Southern Yellow Pine (.45# Penta /.60# CCA)
35' 12.4"
1309/1672 Lbs
11.6"
1139/1368 Lbs
10.8"
985/1182 Lbs
10.0"
855/1026 Lbs
9.2"
739/888 Lbs
40' 13.0"
1630/1956 Lbs
12.2"
1410/1692 Lbs
11.4"
1224/1470 Lbs
10.7"
1060/1272 Lbs
9.9"
919/1104 Lbs
45' 13.7"
1965/2358 Lbs
12.9"
1705/2046 Lbs
11.9"
1475/1770 Lbs
11.1"
1280/1536 Lbs
10.3"
1110/1332 Lbs
50' 14.3"
2329/2796 Lbs
13.4"
2020/2424 Lbs
12.4"
1750/2100 Lbs
11.6"
1519/1824
55' 14.8"
2714/3475 Lbs
13.8"
2355/3014 Lbs
12.9"
2040/2611 Lbs
12.0"
1769/2266 Lbs
60' 15.3"
3130/4006 Lbs
14.3"
2710/3469 Lbs
13.4"
2349/3008 Lbs
12.4"
2035/2605 Lbs
65' 15.8"
3550/4550 Lbs
14.8"
3079/3942 Lbs
13.8"
2670/3418 Lbs
70' 16.2"
4005/5126 Lbs
15.3"
3474/4448 Lbs
14.3"
3009/3853 Lbs
75' 16.7"
4475/5728 Lbs
15.6"
3885/4973 Lbs
14.6"
3365/4307 Lbs
80' 17.1"
4965/6355 Lbs
16.1"
4305/5510 Lbs

This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521-PRC Combination Trailer
05/2017
Page 7
Exceptions
If customer requirements include carrying larger poles within the confines of the extendible tongue, we have three
options. One option is increasing the overall length of the trailer and extension. A second option is relocating the
undercarriage rearward a maximum of 2’. The third option simply lowers the target tongue weight. If 10% or 15%
tongue weight transfer is desired, substitute 1.10 or 1.15 respectively for 1.20 in the equation. Tongue weight is an
important consideration. Too much can raise rear truck axle weights to unacceptable levels and de-load the front
axle, causing steering and control problems. Too little tongue weight will result in reduced trailer control while tow-
ing.
Adjusting the tongue length
Set the chocks at the front of the tires
With both jacks in the down position, raise and store the front jack in the stored position while leaving the mid-
frame jack down. The trailer should be near level. Remove the stainless steel insertion pin. The trailer is now
ready to be expanded to one of the marked extension points, or to the final stop position (fully extended), Keep
the trailer at near level.
Utilizing mechanized equipment such as a truck or forklift attached to the pintle eye, slowly pull out the tongue -
stopping at the desired marked position, or the final stop. Re-insert the stainless steel pin at the indexed position
and swivel to the locked position. Lower the front jack. To retract the tongue, reverse the location of the chocks to
the rear of the tires, remove the pin, push the tongue to the desired position and re-insert the pin.
Pole Binders
Pole binders are provided at each bolster position. Where pole hubs are present, wrap the strap under
the first binder hub, around the pole or poles, under the second binder hub and secure at the hook provided at the
opposite end of the trailer. Tighten the binder strap at the EZ Torque winch with the winch handle provided. The
EZ Torque winch does not lose strap tension when used with 2–4 wraps of strap on the winch shaft per the manu-
facturer’s recommendations. Too many wraps on the winch shaft can cause a situation where the strap can lose
tension depending on the level of tension in the strap. According to the manufacturer, but not verified with our
testing, less than two wraps can also cause a situation where the strap can lose tension because there are not
enough wraps to hold the end of the strap in place on the shaft.

This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521-PRC Combination Trailer
05/2017
Page 8
Components Sourcing Information
Item Item Number Description/Specification
AEP Options AEP Barricade Bracket Set
1.125"ID x 6"L Pipe w/ Stop Installed @ an Angle to
Allow an Inserted 60"L Rod to Extend Approximately
48" Above the Ground
Adjustable Uprights Z1147 Adjustable Upright Frame Set - 1521AP Style; Add
Saddles & Brakes - Galv
(2) 18501 Lower Urethane Slide
(2) 18502 Outer Urethane Slide
(2) 10283 5/8" x 5 3/4" Pin & Chain
Reel Bar 10340
10335
18595
14689
17704
2 1/4" Reel Bar Assembly Complete w/ Power Arm,
Knuckle and RBD2 Insert
74"L for 65"-66" Between Uprights w/o Retriever
Brake Assembly Complete
w/ 16" Bronze Disc & Tensioning Adjustment Wheel
Reel Positioning Collar w/ Hook - C2.25"
Includes 10387 Tapered Insert Sleeve – Bronze
2 1/4" Gen II Saddle w/ Retainer
Tubular Slide-In Reel Bar Holder
Side Packs Z1137 1521-PRC Series Side Pack Per Side; 14 Ga Stain-
less. Top Opening Lids w/ Paddle Latch Lock Height
Just Below Cargo Sides as Wide as Fenders; (7) AL
Dividers Fender Top Box; Drain Holes & Gas Cylin-
ders all Compartments
Lift D-Ring 12316
12317
D-Ring Only 3/4" Dia - 9120# WLL
D-Ring Bracket Only 2 1/2", 4"x6"x.25" Tubing Frame
- 64"W
Tongue Slide 18252
18250
Fixed Poly Slide Pad for 6" Tongue
Slide Boss For 5"-6" Tongue
Pole Chock 17812 Almag Pole Chock - Drilled - S1977
Pole Stanchions 8860 Pole Stanchion Assembly
Cat Track Assembly 19739
19740
Uniflex Link - Large 2.19" Pitch
Uniflex Large Bracket Set
Light bar 8840-4LED
11118
18388
4-Light LED AL Light Bar – Complete w/ 11118 6-Way
SAE Socket & 18388 Almag Cord Wrap Casting –
Machined
6-Way SAE Socket
Almag Cord Wrap Casting - Machined
Winches 19415 BOA EZ Torque Winch - C-Channel Drilled

This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521-PRC Combination Trailer
05/2017
Page 9
10868
16675
Binder Strap - 4"W x 20'L w/ 1026
EZ Torque Winch Handle
Lighting 17160
14021
17161
14020
18063
10448
10334
11121
LED Model 33 PC C/M w/ Grommet – Yellow
Rectangular Reflector Yellow
LED Model 33 PC C/M w/ Grommet – Red
Rectangular Reflector Red
120" Marker Lead Extension
2"W Red/White Conspicuity Tape
Stor-A-Way Plug Holder - 7-Way
7-Way SAE PermaPlug w/ Compression
License Plate Hardware 17387
18032
ABS Plastic License Plate Box
LED Model 33 License Lamp w/ Grommet
Wiring Harness 18065
18061
18062
Pole Trailer Harness – Electric
120" Harness System Main Extension
48" Wiring Harness System Main Extension
Socket Housing 13802 Almag Socket Housing Machined SHC2
13802.SLDDRW Machining - 11119 SAE 7-Way
Socket
Solar System 8854 4-Watt Solar Battery Box
Breakaway 19465
18011
Warner Breakaway Kit Complete
Breakaway Switch w/ 52"L 3/64" Vinyl Coated
Stainless Steel Cable & 19805 Spring Snap
Aluminum Breakaway Protector - S1397
Wheel Nut Indicators 19731 Wheel Nut Indicator N - 1 1/8"/28mm
Fits 006-209 5/8"-18 Swivel Flange Wheel Nut
Fits 006-058 5/8"-18 Flange Wheel Nut
Chain Assembly 17186
15265
3/8"-GR70 Clevis Slip Hook w/ Latch
3/8"-GR70 Transport Chain – Gold
(2) 46.5"L Sections - w/ Extension
8256ST 3/8-Grade 70 Chain Group
S1340 Crucifix Chain Traps
Grounding 15194 Bronze Grounding Lug w/ Holes
Tailgate Assembly 19565
18727
Stainless Steel Paddle Latch and Bolt Tailgate
Center Paddle Latch & Dual Side Slam Bolt Action
Latches w/ 90-Degree Hold Open Cables
DA 180 Finish Exterior w/ Rubber Bumpers & Con-
spicuity Tape
Heavy Duty Tailgate Cable
Hitch Extension 8818-B1 Hitch Extension For 3" Eye – Galv
Pintle Eye 11144 3" Flanged Pintle Eye - Galv
Insertion Pin 13116 Pole Trailer Insertion Pin
Wheel Chocks 8500 BOA EZ Torque Winch - C-Channel Drilled

This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521-PRC Combination Trailer
05/2017
Page 10
Chock Holders 8505 Almag Wheel Chock Holder - S1027ST
Registration Container 19275 Xenoy Registration Container w/ Poly Bag
Trailer Jack 19580 10K Center Mount EZ-Up Jack Complete w/ Sand-
shoe (1) Front LS Tongue; (1) Rear RS A-Frame
Outrigger Jacks 8805 Almag Wheel Chock Holder - S1027ST
Tire / Wheel Assembly 17702 215/75R17.5 LRH Tire/Rim - Goodyear - .31" Out
Jingu 6.75x17.5; .31" Out Single Galvanized Wheel
8 on 6.5" - 4500 lbs @ 125 PSI
4805 lbs @ 125 PSI; 30.2"Dia x 8.3"W – Goodyear
692 Rev. / Mile
Axle 12242
13996
12489
12538
9K Sprung Single Electric Axle
8 on 6.5" Hub w/ 12 1/4" x 3 3/8" SA Elec Brakes
Grease Hubs
5/8" Studs Flange Nuts for Use w/ 17.5" Wheels
72-10-2 2"W Mounted 4500 lbs Slipper Springs Un-
derslung 86" HF x 63" SC
9K Sprung Axle Hubface Over 80"
Single Hgr/AP Kit - 9K
38" Multi-Axle Kit - 9K
Mud Flap 10251 12"Wx18"L Plain Mud Flap - 1/4"T
Note: Most items listed here are in stock at Sauber Mfg. Co.
Maintenance
Operation ................................................................. Interval
Torque Wheel Nuts - See Components Sourcing - Axle ............ After 1st 50 Miles
Torque Wheel Nuts .................................................................... Monthly
Check Trailer Lighting ................................................................. Every Use
Check Tire Wear & Inflation Pressure ........................................ Monthly
Adjust and Inspect Trailer Brakes ............................................... Monthly
Check Trailer Suspension ........................................................... Monthly
Check Pintle Eye Wear ............................................................... Yearly
Check Battery Condition ............................................................. Every Use
Check Trailer Breakaway ............................................................ Every Use
Grease Hub Bearings ................................................................. Monthly