Sauber 1521-PRD Manual

Operation & Maintenance Manual
Sauber Mfg. Co.’s Model 1521-PRD Combination Trailer
10/2021
Page 1
Contents
Preface .................................................................................................................................................................................... 1
Component Sourcing Information .......................................................................................................................................... 1
Serious Hazards ....................................................................................................................................................................... 2
Check Prior to Moving ............................................................................................................................................................. 3
Check Prior to Towing ............................................................................................................................................................. 4
Maintenance Reference .......................................................................................................................................................... 9
Physical Dimensions and Component Detail ........................................................................................................................ 10
Suggested Work Methods ........................................................................................................ Error! Bookmark not defined.
Owner / Operating Company Work Methods....................................................................................................................... 10
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.

Page 2
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.
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.

Page 3
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.
 The trailer jacks are not fully retracted.

Page 4
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.

Page 5
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].
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.

Page 6
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) adjustments 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 recommendations 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 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

Page 7
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
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 towing.
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.

Page 8
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 manufacturer’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.
Power Source & Hoist
Your unit is equipped with our 19757 12VDC Power Source. The 2 HP motor delivers up to 3000 PSI at 1 GPM and
has an 8-quart hydraulic reservoir. The 2-Button tethered remote is labeled “UP” and “DOWN” and controls the elevation
and lower of the bed. Although the unit is equipped with a relief valve, avoid running the unit over relief. Doing so will
reduce hydraulic component life and put unnecessary stress on mechanical components.
The Class D/40 Hoist includes an integrated prop which should be used whenever personnel are servicing the
hoist or before an operator enters the space under the dump bed.
The system includes a 925 CCA AGM battery and a 10 amp fully automatic charger in addition to 10 watts of solar
charging. The automatic charger can be plugged in with the box cover locked for an extended period. The solar charger is
meant to keep the battery maintain and does not have the capacity to recharge a depleted battery.
Prior to using your power source ensure that the reservoir is filled with fluid. Check this with the dump bed fully
retracted. Your unit was shipped with AW32 all-weather hydraulic fluid. Check the system for fluid leaks or exposed
wiring. Check the condition of the oil and replace it if is discolored or dirty.
Physical Dimensions and Component Detail

Page 9

Page 10
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
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.