🎉 Congratulations on your new Kales semi-trailer!
To ensure safe, efficient, and compliant operation from day one, it’s essential to complete a thorough pre-trip inspection and proper connection with your tractor unit. This guide covers everything from safety checks to your first drive.
1. Pre-Trip Inspection: Getting Ready for the Road 📋
Before hitting the road, perform these critical checks to confirm your trailer is ready for service. Proper preparation prevents breakdowns.
✅ Fasteners & Hardware
- Check structural components are undamaged.
- Inspect U-bolts and axle plates for tightness.
- Critical: Check wheel nuts. Torque typically requires 600–650 N·m. Replace loose fasteners immediately.
✅ Lights & Safety
- Confirm brake, turn, and clearance lights work.
- Inspect wiring for fraying or corrosion.
- Ensure reflectors are clean and intact (DOT compliance).
✅ Air Brake System
- Check gladhands (Red/Yellow) for clean seals.
- Build pressure to 800–850 kPa (116–123 psi).
- Listen for hissing sounds (leaks).
- Test brakes: all wheels should engage evenly.
✅ Tires & ABS
- Check tire pressure and cuts/bulges.
- ABS Test: Turn on ignition. The ABS light should flash for ~3 seconds then turn OFF.
- Visually verify axles are parallel.
✅ Confirm Towing Compatibility
Ensure the gross vehicle weight rating (GVWR) does not exceed your tractor’s capacity. Check the height difference:
- 📐 Optimal Height: The trailer kingpin plate should sit 10–30 mm lower than the tractor’s fifth wheel center.
- This ensures the tractor physically “picks up” the trailer during coupling.
2. Step-by-Step Coupling Procedure 🔗
Proper coupling is critical for safety. Follow this procedure to connect your Kales trailer correctly.
Step 1: Aligning and Locking
- Height Adjustment: Adjust landing gear so the kingpin is 10-30mm lower than the fifth wheel.
- Open Jaws: Open the fifth wheel locking jaw.
- Reverse: Slowly back up, aligning centerlines within 40mm. Max angle: ≤5°.
- Engagement: Reverse until the kingpin locks automatically.
- 👁️ VISUAL CHECK (Crucial): Get out with a flashlight. Look under the fifth wheel to visually confirm the jaws are completely closed around the kingpin shank.
- Tug Test: Gently pull forward with trailer brakes engaged to verify connection.
Step 2 & 3: Air and Electric ⚡
- 🔴 Red Gladhand: Connect to Supply (Emergency) line.
- 🟡 Yellow Gladhand: Connect to Control (Service) line.
- 🔌 7-Pin & ISO: Connect electrical and ABS cables.
- Charge System: Open supply valve and build pressure to 800+ kPa.
🚫 Safe Disconnect Procedure
- Park on a level, firm surface. (Use wooden pads if ground is soft).
- Apply parking brakes.
- Lower landing gear until it supports the trailer.
- Disconnect air lines and electrical cables.
- Release fifth wheel lock and drive forward slowly.
3. Critical First Drive Tips 🛑
⚠️ MANDATORY: Retorque Wheel Nuts
Do not ignore this step.
After the first 50–100 km (30–60 miles) of loaded driving, you MUST retorque all wheel nuts to the specified value. New rims and studs “settle” initially, causing nuts to loosen. Failure to do this can result in wheel detachment.
▶️ Driving Best Practices
- Engine Braking: On long descents, use the Jake brake to avoid overheating drums.
- Brake Burnishing: For the first few hundred kilometers, brake gently to allow new linings to seat properly.
- Monitor: Watch for sway or unusual noises indicating suspension issues.
Need Expert Support?
Our technical team is ready to assist with your Kales trailer manual or first-use setup.
