Great Dane Champion CP Maintenance Manual - Page 5

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electrical system

caution

CONNECTOR WIRING CHANGE

NOTICE TO ALL TRACTOR-TRAILER

OWNERS AND USERS

Federal Motor Vehicle Safety Standard No. 121,

Air Brake Systems, was amended by the National

Highway Traffic Safety Administration of DOT to

require that truck tractors manufactured on or

after March 1, 1997, provide constant power for

a trailer's antilock brake system (ABS). Some

manufacturers provided this feature before the

effective date.

These tractors using a single 7-way electrical

connector will have constant power for ABS

on the center pin when the key switch is on.

Tractor-trailer owners and users who presently

use the center pin for auxiliary power to equip-

ment other than trailer ABS (for example, dome

lights, backing lights, bottom dumps, sliding

undercarriages, air ride dump valves, etc.) will

be affected by this change.

In certain uses of this constantly powered

center pin connector, unexpected or unintended

activation of this equipment may be hazardous

or result in personal injury.

BEFORE connecting your trailer to a tractor,

MAKE SURE that the constantly powered center

pin WILL NOT UNINTENTIONALLY TURN ON

TRAILER EQUIPMENT. If you have any questions

about your present wiring, or how to rewire your

vehicles, you should contact the tractor

manufacturer, auxiliary equipment manufacturer,

and/or Great Dane Trailers Customer Service

Department.

WIRING DIAGRAM

FRONT

— TOP VIEW OF TRAILER —

7 COND MAIN HARNESS

The electrical system on every Great Dane trailer meets

or exceeds all federal and state requirements in effect

at the time of manufacture. Wherever required by law,

lamps and reflectors are marked by the manufacturer to

indicate the appropriate specification with which each

complies.

For optimum performance and long life from the trailer's

lamps and wiring, follow this inspection procedure.

Clean all reflective tape or devices and lamps. See that

all lamps burn properly. Replace all burned-out lamps

and broken or missing reflective devices. Factory-

approved replacement parts should be used, and

replacement bulbs or lamps of equal candlepower

should be used for safety.

warning

TRAILER IS EQUIPPED WITH ANTILOCK BRAKE SYSTEM (ABS).

NO. 7 (BLUE) CIRCUIT IS RESERVED FOR CONTINUOUS POWER

SUPPLY TO ABS. FOR MOST EFFECTIVE ABS OPERATION,

TOWING VEHICLE MUST SUPPLY MINIMUM OF 10 AMPS AT

12.5 VOLTS TO NO. 4 (RED) & NO. 7 (BLUE) CIRCUITS.

PIN COLOR

CIRCUIT

WHITE

GROUND RETURN TO TOWING VEHICLE

BLACK

CLEARANCE, SIDE MARKER & ID LAMPS

YELLOW LEFT TURN SIGNAL & HAZARD LAMPS

RED

STOP LAMPS & ABS POWER

GREEN

RIGHT TURN SIGNAL & HAZARD LAMPS

BROWN

TAIL, LICENSE, CLEARANCE &

SIDE MARKER LAMPS

BLUE

ABS CONTINUOUS SHARED POWER

FAILURE TO HEED

J560

THIS WARNING CAN RESULT

SOCKET

IN PROPERTY DAMAGE,

SERIOUS INJURY OR DEATH.

NOTE: Electrical circuits may be protected by circuit

breakers located inside the front nose box.

REAR

GREEN

BROWN

WHITE

GREEN

BROWN

WHITE

RED

BROWN

4 COND ABS HARNESS

WHITE

BLUE

WHITE

WHITE-GREEN

RED

BROWN

RED

BROWN

WHITE

YELLOW

BROWN

WHITE

YELLOW

WHITE

BROWN

WHITE-GREEN

WHITE

BROWN

A warning decal, as shown on the previous page, is

located on the front of each trailer. You may trace

individual electrical circuits by the wire colors indicated.

Refer to the schematic drawing and the decal for

conductor numbers and wire colors.

warning

Do not exceed 21 candlepower bulbs for dome

lamps. Stronger bulbs may generate excessive

heat and start a cargo fire. Cargo must be kept

away from dome lamps. Dome lamps must be

turned off for over-the-road operation.

Use only a 12-volt DC battery for checking lamps or

antilock brake systems. Never use battery chargers or

transformers.

brake maintenance

DISC BRAKE SCHEDULED MAINTENANCE

Several different brands of disc brakes are available

in the marketplace. Because procedures differ brand

to brand, refer to the maintenance and adjustment

information from the manufacturer of the specific

brake in question.

DRUM BRAKE SCHEDULED MAINTENANCE

Establish a preventive maintenance schedule for

the periodic adjustment, cleaning, inspection, and

lubrication of brake equipment on the basis of past

experience and expected severity of operations. Take

into account that linings and drums are particularly

subject to wear and should not be allowed to wear

to the point where rivets or bolts may contact brake

drums. To compensate for this, schedule brake

inspections as frequently as required to maintain

satisfactory operation and maximum safety (not to

exceed 25,000 miles). Accepted maintenance practices

require that bearings should be adjusted properly

before making brake adjustments; that adjustments

provide uniform lining clearance, correct travel of levers,

and proper equalization; and that brakes should be

cleaned, inspected, lubricated, and adjusted each time

the hubs are removed.

MAINTENANCE DURING MAJOR OVERHAUL

OF BRAKES

During a major overhaul, check the following parts and

replace them with original equipment parts or equal, as

required:

1. Spiders – for looseness or sheared fasteners.

2. Anchor pins – for wear or misalignment.

3. Brake shoes – for wear at anchor pin holes.

4. Cam shafts and cam shaft bearings or bushings –

for wear.

5. Shoe-return springs – replace during overhaul and

when you replace lining. Do not reuse springs.

Inspect all wiring to see that it is not damaged, and

that it is properly supported and protected, with all

connections tight. Frayed or damaged wiring should be

replaced with stranded cable of equal size or larger, and

should never be replaced with a smaller cable, or with a

solid conductor. All holes where wiring passes through

must contain rubber grommets.

NOTICE:

Most trailers are equipped with a sealed

wiring harness. Check the circuits at the plugs only

– do not cut or probe test for shorts. Every time

the harness is unplugged, repack connector with

Grafo 112X grease or equivalent.

Never replace fuses or breakers with metal foil or other

devices.

6. Brake linings – for oil or grease saturation, wear,

loose rivets or bolts.

7. Drums – for cracks, scoring, other damage.

Install all new lock rings where they are used.

During a major overhaul, before reassembling parts that

have been inspected, lightly coat cam shaft bushings

and cam roller follower shafts and journals with brake

lubricant.

warning

Brake liners contaminated with lubricant cannot

be salvaged or cleaned. They must be replaced.

For all fittings on cam shafts, meter-type fittings that

have a maximum of 40 psi pressure relief or shutoff are

recommended.

BRAKE LUBRICANTS

A high-temperature waterproof grease in a number 1

NLGI grade to lubricate the brake actuating system is

recommended. It should be smooth textured, corrosion

resistant, and free of fillers and abrasives. It should

maintain a satisfactory softness under normal parking

and storage temperatures so the brakes can be applied

and released.

The following greases meet these recommendations:

Texaco Thermotex EP #1 Shell Darina #1

Marathon 528 HD

Sunaplex #1 EP

Amdex #1 EP

Philube B #1

Trailers operating in extremely cold weather

(below -40˚ F) may require a grease conforming to

MIL-G-25013C.