Sauber 1572 Manual

Operation & Maintenance Manual
Sauber Mfg. Co.’s Model 1572 Rapid Overhead Deployment Trailer
10/29/2018
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
Physical Dimensions and Component Detail .......................................................................................................................... 7
Suggested Work Methods ....................................................................................................................................................... 8
Owner / Operating Company Work Methods....................................................................................................................... 12
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
DRIVING BEHAVIOR AND CONDITIONS
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.
IMPROPER SIZING OF THE TOW VEHICLE
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.
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.

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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.
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 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.
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 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 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.

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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. The sealed breakaway with charging circuit and LED battery condition indicator allows
your operators to check the system with a quick pull of the plunger. A green light shows the battery is charged, wiring is
connected, and the system is ready.
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 is 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 (630)
365-6600.
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.

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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

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Physical Dimensions and Component Detail
Collapsed, transportation-ready dimensions
Typical deployment Dimensions

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Suggested Work Methods
INTRODUCTION
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 following
points illustrate a rubric for operation, in the order of operation, but do not necessarily represent all potential
operational methods and orders for the device. 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.
CAPABILITIES
This trailer has been designed to and tested against the loading specifications for a 50’ wooden pole provided to Sauber
Mfg. Co. by a public utility. The trailer’s moment load rating 21,778 ft.-lbs. It can withstand side strain of 500# @ 40’,
600# @ 35’, 725# @ 30’ and 850# @ 25’.
UPON WORK SITE ARRIVAL
 Conduct a thorough job brief prior to beginning any work to ensure everyone understands the operation of the
unit and the potential hazards
PRIOR TO TRAILER DEPLOYMENT
 Check that the ground is firm enough to support the trailer and pulling vehicle
 Check that the area is free of obstructions for trailer maneuvering and placement, as well as for boom
deployment and rotation
 Approach the work area in a safe direction and manner, positioning the trailer either
o Underneath the destination location if using a centered cross-arm
OR
o Alongside the line of conductor, if using an offset cross-arm
 Use a spotter to direct the vehicle when backing up
WIRED AND REMOTE OPERATION
 Whenever possible, operate the unit using the wireless remote controls, which will achieve improved safety
through increased distance between the operator and the work zone, and greatly-improved visibility of the work
zone itself
 Only perform movements of one component at time when operating any boom section, turntable rotation, or
outriggers
 Valve operation
o Slide the outrigger lockout panel out of the way to enable operation of the valves
o Actuate the movement of the components using the labeled valves at the control box
 Remote operation
o Ensure the M-Stop button is in the disengaged (up) position to enable operation (alternatively, a push of
this button will disable the remote controls)
o The wireless remote control is turned on with the green button on the left, underside of the unit
o The transmitter will attempt to sync with the receiver in the control box; the Tx / Rx buttons will flash
green / amber, respectively when sync has been successfully completed

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o Operate the controller by first selecting the desired device to operate from the row of momentary
switches at the bottom of the controls with the left hand, and drive the device in the desired direction
using the joystick with the right hand
 Both the momentary switch as well as the joystick need to be actuated for movement to occur,
preventing unintended actuation
o The remote will turn off automatically after 5 minutes of inactivity and will need to be turned on and
synchronized with the transmitter prior to use
o To turn off the remote manually, press and hold the green button on the bottom of the remote for 3
seconds, or push the M-Stop plunger switch
o Compartment keys and additional remote batteries are kept on the Xenoy container within the control
box
TRAILER DEPLOYMENT
 Always perform a thorough check of the work area taking extra precaution to ensure there are no people in the
boom’s potential area of reach while the unit is powered on
 Turn on flashing marker lights from the control box
 Consider any additional conspicuity measures to take such as barricades, caution cones, etc. to clearly indicate
the work zone
 Always ground according to the methods outlined and accepted by your organization; this unit is not
dielectrically certified, and is to be treated as any other pole-like structure whose dielectric properties are not
explicitly defined (suc as a common wooden pole)
o To this end, the trailer is equipped with two bronze grounding lugs: one on the right side of trailer on
the tongue, and the other on the elbow just below the base of the pole where it attaches to the rotation
assembly
 The outriggers and booms are operated by hydraulics which are controlled with hard-plumbed controls on the
trailer itself, or from the wireless remote controls; use the 3-position selection switch to choose Remote
(wireless) or Valve (wired) operation
 Use the switch on the control panel to turn on the pump
 Outriggers
o (4) 1818 Almag outrigger pads and (2) 1919 Almag Slope Copers outrigger pads are provided to assist
with trailer incline and stability control
o Slide the outrigger lockout at the valve control panel to the right to allow the valve handles to operate
normally
o Depress the appropriate momentary outrigger switch on the lower left and actuate the feathering
joystick in the upper right to extend or retract outriggers
o Using the inclinometers found on side and rear of the trailer, adjust the outriggers as close as possible to
0° in all directions, but never outside the range from -5° to +5°
o After outriggers are set, re-inspect the work area for outrigger security and check inclinometers for their
slope requirements; reposition trailer and outriggers as necessary to remain within the guidelines of the
inclinometers
o Once outriggers are safely and satisfactorily deployed, slide the outrigger lockout panel to the left to
lock out the outrigger functions

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CROSS-ARM INSTALLATION
 Completely extend the middle-boom stage
 Extend the upper-boom until the fiberglass pultrusion (brown pole) is parallel with the ground
 Securely install cross-arms, “Christmas trees,” insulators and any other supporting components
o Consider an offset configuration for these cross-arms if positioning directly underneath the conductor
line is not possible
CONDUCTOR INSTALLATION
Conductor can be installed in the same position used for the cross-arm installation, or it can be installed once the booms
are in the fully-deployed, vertical position with the use of an aerial device.
 If installing conductor in the cross-arm installation position, route the conductor through an insulated roller
 If insulated rollers are not being used, the conductor will have to be installed once all booms are in the fully-
deployed, vertical position
o Never extend, retract or rotate any boom if conductor is installed without insulated rollers
 The rotation pressure is set separately at the valve spool near 500 PSI to protect aerial plant from inadvertent
rotational torque. This pressure can be adjusted upward by a maintenance technician if desired.
FINAL INSTALLATION
 Once the desired cross-arm configuration has been attained, the upper-boom section can be moved into a
vertical position
 Extend the lower-boom section to achieve the height required for the work zone, ensuring the upper-boom is in
the completely vertical position
 Once proper height and vertical orientation of the upper-boom has been established, the upper-boom stage can
be clocked as needed to align with the conductor path
 The unit has been designed to be left on a work site, and no travel of the booms will occur due to hydraulic
leakage
 If leaving the unit deployed and unattended, ensure that all tools, batteries, generator, gas safety can, controls
and any other loose components are secured in the lockable boxes
 Return all switches to the OFF position except flashers if required
DEINSTALLATION
 Once permanent overhead restoration is complete, conductor can be deinstalled per the deployment scenario.
The booms can be retracted back to the cross-arm installation position, where all those components can be
removed and securely stowed
 Once all cross-arm components are removed, collapse all booms to their travel positions
 Return all switches to the OFF position
CHARGING & POWER
 The unit includes a fully-automatic battery charger that provides approximate capacity and current voltage for
the battery pack
 The charging system charges (4) deep cycle batteries which power the unit’s operation, including the booms,
outriggers, upper stage rotation, emergency flashers and the trailer breakaway system
 To view battery voltage, push and hold the button below the digital readout

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o Caution: battery charge creates heat, so keep material and body aware from charger and batteries
 The charger is fully-automatic and will show “CC” in the display when the battery reaches full charge, and can
therefore, be left plugged in, consuming less than 20W of power in this condition
 The unit can also be charged by the Generac iQ2000 1600W on-board portable generator, which can provide
power for other 120VAC appliances and tools
o The generator has three output settings: Turbo, Standard & Economy
 Turbo provides maximum output of 2000 surge watts/1600 rated watt of output
 Standard can be used for charging the battery pack in all conditions
 Economy can be used for light loads and after the battery reaches 80% of capacity
o The front duplex outlet can be reset with the push button switch to the left
o Fuel capacity and power output meters combine with the operating time remaining at current power
consumption to provide the operator current operating information when running
o Always keep the compartment door open when the generator is running
o Refer to the owner’s manual for detailed operation and maintenance information before operating the
generator
 Do not run the pump for an extended period when the unit is not being operated to conserve battery power and
extend component life
 Battery Maintenance
o Deep cycle batteries perform better and last longer when they are not fully discharged
o Leave charger plugged in when not in service to protect battery capacity and ensure the unit is ready for
deployment
o Periodically remove and reinstall power to the charger to restart the degassing cycle
o Store batteries in a fully charged state
o Replace batteries when required with Group 27DC 660 CCA deep cycle batteries

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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.