Valor 54TS User manual

Heavy Tilt Manual
Heavy Tilt Bed
Owner Manual
Models:
54TS (17.5”)
42TS (6+)
54TS (22.5”)
40T
42T
40TS (6+)
60TS (17.5”)
For warranty information contact Valor Trailers at [phone]
Or find us on our website:
www.valortrailers.com

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Table of Contents
1.0 Introduction .............................................................................................................................................................5
1.1 Purpose ....................................................................................................................................... 5
1.2 Follow Vehicle and Axle Weight Ratings................................................................................ 5
1.3 Understand Design and Safety Factors.................................................................................. 6
1.4 Vehicle Load and Handling Limits........................................................................................... 6
1.5 Meaning of Alert Symbols and Signal Words ........................................................................ 8
Table 1: Alert Symbols and Signal Words..............................................................................................................................8
1.6 Uncaging Air Brakes (for trailers with an Air Brake system) .............................................. 9
Table 2: Removal of Release Tool Assembly .........................................................................................................................9
Figure 1: Spring Brake Release Tool Assembly....................................................................................................................10
1.7 Reporting Safety Defects........................................................................................................ 11
1.8 Pre-Trip Inspection .................................................................................................................. 12
Table 3: Pre-Trip Inspection.................................................................................................................................................12
1.9 Required Trailer Hookup Procedures ................................................................................... 13
Table 4: Trailer Hookup Procedure......................................................................................................................................13
1.10 Proper Trailer Loading and Unloading Practices................................................................ 13
Additional Trailer Loading Precautions....................................................................................... 14
Trailers with Tilt Decks .................................................................................................................. 15
Trailers with Ramps ....................................................................................................................... 15
Section 1 Operations (continued)................................................................................................................................16
Securing Loads with Chains ......................................................................................................... 16
Figure 2: Correct Chain Angle When Securing Loads ..........................................................................................................16
Section 2 Maintenance....................................................................................................................................................17
2.0 Periodic Maintenance.............................................................................................................. 17
Table 6: Periodic Maintenance Checklist.............................................................................................................................18
2.1 Structural Components........................................................................................................... 19
Subframe.......................................................................................................................................... 19
Deck.................................................................................................................................................. 19

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2.2 Sub-Assembly Components .................................................................................................. 19
Pintle Eye or Ball-Type Coupling ................................................................................................. 19
King Pin............................................................................................................................................ 20
Jack Assembly................................................................................................................................ 20
Cushion Cylinder ............................................................................................................................ 20
Deck Latch....................................................................................................................................... 20
Figure 3: Adjusting Hook Receiver on Tilt Deck...................................................................................................................20
Deck Hinge Assembly .................................................................................................................... 21
2.3 Rear Impact Guard....................................................................................................................... 21
Figure 4: Properly Located Rear Impact Guard ...................................................................................................................22
2.4 Running Gear ........................................................................................................................... 23
Suspension...................................................................................................................................... 23
Torque Requirements .................................................................................................................... 23
Axle Alignment................................................................................................................................ 25
Axle End Component Disassembly.............................................................................................. 25
Hub Inspection................................................................................................................................ 25
Broken or Damaged Studs ............................................................................................................ 25
Brake Drum Inspection .................................................................................................................. 26
Brake Drum Troubleshooting Chart............................................................................................. 27
Brake Drum Troubleshooting Chart (continued) ....................................................................... 28
Axle End Component Cleaning and Inspection ......................................................................... 29
Axle End Component Assembly................................................................................................... 29
Wheel Bearing Adjustment............................................................................................................ 29
Wheel Bearing Lubrication............................................................................................................ 29
2.5 Wheels and Tires ..................................................................................................................... 29
Wheels.............................................................................................................................................. 29
Wheel Torquing Procedures ......................................................................................................... 30
Tires.................................................................................................................................................. 32
Inflation Pressure ........................................................................................................................... 32
Tire Wear Diagnostic Chart ........................................................................................................... 33

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2.6 Electrical ................................................................................................................................... 34
Harnesses and Lights .................................................................................................................... 34
Junction Block ................................................................................................................................ 34
Electrical Connection..................................................................................................................... 34
2.7 Air Brake System ..................................................................................................................... 34
Preventive Maintenance ................................................................................................................ 35
Manual Brake (Free Stroke) Adjustment ..................................................................................... 37
Slack Adjuster Function Test........................................................................................................ 38
Brake Lubrication ........................................................................................................................... 38
2.8 Trailers with Tilt Decks ........................................................................................................... 39
Cushion Cylinder ............................................................................................................................ 39
Deck Latch....................................................................................................................................... 39
Deck Hinge Assembly .................................................................................................................... 39
Section 3 Parts Manual...................................................................................................................................................40
Section 3.1 Major Sub-Assemblies.................................................................................................. 40
Section 3.1.1 Drawbar Eye/Lunette Eye....................................................................................... 41
Section 3.1.2 Jack Assembly ............................................................................................................................42
Section 3.1.4 Stationary Deck Latch..................................................................................................... 44
Section 3.1.5 Deck Hinge..................................................................................................................... 45
Section 3.1.6 Cushion Cylinder ............................................................................................................ 46
Section 3.2 Rear Impact Guard ............................................................................................................... 47
Section 3.3 Running Gear ....................................................................................................................... 50
Section 3.4 Toolbox................................................................................................................................ 53
Section 3.5 Wheels and Tires.................................................................................................................. 54
Section 3.6 Electrical Plug....................................................................................................................... 55
Section 3.7 Electrical Harnesses and Lights ................................................................................. 56
Section 3.7.1 Wiring Diagrams...................................................................................................... 57
Section 3.7.2 Wiring Diagrams...................................................................................................... 58
Section 3.9.1 Air Brake System .................................................................................................... 63
Section 3.9.2 Air Brake System .................................................................................................... 64

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Section 1 Safe Trailer Operation
1.0 Introduction
This section describes how trailers can operate differently based on design, load configuration, gross
weights, suspension, articulation, and extreme differences between loaded and unloaded weights.
Trailers have safe operating limits just as automobiles, airplanes, and other vehicles. These limits
are affected by the interaction of the vehicle characteristics, maintenance, load, roadway, weather, the skill of
the driver, and vehicle speed. Knowledge of how these factors affect the vehicle’s operating limits and
utilization of defensive driving techniques should result in safer driving.
1.1 Purpose
The purpose of this section is to describe how the vehicle characteristics, maintenance, road
conditions, and weather can affect trailer control and stability limits—and how driver awareness and
skill can help compensate for these factors. Awareness and knowledge of safe vehicle operating limits will
ensure you can enjoy the maximum utility and productivity from your Valor Trailer.
Do not operate the trailer until you have read and fully understand this instruction
and operating manual. It is also important that every person who operates the trailer
be given the opportunity to read this manual.
1.2 Follow Vehicle and Axle Weight Ratings
Your trailer’s load ratings are important to consider, prior to operating your vehicle. The following are the two key
load ratings, which you must adhere to when operating your trailer:
•Gross axle weight rating (GAWR) is the rated load-carrying capacity of an individual axle and wheel
assembly, which represents the load that may be steadily sustained by the components in the system. These
components include tires, wheels, hubs, bearings, axles, brakes, suspension, and subframe—with the
GAWR limited by the component with the lowest working rating.
•Gross vehicle weight rating (GVWR) is the maximum rated combined weight of a trailer and its payload or
cargo (uniformly distributed) based on its structural limitations.
Note: Consideration of environmental and operational factors may require the manufacturer to reduce the
nominal rating.

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1.3 Understand Design and Safety Factors
Valor Trailers are designed with a maximum load capacity rating, which is based on
trailer use in ideal conditions. Adherence to the load rating ensures the trailer operator can maintain
an adequate level of safety for all types of dynamic and static load conditions. Under dynamic
conditions the trailer encounters shifting weight, vibrations, shocks, and twists that elevate the stress
levels within the major weight-bearing components of the trailer.
Valor trailers should not be loaded past the rated capacity and should be loaded in
consideration of the load warning sticker. It is your responsibility to understand how load distribution
affects your trailer’s load-carrying capacity. The two types of load distribution are as follows:
•Distributed Load: A load is distributed evenly over the length of the trailer deck. Ideally, a trailer fully
loaded to rated capacity should have its cargo evenly distributed.
•Concentrated Load: The cargo is localized within a shorter than normal distance on the trailer deck and
therefore places greater stress in the concentrated load areas. When hauling a localized load configuration, it
is not recommended to carry the maximum rated capacity of the trailer. An extremely concentrated payload
might require additional support.
1.4 Vehicle Load and Handling Limits
The weight of a load, its placement and distribution over the axles, and whether or not the load is
secured properly can all greatly affect your vehicle’s handling limits. Tow vehicle and trailer combinations
are designed to provide the driver maximum directional control and roll stability within the constraints of
highway size and weight limits. Driving too fast around a curve, making too abrupt a maneuver, or leaving the
roadway can cause any combination of vehicle and trailer to roll over. Locking up the wheels on an axle can
also result in a jackknife or trailer swing out.
Extreme caution should be used in maneuvering a vehicle and trailer combination, or any unit
that has a tall load. One of the major contributing factors to vehicle rollover is a high center of gravity on tall
loads. Positioning the load in a central, side to side location enhances directional control, roll stability, and
braking. Trailers with a shorter wheelbase are more prone to roll during an abrupt lane change or because of
quick reactions at the wheel. This rolling tendency can dramatically worsen with a tall load and a higher center
of gravity.
All trailer and tow vehicle combinations are designed with a maximum load rating. Overloading
the vehicle should never be permitted. Overloading results in tire blowouts, spring breakage, frame damage,
SAFETY ALERT

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diminished braking capacity, and will severely alter the vehicle’s normal handling characteristics. To use these
vehicles safely, the load limits on the certificate label should not be exceeded.
Adequate tongue weight (TW) is required for trailers to tow correctly. TW is the measurement of
downward force that the tongue of the trailer exerts on the hitch ball of the tow vehicle. The safe range for TW
is between 10-15 percent of gross trailer weight (GTW). Inadequate TW can cause a whipping action or what is
known as trailer sway, particularly in shorter wheelbase trailers. Too much TW can overload a tow vehicle
hitch resulting in reduced steering load and loss of steering control. Selecting the correct tow vehicle is crucial
for the application. It is crucial to select a truck with the correct tow capacity rating for the trailer load being
carried.
Always maintain enough braking and stopping distance. Erratic or unequal brake action from side to
side on either tow vehicle or trailer can cause handling problems in braking situations. A balance between tow
vehicle and trailer on brake application, release timing—and synchronized pressure—will reduce push/pull
tendencies, which when excessive may result in a jackknife. The use of properly matched brake lining is also
recommended to enhance safer braking.
Proper alignment of both tow vehicle and trailer wheels adds significantly to the handling characteristics
of the combination and allows the driver to utilize all of the design responsiveness of the vehicle to make
evasive maneuvers in the safest manner.
Always be aware of your driving conditions/environment. Irregular terrain, steep grades and crowned
roads, especially rural roadways, freeways, exit ramps, curves, bumps, and depressions introduce forces into a
tow vehicle and trailer combination that could result in an accident if proper precautions and driving techniques
are not followed.
Even a vehicle that meets all maintenance and load requirements can become
hazardous when excessive speeds and irregular roadway characteristics are
combined.
While on a downgrade, the force of gravity works against the driver’s ability to maintain control
of the vehicle, particularly if the road surface is wet or slick from snow and ice or covered with loose material.
On upgrades, the problem changes to spinning out because of insufficient traction of the drive wheels,
particularly on snow and ice or other slippery road conditions.
Great care must be taken to avoid excessive use of brakes on long downgrades.Overheated brakes
are dangerously inefficient. It is very dangerous to brake on a downgrade using only the trailer brakes. If this is
done, the trailer brakes heat up and fade and the tow vehicle brakes alone will not be able to stop the
combination of two vehicles. Drivers should reduce speed, downshift, and use engine compression as the
principal means of controlling speed on long grades; and use both trailer and tow vehicle brakes so brake
temperatures can be held to a safe level.

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Weather conditions can be a major factor in the cause of accidents. Rain, ice, snow, high winds, and
poor visibility combined with excessive speed, sudden lane changes—or other factors that put lateral forces into
a tow vehicle and trailer combination—may contribute significantly to an accident. Slippery roads can increase
stopping distances and reduce the ability to control the vehicle. When the road is wet, the available tire/road
friction to enable braking may be half that of a dry road. Icy roads can further reduce tire friction for braking
many times over the tire friction available for wet roads. If hard braking or rapid acceleration occurs, there may
be little or no friction available to prevent lateral tire movement and skidding results.
Control and stability may be maintained if the driver knows his or her vehicle, his or her load,
and the road. The driver must compensate for the characteristics and conditions of his or her vehicle, the road
conditions, and weather. Reducing speeds and increasing attentiveness may compensate for most of these
conditions. The more familiar the driver is with the vehicle and the road, the less likely he or she will need to
make abrupt emergency maneuvers, which will take the vehicle to its limits.
Either braking or accelerating while cornering can significantly reduce the controllability and stability of
the vehicle and should be avoided. The best driving practice is to decelerate to a safe conservative speed, before
entering a corner or approaching congested traffic, and then apply only moderate power until an essentially
straight path has been established.
It is imperative that a safe speed always be maintained. The safe speed is defined as that speed at
which control can always be maintained within the bounds of the vehicle. This reasonable speed will ensure
vehicle control is maintained to allow an emergency change of lane maneuver, travel off an exit ramp with a
tightening radius, and recovery from pavement drop-off or wet pavement.
Note: Safe speed will vary from one combination of vehicles to another and takes into consideration such
factors as road conditions, weather, traffic, visibility, type of load, and experience of the driver.
1.5 Meaning of Alert Symbols and Signal Words
It is important that you understand the meaning of the following symbols that are used throughout this
document. The signal words indicate the level of risk. Table 1 lists the various safety symbols used throughout
this document.
Table 1: Alert Symbols and Signal Words
Alert Symbols and Signal Words
Symbol
Signal Words
Definition
SAFETY ALERT!
Alerts operator to potential personal injury
hazards.
Note: Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER!
DANGER! indicates an imminently
hazardous situation which, if not avoided,
will result in death or serious injury.

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Alert Symbols and Signal Words
Symbol
Signal Words
Definition
WARNING!
WARNING! indicates a potentially
hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION!
CAUTION! indicates a potentially
hazardous situation which, if not avoided,
might result in minor or moderate injury.
CAUTION
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, might result
in property damage.
1.6 Uncaging Air Brakes (for trailers with an Air Brake system)
Air brakes are designed with a safety feature called a spring brake; if no air pressure is present in the
system, springs will apply force to the brake system linkages and apply the brakes. To allow the trailer to be
moved during shipping, a release tool assembly is installed in each of the spring brake cans to prevent the
brakes from being applied. These release tools must be removed before the trailer can be put into service.
INOPERATIVE BRAKE SYSTEM!
The spring brake release tool assemblies must be removed from the spring brake cans before the trailer is put
into service. The brake system will not function with the release tools installed, and the trailer will roll freely
until they are removed. To remove the release tool assemblies, use the following procedure in Table 2:
Table 2: Removal of Release Tool Assembly
Removal of Release Tool Assembly
Step
No.
Action
1.
Hook up trailer to tow vehicle and/or put air to the air brake system on the trailer.