Sauber MFG 1521-AP 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
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Custom Engineered For AEP
Preface
Thank you for choosing Sauber Mfg. Co. You have purchased a trailer that has been designed and built
with care. With a small amount of maintenance and by understanding its operation, your new trailer will provide
you with years of e cellent service. We welcome your suggestions on its improvement and stand willing to assist
you if any questions arise during its operation. If we can help you in any way, please contact your account repre-
sentative toll free:
Voice Communications: [phone]
Fa Communications: [phone]
Trailer Towing
Proper tongue weight is essential to good trailer tracking and safe operation. If too little weight is dis-
tributed to the tongue, towing will be erratic. Too much tongue weight may overload the towing vehicle's rear a le
or the pintle hitch rating. Ten to twenty percent weight transfer is considered a "normal" range. Smaller, single
a le trailers can transfer weight on the high side of this range. Larger, multiple a le trailers are designed to trans-
fer less because of the limited capacity of the towing vehicle's rear a le.
When necessary, tongue weight can be controlled by distributing the load or by adjusting the pintle eye.
Even loading is ideal, but when this is not possible, place more weight toward the trailer front to provide a safe
tongue weight. Be aware that too much tongue weight from an uneven load can overload tow vehicle compo-
nents. It is incumbent upon the operator to provide a safe, towable tongue weight without e cessive 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-a le 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.
Electric Brake Systems
Connect the breakaway cable on electric brake trailers. To check the condition of the electrical brake sys-
tem, pull the breakaway pin and check for the illumination of the green LED indicator light. When fully lit, the bat-
tery is charged and the system wiring is correct.
Grounding
Your trailer is equipped with a bronze grounding lug. When the trailer is used near energized conductors
the trailer must be grounded. A non-ferrous, conducting rod should be driven into the ground and connected via
grounding cable to the trailer grounding lug.
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & aintenance anual
odel 1521-AP Combination Trailer
11/2007
Page 1

Outriggers
Stability is an important part of safe trailer use. Because the towing vehicle can provide additional stabili-
ty, leave it connected to the trailer when you can. Set the rear outriggers to their lowest level. If you need to de-
couple the towing vehicle, lower the front jack slightly, set the outriggers and then raise the jack to "seat" the out-
riggers firmly in the ground.
Wheel Chocks
Set the chocks at each rear wheel in the direction of the e pected load or grade.
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 e tension cords. Technical pole carrying recommen-
dations follow:
General
Sauber Mfg. Co. builds standard e tendible 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 E tendible 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
Recommendations
The following guide indicates the recommended adjustment position for each pole shown. "Muzzle" indi-
cates that the pole would require a pole muzzle which can be used in conjunction with our e tendible trailer. If
customer requirements include carrying larger poles within the confines of the e tendible tongue, we have three
options. One option is increasing the overall length of the trailer and e tension. A second option is relocating the
undercarriage rearward a ma imum 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 a le weights to unacceptable levels and de-
load the front a le, causing steering and control problems. Too little tongue weight will result in reduced trailer
control while towing.
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & aintenance anual
odel 1521-AP Combination Trailer
11/2007
Page 2

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 winch with the stainless steel breaker bar provided.
Rotate the tightening process through each binder twice to ensure a firm hold.
Rear Light Bar Use
The integral rear light bar can be removed and fastened to the rearmost pole. By connecting the e ten-
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.
Components Sourcing Information
Item....................................Source....................Description/Specification
Tires........................................... Major Brand................... 235/85R17.5, LR H - 120 PSI
Wheels....................................... De ter............................ 6.75 17.5 8 on 6.5”
A le............................................ De ter............................10K/Slipper Springs - 110-120 ft-lbs
Brakes........................................ De ter............................ 12.25” 4”, S.A.
Pintle Eye................................... Holland.......................... 11144, 3" I.D.
Safety Chain.............................. C-M............................... 3/8" Grade 43, 5400 LB's ea.
Chain Hook................................ C-M............................... M6405A, 6000 LB's ea.
Hitch E tension.......................... Sauber........................... Model 8818-B1
Solar Battery Pack..................... Sauber...........................Model 8852 - 2 Watt
Striping....................................... 3-M................................ # 29804-SP DOT-C2, 2"W Red/White
Jack........................................... Sauber........................... Model 8808 EZ-Up w/ Sand Shoe
Outrigger Jack............................Sauber........................... Model 8805
Electrical Connector................... SAE............................... 11119, 7-way
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & aintenance anual
odel 1521-AP Combination Trailer
11/2007
Page 3

Sauber fg. 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 TM / 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 e pected to be wired hot on ABS
4-Lite systems will be wired in parallel unless otherwise noted
The Stop/Red circuit is generally run back to the rear junction bo and is only used on a separated 4-lite system
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 pro imity to battery bo .
7/C Cable - (6) 12 Gauge; (1) 10 Gauge - White
All Primary & Brake Feed Wire: 12 gauge
All Secondary Feed Wire: 14 gauge
Breakaway................................. Warner.......................... 10475 w/ Charging Circuit
Hubodometer............................. Sauber...........................8824 w/ 10526 Hubo
Chocks....................................... Sauber........................... Model 8500-FO All Weather Wheel Chock
Lighting...................................... Truck Lite...................... LED Sealed Beam/Sealed Wiring Group
Registration Container............... Sauber...........................16755
Grounding Lug........................... Sauber...........................10481 Bronze
Winch Strap Only....................... Sauber...........................10868 4 " 20'L w/D-Ring
Winch Binder Only..................... Sauber...........................14147
Binder Release E t.................... Sauber...........................11015
Breaker Bar................................ Kinedyne....................... 10528 w/ SMC Galvanizing
Binder Hook............................... Kinedyne....................... 12955
Light Bar Junction Bo ............... Midland-Berg................. # 22040
Light Bar.....................................Sauber........................... Model 8840
Light Bar Binder......................... Acme Rigging................ # 2LHR-2 w/ 4' 1.75" Strap w/ Loop
Tensioning Brake....................... Sauber...........................Model 1602-Detail Attached
Retriever.................................... Sauber........................... Model 1000 -Detail Attached
Note: Most items listed here are in stoc at Sauber Mfg. Co.
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & aintenance anual
odel 1521-AP Combination Trailer
11/2007
Page 4

aintenance
Operation................................................................... Interval
Torque Wheel Nuts - See Components Sourcing - A le........... 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 Tensioning Brake Pad Condition..................................... Each Use
Torque Saddle Bolts................................................................... Yearly
½“-Grade 8 fastener: 130-135 ft-lbs
5/8“-Grade 8 fastener to 140-145 ft-lbs
Grease Tensioning Brake Hub................................................... Monthly
Oil Drive Chain........................................................................... Monthly
Inspect Sprocket Tooth Wear..................................................... Yearly
Check Drive Chain Tension....................................................... Monthly
Grease Engagement Hub.......................................................... Monthly
Tensioning Brake Factory Maintenance..................................... Apro 2500 hours of use
Includes:
1. Rotor inspection/machining
1. Brake lining replacement
1. Pivot pin inspection
1. Alignment
1. Dynamic brake load testing
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & aintenance anual
odel 1521-AP Combination Trailer
11/2007
Page 5

Reference Drawing
This information is the property of Sauber Mfg. Co. and is intended for customer use only.
Operation & aintenance anual
odel 1521-AP Combination Trailer
11/2007
Page 6
96
48
51
36 3/4
5
15
Ø66 REEL
Ø60 REEL
5 3/8
54
58
14
16 5/8
57
96
2047ST
20 3/4
26 3/4
98 1/4
21' 6" CLOSED LENGTH
30' EXTENDED LENGTH
24 1/8

Care and Use of BOA 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 crank.
•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.
•Turn the hex drive clockwise to engage the gears and continue to turn clockwise to apply
tension to the binder. Applying 40 to 60 lb to the end of the torque crank will result in
approximately 1500 lb of strap tension. By increasing the applied force to the 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.
•When tensioning or releasing the winch in rain, snow, or other slippery conditions, carefully
position your feet and body to prevent a fall.
•Winches should never be loaded in excess of their working load limit (WLL).
•Winches should be used in accordance with all applicable federal, state, local, and industry
regulations applicable to cargo securement.
•A training program for operators is recommended for the correct and safe use of cargo
securement systems.

BINDERS:
•BOA winches are designed for use with webbing strap binders only.
•Do not use cable binders with BOA 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 BOA Winch will result in voiding the warranty and liability
responsibility of the manufacturer.
•Do not use as a lifting or pulling device.
•Do not use tensioning bars other than the provided crank handle, which is designed specifically
to work with the BOA winch.
SHIPPING FROM SAUBER MFG. CO.
In preparation for shipping, nearly the entire length of the strap is wrapped on the BOA 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 the manufacturer's recommendation. Test results confirm that too few or
too many wraps can result in the release of strap tension which will create a dangerous condition..
This document lists the most commonly encountered considerations for the proper maintenance and
operation of BOA winch tie-down assemblies, but it is not an all-inclusive list.

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.