Sauber 1539 Manual

Operation & Maintenance Manual
Sauber Mfg. Co.’s Model 1539 Three Reel Turret Trailer
05/2020
Page 1
Contents
Preface .................................................................................................................................................................................... 1
Component Sourcing Information .......................................................................................................................................... 1
Serious Hazards ....................................................................................................................................................................... 2
Check Prior to Moving ............................................................................................................................................................. 3
Check Prior to Towing ............................................................................................................................................................. 4
Maintenance Reference .......................................................................................................................................................... 6
Suggested Work Methods ....................................................................................................................................................... 7
Owner / Operating Company Work Methods....................................................................................................................... 11
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:
 Website: https://saubermfg.com/sauber-contact-about/
 Phone: [phone]
The following manual provides important safety information and instruction. Please read this manual before operating
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.
Component Sourcing Information
Our equipment is designed and built with operators and maintenance personnel in mind. To this end, non-rusting
hardware and bolt-on / bolt-off componentry is used at every possible opportunity. This encourages routine
maintenance by making the work easier on the technician, as well as on the equipment. Sauber Mfg. Co. will have most
of the components that might need replacement in stock at our facility, and we are always ready to help get you any
replacement parts you might need.

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Serious Hazards
D
RIVING
B
EHAVIOR AND
C
ONDITIONS
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 blowout.
Decrease your speed as road, weather, lighting, and other conditions decline.
I
MPROPER
S
IZING OF THE
T
OW
V
EHICLE
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
drivetrain 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.
O
VERLOADING 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 possible.
Make certain the tongue weight is within the allowable range. Keep the center of gravity as low as possible.

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U
NSECURED 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 properly-sized fasteners. Always secure doors or lids if
present on your trailer by securing its latch.
I
MPROPER 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 steering inputs
and more likely to be have its stability affected in windy conditions or when passed by large vehicles. You will also need
to adjust driving accordingly, i.e. taking a longer distance to pass and allowing for increased braking distances, etc.
Taking common-sense measures will be necessary, such as:
 Being alert for slippery conditions
 Anticipating trailer sway, being ready to reduce speed and using small, trim-like steering adjustments to regain
control
 Check rear view mirrors frequently to evaluate trailer towing and traffic conditions
 Using a lower gear when driving downhill or on long grades
 Being aware of your trailer height always, especially when approaching bridges and roofed areas.
I
MPROPER 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 breakaway 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. Compatibility
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.
Check Prior to Moving
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 coupling of the trailer can still be maintained. Improper rigging of the
safety chains could result in loss of control coupling. 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.

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 The trailer jacks are not fully retracted.
Check Prior to Towing
Do not tow the trailer on the road until:
Trailer Breakaway System
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 detached 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. Before towing the trailer, test the system. If the system is not working, do not tow the trailer and have it
serviced or repaired.
Tires and Wheels
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 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. Our wheel nuts are torqued to manufacturer specifications and are then fitted with high-visibility
wheel nut indicators. The indicators are fitted in a uniform pattern, so when a wheel nut has loosened, the
indicator will become out of sequence. The wheel nut indicators are also heat sensitive. If there is a binding
brake or seized bearing, the heat is transferred through the stud and nut. If this temperature exceeds 120º C
(248º F), the indicator will start to blister around the circumference and eventually start to distort. Pre-flight
walkaround checks should include wheel nut checks.
Lighting, Signaling and Brakes
Be sure the trailer brakes and all the general and signaling 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.

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Proper Tongue Weight
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 designed to transfer less because of the limited capacity of the towing vehicle’s rear axle.
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
components. 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 exceed their
GAWR and the entire trailer and load does not exceed the GVWR rating.
Grounding
Your trailer may be equipped with a bronze grounding lug. When the trailer is used near energized conductors
the trailer must be grounded. A grounding lug is provided to help you follow your company’s safety practices.
Outriggers
Stability is an important part of safe trailer use. Because the towing vehicle can provide additional stability, leave
it connected to the trailer when you can. Set the rear outriggers to their lowest level. If you need to decouple
the towing vehicle, lower the front jack slightly, set the outriggers and then raise the jack to seat the outriggers
firmly in the ground.
Wheel Chocks
Set the chocks at each rear wheel in the direction of the expected load or grade.
Trailer Modifications
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
inadvertently damage an electrical wire or other hidden component. Before making any alteration to your
trailer, contact Sauber Mfg. Co. at [phone].

Page 6
Fuel and Battery Levels
Ensure any on-board fuel sources in spare gas cans, or power sources are in adequate quality and supply before
departure to the work zone. Additionally, check the voltage and load test, if possible, any on-board batteries to
ensure maximum capacity at the work zone.
Maintenance Reference
Operation
Interval
Check Trailer Lighting
Every Use
Check Battery Condition
Every Use
Check Trailer Breakaway
Every Use
Torque Wheel Nuts
First 50 Miles, then Monthly
Check Tire
Wear and Inflation Pressure
Monthly
Adjust and Inspect Trailer Brakes
Monthly
Check Trailer Suspension
Monthly
Check Oil Bath Level in Axle Hubs
Monthly
Inspect Any Hydraulic Hoses and Connections
Monthly
Check Pintle Eye Wear
Annually
Grease Turntable Bearing ..................................................................... Every 6 Months
Torque 5/8"-Grade-8 Turntable Fasteners to 200 ft-lbs ............. Within First 6 Months; Then Yearly
** Tighten progressively @ 180-degree intervals
** If 20% of all bolts have less than 80% of prescribed torque replace all bolts.
** If one or more bolts are loose to less than 80% of the prescribed torque replace these and adjoining
bolts.
Replace Turntable Fasteners ...................................................... Every 5 Years
Inspect Turret Positioning System .............................................. Quarterly
Inspect Reel Frame for Cracks and Deformation ....................... Quarterly
Torque Saddle Bolts.................................................................... Yearly
1/2"-Grade 8 fastener: 130-135 ft-lbs
5/8"-Grade 8 fastener to 140-145 ft-lbs

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Physical Dimensions and Component Detail
Suggested Work Methods
I
NTRODUCTION
There is no single, standard work method to assign to this trailer. As with any other tool in the line worker’s toolbox,
practices and methods will need to be outlined according to the individual organizational requirements. The last section
of this document is a provisional space for any work methods that might be specific to the owner / operating company-
specific work methods.
Turrets
Your trailer is equipped with one or more rotating turrets. The turret frames are galvanized and can be removed,
allowing the trailer to be used for other applications. These individual frames can also be used on other transportation
equipment to string wire. The turrets are free turning and can be locked on fifteen-degree intervals by a spring-loaded
locking device. Always stop the reel rotation before locking it into place. Large forces from heavy, turning reels can
damage the locking mechanism if an attempt is made to lock the reel while rotating.
Series 1602 Tensioning Brake
Apply the brake by rotating the tensioning adjustment wheel clockwise. Continue to apply braking pressure until
the desired wire sag is present. The brake has a maximum torque of 3000 ft-lbs. This provides 3000 lbs of line tension 1’
from the reel bar center. If wire is filled to 2’ from the reel bar center the resulting line pull would be 1500 lbs (3000/2).

Page 8
The reel bar can be removed with a continuous sling. Loop the sling through the hooks on the power arm and
reel positioning collar and elevate the load line. Your tongue and groove assembly will automatically line up. There is
nothing to disassemble.
Power Source
Preface
Thank you for choosing Sauber Mfg. Co. Your new generation Power Source represents the state of the art in
mobile hydraulic power. We welcome your suggestions on its improvement and stand willing to assist you if any
questions arise during its operation. With a very small amount of maintenance, and by understanding its operation, your
Hydraulic Power Source will provide you with years of good service. If we can help you in any way please contact your
national account representative toll free:
Voice Communications: [phone]
Fax Communications: [phone]
Principle of Operation
Your power source is designed as a compact, reliable source of hydraulic power. It features the best power plant
technology available. The vertical shaft engine is mounted directly to the power source cover. Beneath the cover
a mounting bracket houses the hydraulic pump. The pump is driven through a flexible shaft coupling set. It draws oil
from the tank bottom through a suction strainer. Pressurized oil is delivered through a manifold providing flow and
pressure regulation prior to being delivered to the tool. Oil is filtered prior to returning to the tank.
Pre-Operation Checks
Prior to using your new power source, make a complete review of the engine information provided with this
manual. After doing so, invest a few minutes prior to starting the power source to perform these simple checks:
•
Fuel Level
•
Engine Oil Level
•
Recoil Rope Condition
•
Air Cleaner Condition
•
Hydraulic Oil Level and Condition
•
Signs of Excessive Hydraulic Leaks
Engine Starting & Operation
To assure easy starting be sure the pressure and return hoses are connected to our Retriever or any tool that will
allow oil to circulate to the system tank in neutral. The valve spools in these tools are commonly referred to as “open” or
“tandem” center spools. An attempt to start the power source without this connection will result in an engine stall
condition and will strain the engine and pump components. If the engine is cold, the choke will be required. On single
cable systems, pull the throttle out as far as possible to engage the choke. Depressing the control will disengage the
choke. If the choke is controlled separately, its function will be labeled. Pull the cable out to engage the choke, push in to
disengage. On electric start models, engage the starter with the keyed switch provided or pull the recoil rope with the
key switch in the “RUN” position.

Page 9
When work is being done, the power source should normally be operated at full throttle. This will provide maximum
power capability. The unit should be returned to idle or shut off when power is not required. This will help reduce system
heat build-up and conserve fuel. Although the unit may be run at “mid-throttle” to conserve fuel or reduce noise, recognize
that the engine will stall prior to reaching system relief pressure. Flow is also reduced anytime the engine is operated at
less than full throttle or when the flow control knob is rotated counterclockwise.
Use with Sauber Retrievers
Your power source was designed so that both Retrieving and Tensioning functions can be used without
disconnecting hydraulic lines. Therefore, once the hydraulic lines are connected, they will need to be removed only to
run other hydraulic tools. Sauber Retriever valves include an internal relief; therefore, your power source relief should be
set to the maximum level while operating Sauber Retrievers. Disengage Retriever when tensioning.
Use with Sauber Brakes
The power source will have no effect on brake unit operation. The power source can be off or running,
connected or unconnected during brake operation.
Hydraulic Leaks
With any hydraulic system, some small amount of leakage and spillage are common; but, persistent leaks pose a
problem from a clean-up and operation standpoint. When hydraulic oil is found, check the following areas:
Quick Couplers
Tighten or replace as necessary; try dripless fittings if problem persists
Tank Lid
Remove tank lid and re-seal w/ new gasket and gasket compound
Engine Mounting
Remove tank lid and engine and re-seal w/ gasket compound
Sight Gauge
Remove sight gauge and replace O-rings or entire gauge
Tank Drain
Tighten drain plug
Return Line Filter
Tighten or replace filter
Pressure Manifold
Remove cover and tighten fittings or replace O-rings
Oil Filtration
Keeping the oil clean in your power source is one of the best precautions you can take to ensure maximum
system life. There are three components to the filtration system. The sump strainer, located inside the tank, filters large
particles introduced into the tank. The return line filter is located outside the tank. This filter has a back-pressure gauge
that shows relative filter effectiveness. As the filter becomes dirty and clogged, the dial will move into the red area of the
gauge. This signals that a filter change is required. The third element of the filtration system is the fill/breather element.
This filter is designed to keep large scale impurities from entering the tank during fill operations. Hydraulic oil works at
peak performance when it is pure. Therefore, change the oil and flush the tank if water or impurities inadvertently enter
the system. A drain plug is provided at the base of the tank. Always change the return line filter with the hydraulic oil.

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Oil Level/Temperature Gauge
At the power source side a sight gauge has been installed. This gauge shows the level of hydraulic fluid in the
tank, its temperature and visual condition. Look for signs of impurities or water (cloudiness) in the glass. If found, refer to
the oil filtration section above. On level ground, the optimal oil level is 1” from the top of the sight gauge. Over-filling the
tank will result in leakage through the tank/lid seal. Low oil levels will cause increased system heat and may “starve” the
pump resulting in loss of flow and pressure. Check the temperature gauge periodically during use. Hydraulic oil
temperatures should not exceed 250 degrees Fahrenheit. If this temperature level is encountered, we recommend an
optional oil cooler for your system.
Pressure Gauge & Control
Your unit is equipped with a gauge that indicates operating pressure in pounds per square inch (PSI). While in
operation, the system pressure gauge will indicate pressures between 50 PSI and the maximum pump pressure shown in
the Components Sourcing Information section. The system pressure should correlate to the amount of work being done
by the tool in use. If it appears that this relationship is not true, check for restrictions in the line or excessive heat build-
up.
The maximum system pressure can be controlled by changing the relief setting at the side of the power source. Turn
the relief screw counterclockwise to lower the relief setting. Rotating it clockwise will raise the relief setting. Always make
certain the relief setting is set at least 100 PSI below the engine stall level. Many tools, including our Retrievers have their
own internal relief. The lowest relief setting in the system will prevail. Set the power source relief at the maximum level
unless you wish to limit maximum tool power or your tool does not have internal relief.
If the power source will not produce its rated pressure, check other reliefs in the system. Also check for blockage
between the pump and the pressure manifold/gauge. In order to produce maximum pressure, the engine must be running
at top performance. Any reduction in engine horsepower will reduce system pressure and/or flow. If engine performance
is satisfactory, check the pump output.
Hour Meter
Your system is equipped with an hour meter. Use this meter to track service intervals shown in maintenance
section.
Flow Gauge & Control
Tool speed can be controlled by the flow control knob located above the “Slower/Faster” placard. The flow can
be read directly from the flow meter located on the instrument panel. Flow is indicated in liters per minute (LPM) and
gallons per minute (GPM). For most applications full flow is recommended. Some tools, however, require specific flow
rates for optimal performance. This information should be available from the tool manufacturer’s documentation.
Sauber Retrievers can be operated at flows up to 20 GPM and therefore can be run at full flow. If oil flow is at or near 0
GPM rotate the flow control clockwise until desired flow is restored. If flow does not respond, check the hydraulic oil
level in the tank and ensure that the unit is not being operated on a slope exceeding 10 degrees. Finally, check the
condition of the pump.
Maintenance
Operation ................................................................................................. Interval
Check Fuel Level ...................................................................................... Each Use
Check Hydraulic Oil Level ........................................................................ Each Use
Check Recoil Rope Condition................................................................... Each Use
Check Air Cleaner .................................................................................... Each Use
Check For Hydraulic Leaks ....................................................................... Each Use

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Check Engine Oil ...................................................................................... Each Use
Check Hydraulic Filter Back Pressure Gauge ........................................... Each Use
Clean Fuel Tank & Strainer ...................................................................... 12 Months or 300 Hrs
Check Fuel Line ........................................................................................ 12 Months or 300 Hrs
Clean Air Cleaner ..................................................................................... 3 Months or 50 Hrs
Clean/Gap Spark Plug .............................................................................. 6 Months or 100 Hrs
Clean Spark Arrester ................................................................................ 6 Months or 100 Hrs
Adjust/Check Valve Clearance ................................................................. 12 Months or 300 Hrs
Replace Return Line Filter ....................................................................... 50 Hrs or at “Red” Gauge Reading
Replace Suction Strainer ......................................................................... 300 Hrs
Replace Fill Screen/Breather ................................................................... 100 Hrs
Change Hydraulic Oil & Filter .................................................................. 100 Hrs
Check Hydraulic Relief Setting ....................................................................... 6 Months or 100 Hrs.
Owner / Operating Company Work Methods
This section is provisional space for work methods that would be specific to the owning or operating company.
Incorporating the company-specific work methods here may provide for more thorough adherence to safety procedures
prescribed here by Sauber Mfg. Co., as well as those that might be prescribed by the operating company itself.