Sauber 1521 Manual

Operation and
Maintenance Manual

Valued Customer:
Please review the following manual. If you have any ques-
tions or need assistance of any kind, please contact your
account representative toll free:
Voice Communications.............................. 800) 323-9147
Fax Communications................................. 800) 833-3264
We welcome feedback on your manuals and our marketing
communications. We need, and are driven to constantly improve.
If you have any suggestions, comments or criticisms we’d love to hear from you.

Custom Engineered For Delmarva Power Company
S/N 1F9UZ2224BV048188 & 1F9UZ2222BV048187
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 dur-
ing 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.
•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.
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521 Pole, Reel and Cargo Trailer
10/2011
Page 1

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
possible.
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
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 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.
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521 Pole, Reel and Cargo Trailer
10/2011
Page 2

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. Improper rig-
ging 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 de-
signed 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 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 at-
tached to the towing vehicle and not to any part of the hitch. Before towing the trailer, test the system. If the sys-
tem 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
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521 Pole, Reel and Cargo Trailer
10/2011
Page 3

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.
If your trailer has hydraulic, or “surge” brakes, pull the emergency breakaway lanyard to check the operation of
the emergency brake system.
Straight Air Brake Systems
Air systems include spring applied brakes as standard equipment. There is no breakaway cable; connect-
ing the emergency and service glad hands is all that is required. The spring brakes are shipped in a mechanically
retracted position for receiving and handling purposes. They must be activated prior to use. Loosen the nut on the
threaded rod located on the back side of the spring brake canister. Rotate the threaded rod one quarter turn, re-
move the threaded rod and insert it in the storage pipe provided on the brake actuator casting. Insert the rubber
plug provided into the center spring brake canister hole.
ABS Information
If your trailer is equipped with and anti-lock braking system. Anti-lock brakes greatly enhance trailer
stability while braking. Because a sliding wheel always leads, a brake lockup situation under manual braking can
cause loss of control as the trailer slides sideways. Anti-lock brakes provide the electronic and physical control to
prevent wheel lockup and the ensuing control problems. Although Anti-lock brakes may not necessarily help you
stop over shorter distances, it will help keep you in control while eliminating excessive tire wear and flat spotting.
Anti-lock brakes use microprocessor technology to sense when the wheels are about to lock up under braking
and then controls the brake pressure and timing to prevent it. Each wheel must be controlled independently, al-
though only one axle of a multi-axle configuration needs to be equipped with sensors. An exciter ring (sometimes
referred to as a tone ring) is installed on the inside of the hub. A sensor reads the level of magnetism present as
the teeth of the exciter ring pass it. Since they don’t touch, there is no wear or friction between them. The sensors
provide wheel speed information to the Electronic Control Unit (the ECU or system brain). Input from the sensors
is used to determine if a wheel is about to lock during braking. If so, the system can release and apply the brake
up to six times per second through the modulator valve.
The system is powered by the stoplight circuit. This allows any of your trucks currently equipped to pull
trailers to be used with a Sauber ABS equipped trailer. The system is off while the brakes are off and powers on
and checks itself when the brakes are applied. It is so fast that it can test itself sixty times before air from the tow
vehicle gets to the trailer brake valves. A warning light is provided on the trailer side and will illuminate if any com-
ponent is not functioning. The system will continue to have normal brakes until the problem is resolved. Although
there are no batteries in the system, the electronic control unit (ECU) has a special microprocessor that can re-
member up to ninety-nine problems and keep them stored until they’re fixed. A number displayed on the hand
held display unit (DDU) identifies one of sixty-three fault codes - providing accurate and quick troubleshooting.
This unit is available from Sauber Mfg. Co. and should be kept at each garage location expecting to service ABS
brakes. All cables are sealed, weatherproof and polarized to provide high reliability and mistake-free serviceabil-
ity.
Air Over Hydraulic Brake Systems
Air over hydraulic systems have a built-in valve to allow application of the hydraulic trailer brakes in the
event of a breakaway. The energy for this operation is stored in the air tank of the system. Therefore, once the air
is expended, braking power is released unless equipped with a spring brake mechanism.
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521 Pole, Reel and Cargo Trailer
10/2011
Page 4

Hydraulic Brake Systems
Straight hydraulic systems are equipped with a surge-actuated braking system. Pressure exerted on the
towing eye is transferred to the axle brake hydraulic cylinders. The greater the braking inertia, the more pressure
is applied to the brakes. An over-center actuator provides breakaway protection.
•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.
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 compon-
ents. 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 is 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 prac-
tices.
•Outriggers
Stability is an important part of safe trailer use. Because the towing vehicle can provide additional stabil-
ity, 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.
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521 Pole, Reel and Cargo Trailer
10/2011
Page 5

•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].
Series 1602 Tensioning Brake
Apply the brake by rotating the tensioning adjustment wheel clockwise. Continue to apply braking pres-
sure 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).
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.
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.
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 recommend-
ations follow:
GeneralSauber Mfg. Co. builds standard extendible tongue pole trailers w/ five length 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 for-
mula:
(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 information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521 Pole, Reel and Cargo Trailer
10/2011
Page 6

Recommendations
The following guide indicates the recommended adjustment position for each pole shown. "Muzzle" indic-
ates that the pole would require a pole muzzle which can be used in conjunction with our extendible trailer. If cus-
tomer requirements include carrying larger poles within the confines of the extendible tongue, we have three op-
tions. 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.
Computed Trailer Length / Recommended Position Chart
Pole Length & Class Standard Pole Trailers Combination Trailers
Empty................................................................n/a / # 1 (closed).............................n/a / # 1 (closed)
20' - Class 2.......................................................16' / # 1............................................17' / # 1
25' - Class 3.......................................................17' / # 1............................................18' / # 1
30' - Class 1.......................................................20' / # 2............................................21' / # 1
35' - Class 1.......................................................22' / # 3............................................23' / # 2
40' - Class 1.......................................................24' / # 4............................................25' / # 3
45' - Class 1.......................................................26' / # 4............................................27' / # 4
50' - Class 1.......................................................28' / # 5............................................29' / # 5
55' - Class 1.......................................................29' / # 5............................................30' / # 5
Above 55'...........................................................Muzzle...............................................Muzzle
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.
Rear Light Bar Use
The integral rear light bar can be removed and fastened to the rearmost pole. By connecting the exten-
sion coil cord provided, approved lighting can be used regardless of the overhang present. Remove the retaining
clips from the light bar in the rear channel. Fasten the light bar at the top of the rearmost pole and tighten the
strap until the light bar is seated securely into the pole. Wrap the coil cord around the pole or poles and connect it
into the rear socket provided.
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521 Pole, Reel and Cargo Trailer
10/2011
Page 7

Components Sourcing Information
Item...................................Source....................Description/Specification
Tires............................................Major Brand...................12.00 x 16.5, LR F - 75 PSI
Wheels........................................Dexter............................9.75 x 16.5 8 on 6.5”
Axle.............................................Dexter............................8K/Slipper Springs
Brake Kit.....................................Blue-Dot.........................# 1927-001 Air Brake Kit
Installation Manual.....................Haldex............................# L30027 Full Function Mod 1
ABS Components........................Haldex............................# 400211 2-Port Valve
# 400210-BA Wire Loom
# 201186-JD Power Cable
# AQ15463 2” Light w/ Grommet & Pigtail
ABS Tandem Kit.........................Sauber...........................Z1331 Air/ Hydraulic
Tandem Brake Cable Kit............Sauber...........................18358
Multi-Axle ABS Air/Hydr Sprung.Sauber...........................18361
Hubodometer..............................Sauber...........................1130 w/10526 Hubo
Pintle Eye...................................Holland...........................11144, 3" I.D.
Safety Chain...............................Sauber...........................8256ST 3/8” Grade 70 Chain Group w/ 8250ST Cru-
cifix Chain Traps – 26400# Breaking Strength
Clevis Slip Hook.........................Sauber...........................17186, 3/8” -GR70 w/Latch
Transport Chain..........................Sauber...........................15265 3/8” -GR70 Gold Chain – Galv -43”L w/Hitch
Extension
Hitch Extension..........................Sauber...........................Model 8818-B1
Striping.......................................3-M.................................# 29804-SP DOT-C2, 2"W Red/White
Winch Strap Only.......................Sauber...........................10868 4 “x20’L w/D-Ring
Winch .........................................Sauber...........................16674 EZ Torque Winch w/ 16675 Handle
J-Hook........................................Sauber...........................12955Winch Binder Sauber 14147 4 “x20’L w/
1026 D-Ring
Lightbar.......................................Sauber...........................8840-2LED
Tongue Jack...............................Sauber...........................17189 EZ-Up jack w/Sandshoe
Outriggers...................................Sauber...........................Model 8805
Grounding Lug............................Sauber...........................15194
Grounding Reel..........................Sauber...........................17696 w/ 50' 2/0 Cable
Electrical Connector...................SAE................................11121, 7-Way
Lighting.......................................Truck Lite.......................2-Lite LED Sealed Beam/Sealed Wiring Group
Registration Container................Truck Lite.......................16755 HD, Aluminum
Wheel Chocks............................Sauber...........................Model 8500 w/ 8505 Holders
Solar Battery System..................Sauber...........................Model 8852 2-Watt
Breakaway..................................Warner...........................10475
Tensioning Brake.......................Sauber...........................Model 1602
Retriever.....................................Sauber...........................Model 1000
Hinge Collar................................Sauber...........................Model 1250 w/ 10387 tapered sleeve
Note: Most items listed here are in stock at Sauber Mfg. Co.
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521 Pole, Reel and Cargo Trailer
10/2011
Page 8

Sauber Mfg. Co. Standard Wiring Code for Trailers
Function From ABS/ECU (as applicable) 7-Way SAE ABS Socket
Terminal ID / Color / Pos 7-Way SAE Socket Terminal ID / Color / Pos 6-Way SAE Socket Terminal ID / Color / Pos
LT n/a 3 / Yellow / 4:00 3 / Yellow / 4:00 LT / Yellow / 4:00
RT n/a 5 / Green / 8:00 5 / Green / 8:00 RT / Green / 7:00
Ground White 1 / White / 12:00 1 / White / 12:00 GD / White / 2:00
Brakes Blue 7 / Blue / Center 7 / Blue / Center A / Blue / Center
Clearance/Tail n/a 6 / Brown / 10:00 6 / Brown / 10:00 ™ / Brown / 12:00
Stop Red 4 / Red / 6:00 4 / Red / 6:00 S / Red / 10:00
Breakaway n/a n/a Black / To Battery Black / To Battery
Notes:
Clock positions are as viewed from male pin side
Center pin on chassis is expected to be wired hot on ABS
4-Lite systems will be wired in parallel unless otherwise noted
If clearance and tail need to be run on separate circuit, breakaway wire (orange) must be run outside 7/C Cable.
Breakaway may be wired directly to battery or through the 7/C cable depending on proximity to battery box.
7/C Cable - (6) 12 Gauge; (1) 10 Gauge - White
All Primary & Brake Feed Wire: 12 gauge
All Secondary Feed Wire: 14 gauge
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
Check Oil Bath Level in Axle Hubs.............................................Monthly
Torque Saddle Bolts....................................................................Yearly
1/2"-Grade 8 fastener: 130-135 ft-lbs
5/8"-Grade 8 fastener to 140-145 ft-lbs
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & Maintenance Manual
Model 1521 Pole, Reel and Cargo Trailer
10/2011
Page 9

Care and Use of EZ Torque Winches
MAINTENANCE:
-The gear mechanism requires periodic lubrication to maintain proper function. It is important to use premium
grade 2 lithium based bearing grease with molydisulfide.
-The grease fitting is located on the back of the gear housing and mates with a standard zerk adapter on a grease
gun.
-Inject grease until it comes out either the main shaft bushing or the input hex drive shaft bushing.
OPERATION:
-Turn the input hex drive counterclockwise to disengage from the main gear. The hex drive shaft will move
outward from the gear housing.
-With the gears disengaged, the main shaft can be turned by hand using the hand wheel.
-Pull excess binder strap webbing through the web slot in the main shaft as with a standard winch. Using the
hand wheel, rotate the main shaft and snug up the binder with 1 ½ to 2 wraps on the spool.
-Turn the hex drive clockwise to engage the gears and continue to turn clockwise to apply tension to the binder.
Six to ten turns of the input hex drive should be sufficient. Do not over tighten.
-Using a portable power drill with a 1” hex socket is an optional way to turn the hex input shaft. DO NOT use
the “hammer” setting available on some drills and DO NOT use an air impact wrench to drive the hex input
shaft. Most power drills do not have sufficient torque to fully tighten the binder straps and one or two turns
using the EZ Torque Crank Handle may still be required.
CAUTION
Use only the EZ Torque Crank handle for tensioning the EZ Torque Winch. Use of
longer handles will produce excessive strap tension, may damage the gear mechanism and
will void the warranty.
-Applying 40 to 60 lb to the end of the EZ Torque Crank will result in approximately 1500 lb of strap tension. By
increasing the applied force to the EZ Torque Crank to 100 to 140 lb, strap tension of approximately 2200 lb
can be achieved. Additional strap tension is not needed to adequately secure typical cargo.
EZ Torque Crank Handle
BINDERS:
-EZ Torque Winches are designed for use with webbing strap binders only.
-Do not use cable binders with EZ Torque winches.
-Do not use damaged, deteriorated or cut web binders. See CVSA guidelines for out-of-service criteria.
-Check binders periodically during transit and re-tighten as required.
MODIFICATION OR MISUSE:
-Any modification or misuse of the EZ Torque Winch will result in voiding the warranty and liability
responsibility of Ancra International.
-Do not use as a lifting or pulling device.
-Do not use tensioning bars other than the EZ Torque Crank Handle, which is designed specifically to work with
the EZ Torque Winch.
ANCRA INTERNATIONAL LLC CARGO SYSTEMS, ERLANGER, KY 41018
Ancra International LLC proprietary rights are included in the information disclosed herein. Recipient, by accepting this document,
agrees that neither this document nor the information disclosed herein nor any part thereof shall be reproduced or transferred to
other documents or used or disclosed to others for manufacturing, technical or any other purpose except as specifically authorized
in writing by Ancra International LLC. Unpublished - all rights reserved under copyright laws.
© 2008 Ancra International LLC EZ-01 18-08-08

Operation of Winches
•Before tensioning, pull excess webbing through mandrel slot. When the tie
down is fully tensioned, two (2) to four (4) wraps of webbing shall be on the
mandrel (4 to 8 layers of webbing). Additional wraps can cause damage to
the winch due to excessive torque, or make it difficult to apply or release
tension.
•When tensioning or releasing the winch in rain, snow, or other slippery
conditions, carefully position your feet and body to prevent a fall.
•Use only winch bars that have been designed to tension and release winch
tie downs. A slip resistant handle is recommended. Never use a bar or
tube as an improvised winch bar as they can slip out of the end cap holes
and cause injury.
•The winch bar shall be inserted through both sides of the winch end cap.
Using only one (1) hole in the end cap can damage the winch and the bar
tip, causing them to fail and cause injury.
•An extender (“cheater bar”) shall never be used to apply tension to a winch
tie down assembly. Extenders can overload the assembly or slip off, and
can cause injury in either case.
•When tensioning or releasing the tie down assembly, always stand to one
side of the winch bar in case it slips. Maintain a firm grip on the winch bar at
all times, and check to see that the pawl is properly and completely
engaged in the sprocket teeth before releasing the bar. See Fig. 2.
•Winches shall not be positioned between the tire and the bed of the vehicle
as this creates a potentially hazardous condition.
•The set screws on portable winches are designed to hold the winch in
position while the tiedown is being tensioned. They shall only be “snug”
tight as overtightening may damage the winch or winch track and cause a
failure in service.
•Winches shall never be loaded in excess of their working load limit (WLL).
•Winches shall be used in accordance with all applicable federal, state,
local, and industry regulations applicable to cargo securement.
•A training program for truck drivers is recommended for the correct and safe
use of cargo securement systems.
NOTE: This document lists the most commonly encountered considerations
for the proper maintenance and operation of winch tie-down assemblies, but it
is not an all-inclusive list.
Sauber Mfg. Co. Note:
In preparation for shipping, nearly the entire length of the strap is wrapped on
the EZ Torque winch mandrel. However, the operator needs to ensure that 4-8
layers of webbing are on the winch mandrel when the winch is fully tensioned
per Ancra's recommendation. Our internal test results confirm that too few or
too many wraps can result in the release of strap tension which will create a
dangerous condition when carrying poles.

We Guarantee
Sauber Manufacturing Company guarantees satisfactory
operation of its products and will refund the full purchase
price to utility customers who are not fully satisfied.
We Warranty
We specifically warranty that our products will be free
from any defective materials or workmanship when
purchased. We will repair or replace, at our option, any
part(s) that prove to be defective within the warranty
period specified below. This warranty is voided only by
evidence of misuse, and does not include shipping
charges.
Sauber Manufacturing offers the industry’s only 10-year, comprehensive, trailer warranty. This warranty comes at
no charge to our customers, yet covers parts and labor on all Sauber manufactured components.
As a leader in the utility industry, we have the financial strength and have demonstrated the integrity necessary
to honor our commitments. This expanded warranty is a clear extension of who we are, what type of equipment
we build, and how we are investing in our future and yours.
•10 Year Structural, Parts & Labor on all Sauber Manufactured components
•10 Year Galvanized Finish Warranty
•3 Year total Parts & Labor Coverage
•Retroactive total parts & labor coverage includes all trailers built after 04/01/2006
•All warranty support will be provided directly from Sauber Mfg. Co.
•Customer Labor Reimbursement @ $65/hour
•A credit memo will be issued for claims under $400 and can be applied to a credit card
For additional details about our warranties, contact your sales professional, and thank you for investing in Sauber
Manufacturing equipment.