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Kässbohrer TANKER Series User Manual

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  • Page 2: Table Of Contents

    I I n n d d e e x x 1. GENERAL INFORMATION AND SAFETY INSTRUCTIONS 1.1. About the User Manual .............9 1.2. Meanings of Symbols Used in User Manual......9 1.3. Personal Protective Equipments..........10 1.4. Terms of Use and Safety Information ........11 1.5.
  • Page 3 3.7.3. Hubodometer..............32 3.8. Tires ..................32 3.9. Spare Wheel Holder ..............33 3.9.1. Crane Type Spare Wheel Holder........33 3.9.2. Basket Type Spare Wheel Holder ........34 3.10. Mudguards................34 3.11. Wheel Chock ................34 3.11.1. Pin Type Wheel Chock Holder........35 3.11.2. Pocket Type Wheel Chock Holder ........35 3.12.
  • Page 4 4.1.12. Safety Valve ..............50 4.1.13. Remote Control System ..........51 4.1.14. Sampling Valve ...............56 4.1.15. Thermometer ..............56 4.1.16. Manometer ..............57 4.1.17. Heating Line..............58 4.1.18. Warning Signs On the Tank ..........59 4.2. Chemical Tanker ..............59 4.2.1. Overview of Tank Components ........59 4.2.2. Tank...................61 4.2.3.
  • Page 5 4.4.3. Filling Manhole..............76 4.4.4. 6" Pneumatic Control Gate Valve For Ventilation ....76 4.4.5. Safety Valve ..............76 4.4.6. Vacuum Valve..............76 4.4.7. Pneumatic Valve for Tank Ventilation.......77 4.4.8. Pneumatic Overfill Protection For Stop The Pump ..77 4.4.9. Filling Funnel ..............77 4.4.10. Filling Funnel 8’’ Pneumatic Control Gate Valve ..77 4.4.11.
  • Page 6 5.5.4. Air Leakage...............85 5.5.5. Oils ..................85 5.5.6. Welding ................86 5.5.7. Spare Wheels..............86 5.5.8. Considerations For the Environment ........86 5.6. Cleaning of the Vehicle ............87 6. TRANSPORTATION SOLUTION 6.1. Dangerous Goods Transportation (ADR) .......89 6.2. Transportation Compliant with ATP Legislation .....89 6.3.
  • Page 7 7.4.2. Load Distribution and Load Limits of Tractor-Semi-trailer Combination.................112 7.4.3. Loading ................113 7.4.4. Discharge.................114 7.4.5. Warnings for Filling and Discharging Operations ..118 7.4.6. Checks After Loading and Unloading......118 8. INSPECTION AND MAINTENANCE 8.1. Safety Instructions..............119 8.2. Main Principles ..............119 8.3. Checks to Be Performed Of The Time of the Delivery ..119 8.4.
  • Page 8 FOREWORD First of all, thank you for choosing us for your new vehicle investment. Your vehicle is manufactured with the latest production technologies to the highest quality standards and equipped with the best safety and efficiency features. You can find detailed information about the accessories, equipment and hardware that might be in your vehicle in this manual.

  • Page 9: General Information And Safety Instructions

    1. GENERAL INFORMATION AND • Exceeding of the maximum vehicle SAFETY INSTRUCTIONS speed 1.1. About the User Manual • Exceeding the permissible length, width and height The usage and operation information given in this manual is prepared to make • Unapproved parts like tires, acces- sure the vehicle is used in compliance sories, spare parts and etc.

  • Page 10: Personal Protective Equipments

    The information specified by It is obligatory to use approp- this warning symbol is very riate personal protective important for health and hu- equipment during man safety. When the given in- operations. formation is ignored, serious damage, injuries and even Long hair is particularly dan- death may occur.

  • Page 11: Terms Of Use And Safety Information

    To prevent possible accidents and envi- When working around the ve- ronmental pollution, follow the operating hicle, a lightweight helmet instructions and binding regulations. approved by an accredited institution should be worn. • Pay attention to the safety and warning signs placed on your Protective Ear Plugs vehicle.

  • Page 12: Danger Areas

    • Wear protective clothes against load and hazards that may arise from load. • If the load causes an injury, contact to ma- terial safety document for necessary emer- gency measures. Rubbing of load against tank Risk of fire and explosion! walls and connections If the identical potential conductor (grounding pins) is not connected, statical load may cause sparks...

  • Page 13: Weather Conditions

    Around tanker vehicle Presenting unauthorized persons around the ve- hicle during loading and unloading is dangerous for you and other persons. • Ensure the unauthorized persons are out- side the danger area. All sides of not connected tanker In some cases not connected tanker can suddenly vehicle fall down and injure people.

  • Page 14: Main Informations

    2. MAIN INFORMATIONS In addition, since the Stainless Chemical and Bitumen (Tar) tankers are pressur- There are vehicle identification stickers ized/non-pressurized vessels carrying on the vehicle. dangerous goods, they are in compli- ance with ADR and the seal of approval by the 3rd organization is on this plate.

  • Page 15: Vin (Chassis) Numbers

    2.3. VIN (Chassis) Numbers the date that the vehicle is delivered to the customer. The VIN (chassis) number is located on the right side of the vehicle and marked The performance of maintenance and re- with a different color than the chassis pair/servicing of the vehicle with the use color.

  • Page 16: Trailer Running Gear And Usage Instructions

    3. TRAILER RUNNING GEAR AND USAGE INSTRUCTIONS 1-2 Brake/Electric Connections Service Line: Pneumatically air hose which will feeds the brake line. 3 King Pin Supply Line: Pneumatically air hose 4 Landing Legs which will feeds the air tanks and trailer 5 Side Protection According to the type of vehicle, your ve- hicle can be equipped with one or two...
  • Page 17 If your vehicle is equipped with 2 different types of coup- lings, you must use only one type at the same time. When couplings mounting/demounting, parking brake of the truck and trailer must be engaged. Palm coupling with a test point If the brake parameters are modified, your vehicle's brake 3.1.1.1.
  • Page 18 • • First demount the supply line red Be sure that couplings are matched (2). correctly. • 3.1.1.4. Demounting of C (UK) Demount the service line yellow (1). Couplings • Slightly slide plastic covers to the • Push the latch from front to back lower side and close the plastic side on the C couplings and covers.

  • Page 19: Compressed Air Tanks

    3.1.2. Compressed Air Tanks The water in the compressed air tank can cause corrosion Pressured air can be stored in the air problems and affect the func- tanks. tionality of the brake system. The quantities and capacities of the air The frozen water in the pneu- tanks can be changed according to your matic lines can cause the fai-...

  • Page 20: Rollover Stability Support (Rss)

    • If you drive without EBS con- Driving with a non-connected EBS nectors or if there is a prob- connection is illegal. lem on the EBS system, the • Drive only with an approved and brake system will not be wor- well-operating EBS plug connection ked properly.

  • Page 21: Brake Chambers

    The service brake is not sui- table for braking of the semi- trailer permanently. During longer waiting periods, the se- mi-trailer must be secured with a spring-loaded park bra- ke and with wheel chocks. 3.1.5.2. Spring Loaded Park Brake PREV Buttons Black button (1): Service brake button.
  • Page 22 3.1.6.1. Manually Deactivation of On some brake chambers Parking Brake Spring used in vehicles, the emer- gency release screw is lo-ca- The Parking brake spring may be deacti- ted in its socket (1) behind the vated manually in emergency situations. brake chamber, not in its soc- ket (4) next to it.

  • Page 23: Suspension System

    • Close the plastic cover on the brake chamber. Brake chamber will be activated after this operation. Before this operation, the ve- hicle must fixed securely with wheel chocks. Serious inju- ries may occur. Don't drive without being sure that all the brake system is working properly after this Higher driving height operation...

  • Page 24: Electrical System

    lamps, signal lamps etc. 15 pin socket connections are made according to ISO 12098. Open the protection cover and mount the sockets regularly. You may find extra information about the pins function in below. ECAS control panel 3.3. Electrical System 15 pin, 2x7 pin (For tankers without ADR) or 15 pin +2x7 pin (For tankers without ADR) electrical sockets are op-...

  • Page 25: 2X7 Pin Socket

    Supply line Left indicator Brake light Empty Right indicator Axle lifting Right taillight Ground Empty Empty 3.3.2. 2x7 Pin Socket This system provides electricity for the electrical system on the vehicle like stop lamps, signal lamps etc. 2x7 pin socket pin connections are made suitable for 24S ISO 3731 and 24N ISO 1185 norm.

  • Page 26: Light System

    Please be careful with the co- black socket on the truck will lor of the sockets. The black be connected to the black soc- socket is suitable for ISO 1185 ket on the trailer and the white and the white socket is suitab- socket on the truck will be le for ISO 3731.

  • Page 27: King Pin

    If you add or remove any lamps on the vehicle, your ve- hicle may be non-suitable for regulations. Vehicles with LED electrical systems consume very low energy. For this reason, alt- hough there is no problem in the system, it may cause the failure lamp to come on in old tractors.
  • Page 28 In all conditions, secure the semi-trailer against tipping with correctly positioned wheel wedges. If the vehicle is not properly secured, the lan- ding gear or the vehicle may be damaged. If the loading / unloading ope- ration is performed while se- mi-trailer is not paired with the tractor, the front or rear of the vehicle may raise.

  • Page 29: Side Protection Equipment (Underrun Protection)

    Travelling with the opened un- derrun protection is dange- rous and illegal. In this case, there may be serious injuries, including death, in road acci- dents that may occur. Before travel, make sure the under- run protection is lowered and properly secured.

  • Page 30: Self-Steering Axles

    this reason, it is obligatory for the buyer locked automatically when the reverse to make the brake adjustment at the au- gear is engaged in order to reverse. It is thorized service of the tractor company also possible to lock this axle manually. to which these semi-trailer/trailers are to Drive the vehicle straight ahead so that be matched.

  • Page 31: Axle Lifting

    a spring load-ed button to be installed in When the self-steering axle is the tractor cabin. Fort his feature, your locked manually, the axle will tractor must be adjusted according to the not be unlocked automatically. tractor. It must be unlocked manually. It is also possible to activate /deactivate the axle lift with the help of the button on the trail-er.

  • Page 32: Hubodometer

    Axle lifting There is a danger of being Digital Hubodometer pinched and injured when lo- 3.8. Tires wering /raising the axle. During the selection of semi-trailers tires, 3.7.3. Hubodometer it should be ensured that the tire has ap- propriate carrying capacity. Hubodometers show the distance trav- eled by the vehicle in kilometers or The manufacturer offers tires suitable for...

  • Page 33: Spare Wheel Holder

    when radial and crossply tires are used Make sure that you put the ne- side by side. cessary warning signs and ta- safety precautions during the tire change. Driving with insufficiently se- cured spare tire (s) can occur accidents. The tires are heavy parts. Be careful about ergonomics and occupational health and sa- fety rules during the tire repla-...

  • Page 34: Basket Type Spare Wheel Holder

    substances on the ground from splash- • Lift the tire upwards by turning the ing onto other vehicles. handwheel (3) clockwise. Some vehicles may have folding mats to • Turn the lever (3) clockwise and the prevent the mat from rubbing against the tire will be lifted.

  • Page 35: Pin Type Wheel Chock Holder

    3.11.2. Pocket Type Wheel Chock The vehicle must be secured Holder with wheel chocks when par- ked on a slope area, during the loading and unloading operations or when parked without a tractor. Only place wheel chocks on wheels on fixed axles, never on idle/steer axles.

  • Page 36: Steel Food Box

    Unlocking the Food box: • Insert the key into the lock and switch it to the unlocked position. • Pull the lock arm back and open the cover by turning it. Toolbox Steel food box Opening the lock Opening the lock: •...

  • Page 37: Plastic Toolbox

    3.12.3. Plastic Toolbox Fire extinguishers should be maintained regularly, and their expiration dates should be observed. Plastic toolbox Plastic toolbox Unlocking The Toolbox: Fire extinguisher cabinet • Remove the lock cover. Opening The Cover: • Unlock by turning the key. •...

  • Page 38: Water Tank

    3.12.5. Water Tank 3.12.6. Document Box The vehicle may have a water tank for You may store your non-valuable docu- general cleaning. You can turn the water mentation in the round or square type on by turning the faucet handle. You can document box.

  • Page 39: Armature Box Cover

    inside and on the cabinet are explained • At last lock the cover with key. below: 1. Armature box cover 2. Butterfly valve and dust covers 3. Parking brake activation sensor 4. Discharge adapter 5. 'Ex-proof' lamp for lighting inside the box and on-off power switch.

  • Page 40: Working Lamp

    Working lamp Hose holder Do not forget to close the co- vers of the hose carriers befo- re driving. Hoses can fall, causing injuries accidents. Prevent the product remaining in the discharge hoses from dripping onto the ground. In case of dripping into the Working lamp switch chamber, valve can be used to drain the liquid.

  • Page 41: Rear Bumper (Rear Protection Equipment)

    3.12.12. Rear Bumper (Rear single, the ladder is located on the side Protection Equipment) of the vehicle for easy access and safety (3). Your vehicle has a rear bumper (rear protection equipment) in accordance with legal regulations. If you drive with a damaged bumper, traffic safety is to be compromised.
  • Page 42 the fix part of the ladder, secure the ladder. Do not drive without fully se- curing the folding ladder with the lock-latch mechanism. Ot- herwise, the ladder may be thrown while driving and cau- se injury. 3.12.13.2. Fixed Ladder The ladder used to climb to the top of the vehicle is manufactured for easiness and safety.
  • Page 43 mounted on a bracket (3) connected with the handrail, with the pneumatic control buttons (5,6) positioned on the tank. Opening handrail Pneumatic piston Closing manual handrail Lift the locking bracket upwards, grab the handle of the handrail and push it for- ward.

  • Page 44: Lubrication System

    3.12.14. Lubrication System 3.12.14.1. Central Lubrication Automatic Counter System Control Unit This system ensures that the central lu- brication works for 45 seconds when the brake is pressed 100 times. Central lubrication system continuous operation time is maximum 25 minutes. The mi- nimum waiting time...

  • Page 45: Upperstructure Components And Use

    4. UPPERSTRUCTURE COMPONENTS AND USE In this chapter, components of upperstructure of the tanker and their use will be explained. It is very important to understand the use and purpose of this components to achieve loading and unloading securetly. For this reason, before loading and unloading processes, please read this chapter carefully and follow the instructions.

  • Page 46: Tank

    Sampling valve It is used to take samples from the discharge outlet. Thermometer Measures temperature of material inside the tank. Manometer Measures pressure on the system. Drain valves They are used to drain rain water, cleaning water or any water accumulated in the manhole pool. Heating line It facilitates the discharge of the product inside the tank, which is welded from the outside to the bottom sheet of the...

  • Page 47: Pressure Safety Valve

    Manhole cover is manufactured from Damaged thread of the hatch stainless steel and is resistant to heat. clamp cannot withstand inner pressure of tank and will be Opening the cover: broken. • There are hatch clamps (2) on the Consider the following subjects dur- tank, loosen them by turning the ing opening or closing manhole levers.

  • Page 48: Vacuum Valve

    Valves in the pictures are; 4.1.8. Side Air Line When the left (1) side is OPEN and right (2) side is CLOSED air from the com- pressor enter to tank. Side air line It is the air line (1) that supplies air to the system by connecting to the compressor.

  • Page 49: Top Air Line

    After discharge of remaining material, Handwheel bottom valve opening close the mechanism (3) by turning control clockwise and push the safety lock (2) The bottom valve is opened and closed forward. manually. The valve (1) is opened by turning the wheel counterclockwise, and closed by turning it clockwise.

  • Page 50: Safety Valve

    Gate valve Pneumatic bottom valve opening control The bottom valve is closed by pressing the pneumatic control button. The ability to control the pneu- matic actuator with a remote control system can be added to the vehicle upon customer request. 4.1.12.

  • Page 51: Remote Control System

    Open the valve by pulling the pneumatic control button (5). Close the valve by pressing the pneu- matic control button. In some cases, the butterfly valve that used as a safety valve may not be pneu- matically controlled, manually controlled. The ability to control the pneu- matic actuator with a remote control system can be added...
  • Page 52 Remote control Activation of the remote control: • Press two buttons that says ‘Ober- Opening and closing of the bottom luft’ (7,8) for minimum 2 seconds valve: simultaneously. When the button that says ‘Boden-ventil’ • Thus, the remote control connects (1) is pressed, the pneumatic bottom with the receiver inside the panel.
  • Page 53 Opening and closing the safety valve: • Entering the PIN code to the remote When the button that says control: ‘Schnellschlussschieber’ (2) is pressed, the pneumatic safety • Enter the PIN code specified (3-4-5- valve, which is the second closing element of the discharge line on the 6) respectively using the buttons rear side of tanker opens.
  • Page 54 the tank on the other end of the fluid • Thus, all valves that has been discharge hose. opened earlier (top air line valve, pneumatic bottom valve, pneumatic • When the button that says safety valve) turn off automatically. ‘Schnellschlussschieber’ (2) is pressed again, the bottom valve closes and the relevant LED light (3) turns off.
  • Page 55 Control panel Control panel Opening bottom valve; • Rotate the button on the left end (3) • By turning the bottom valve button of the panel to left to activate the (5) on the panel to the right, the bot- control by panel.

  • Page 56: Sampling Valve

    If the air pressure of the system is lower than 6.5 bar, the air tube of the trailer may be empty. Check the air tubes. 4.1.14. Sampling Valve It is used to take samples from the dis- charge outlet. Open by rotating the lever clockwise, close by turning it counter- clockwise.

  • Page 57: Manometer

    4.1.16. Manometer or any remaining material. Hose carrier discharge valve is located on back of the One thermometer (1) is located on the carrier, with opening of this valve col- rear part of the tank, upper part of hand- lected water discharges directly to wheel bottom valve control, in order to ground.

  • Page 58: Heating Line

    4.1.17. Heating Line STS tankers have a heating line to heat the transported material. Heating is being done in two different ways, with steam and liquid. Heating with steam • Connect the hose line that will sup- ply the system with hot steam to the heating line inlet (1).

  • Page 59: Warning Signs On The Tank

    After the switch is turned to the '0' position, the heater continues to operate for a whi- le. Do not disconnect the elec- trical connection vehicle during this period. 4.1.18. Warning Signs On the Tank There are warning labels and plates (1) at various places on the tank, especially at the back of the tank.
  • Page 60 Pressure safety valve It prevents the formation of pressure higher than the oper- ating pressure in the tank. Vacuum valve It prevents negative pressure higher than the specified val- ue that may occur in the tank. Blast valve In case the pressure in the tank exceeds 3.67 bar, it stabil- izes the pressure and secures the tank.

  • Page 61: Tank

    4.2.2. Tank Walk on the walkway when you climb up the tank. Do not The tank of the chemical tanker vehicles step on the coating sheet to is manufactured from stainless steel. prevent damage to the coating Tank is coated by aluminium or stainless sheet on the exterior surface steel sheet after being insulated with of the tank.

  • Page 62: Pressure Safety Valve

    4.2.5. Pressure Safety Valve In case tightening or loose- ning the clamps of manhole Pressure safety valve (1) is an important cover when the tank is under protective equipment. It prevents the ex- pressure, manhole cover may plosion of the tank by keeping the pres- break off from tank body and sure (operating pressure) in the tank may result in injuries even...

  • Page 63: Blast Valve

    4.2.7. Blast Valve After removing the remaining material, bring the lever (2) of the ball valve to closed position, remove the compressor connection and install the coupling to the end of the jet air line again. As an option, pneumatic blowing mecha- nism is also provided.

  • Page 64: Bottom Valve

    position to supply air to the inside of the tank. And both the butterfly valve (2) and the ball valve (3) shall be brought to the open position to discharge the air from the tank. Top air line may be equipped with a pneumatic actuator as per cus- tomer request.

  • Page 65: Safety Valve

    with the pneumatic bottom valve button Pneumatically Controlled Butterfly (2) inside the control cabinet. Valve Bottom valve is opened by pulling the Pneumatically controlled butterfly valve pneumatic control button (2). (3) is used for turning the flow on or of pneumatically.

  • Page 66: Sampling Valve

    Pneumatic control button Thermometer 4.2.12. Sampling Valve 4.2.14. Manometer It is used to take samples from the dis- There is a manometer (1) right after the charge outlet. Open by rotating the lever pressure safety valve on the side air line clockwise, close by turning it counter- to measure the pressure in the system.

  • Page 67: Heating Line

    box pool. Water discharged from here is Heating by Steam discharged to the ground from the valve • (3) under the tank. Hose line that shall provide the hot steam to the system shall be con- nected to the heating line inlet line (1).

  • Page 68: Warning Signs On The Tank

    • Open the ball valve (2) at the inlet of the heating duct located at the back of the tank. Heater cabinet and fuel tank After the switch is turned to the '0' position, the heater Ball valve continues to operate for a whi- le.

  • Page 69: Food Tanker

    people about the material in the tank and to remind people how to behave. Warning signs 4.3. Food Tanker 4.3.1. Overview of Tank Components Component Function Tank It is the main body with cylindirical structure, manufac- tured from stainless steel. Isolation coating It prevents the transported material from freezing due to heat loss.

  • Page 70: Tank

    Ladder and handrail It allows the operator to climb onto the vehicle and work safely. Portable stepladder It is used to enter the tank. 4.3.2. Tank vehicle has approached to the station. Manhole cover is manufactured from stainless steel and is resistant to heat. Opening the cover: •...

  • Page 71: Breather Valve

    • Before closing, check whether the contact surfaces of the manhole and the manhole cover are clean and undamaged. • After closing the manhole cover, tighten the wing nut only by hand. • Never tighten the wing nut with your foot, pipe, hammer or any other tool.

  • Page 72: Bottom Valve

    Bottom valve Handwheel bottom valve opening control: Cleaning line and butterfly valves The handwheel bottom valve opening control (2) is used to open and close the bottom valve. The valve is opened by turning the handwheel counterclockwise and closed by turning it clockwise. Butterfly valves Handwheel bottom valve opening control 4.3.8.

  • Page 73: Thermometer

    4.3.10. Drain Valves Two discharge valves are located on spill box (1) around manhole cover. They are used for discharge of rain water, clean- ing water or any remaining material. Drain holes are located behind the spill box on the right and left, and the water drained from here is discharged to the ground through the valves (2) at the bot- tom of the tank.

  • Page 74: Waste Tanker

    4.4. Waste Tanker 4.4.1. Overview of Tank Components Component Function Tank It is the main structure made of stainless steel and carry- ing liquid waste products. Filling manhole It is used to fill from the top and enter the tank. 6"...
  • Page 75 Discharge pump outlet line It is the pipeline that provides the discharge Tank mixing, pump inlet line It is the pipeline that provides the pump inlet for the tank mixture. Discharge pump inlet line It is the pipeline that provides the pump inlet. Tank mixing, pump outlet line It is the pipeline that provides the pump outlet for the tank mixture.

  • Page 76: Tank

    4.4.2. Tank Tank (1) is the main structure made of stainless steel and carrying liquid waste products. Pneumatically controlled ventilation valve 4.4.5. Safety Valve It is the valve (4) used to balance the pressure. Tank 4.4.3. Filling Manhole Filling manhole (2) is used to fill from the top and enter the tank.

  • Page 77: Pneumatic Valve For Tank Ventilation

    4.4.7. Pneumatic Valve Tank Ventilation It is a tank ventilation on-off pneumatic valve (27). Filling funnel 4.4.10. Filling Funnel 8’’ Pneumatic Control Gate Valve It is a pneumatically controlled valve (9) Tank ventilation valve for filling. 4.4.8. Pneumatic Overfill Protection For Stop The Pump Float (7) indicates the filling level, pneu- matically controlled.

  • Page 78: 6" Manual Control Gate Valve

    4.4.14. Turning Joint Turning joint (13) serves to turn the dis- charge pipe for right and left discharge. Tank level indicator 4.4.12. 6" Manual Control Gate Valve Manuel control gate valve (11) is used to Turning joint control the discharge line. 4.4.15.

  • Page 79: Discharge Pump Outlet Line

    4.4.19. Discharge Pump Inlet Line It is the pipeline (18) that provides the pump inlet. Ball valve 4.4.17. Discharge Pump Outlet Line It is the pipeline (16) that provides the discharge. Discharge pump inlet line 4.4.20. Tank Mixing Pump Outlet Line It is the pipeline (19) that provides the pump outlet for the tank mixture.

  • Page 80: Perrot Coupling Cover

    Sampling valve Hydraulic control lever 4.4.22. Perrot Coupling Cover 4.4.24. Hydraulic Pressure Gauge It is the cover used for closing the port It is the indicator (23) showing the pres- after filling and discharging (21). sure in the hydraulic line. Perrot coupling cover Hydraulic pressure gauge 4.4.23.

  • Page 81: Filling Funnel Valve

    Pneumatic manometer Pneumatic valve 4.4.28. Pneumatic Valve for Tank 4.4.26. Filling Funnel Valve Ventilation It is the filling funnel valve on-off pneu- It is a tank ventilation on-off pneumatic matic valve (25). valve (27). Filling funnel valve Tank ventilation valve 4.4.27.

  • Page 82: Central Lubrication Electronic Counter System

    Central lubrication on – off button Central lubrication system 4.4.32. Hydraulic Quick Coupling 4.4.30. Central Lubrication Electronic Hydraulic quick coupling (31) provides Counter System the hydraulic connection between the tractor and the trailer. This system (29) ensures that the central lubrication works for 45 seconds when the brake is pressed 100 times.

  • Page 83: Transportation Process

    5. TRANSPORTATION PROCESS • Check that kingpin and its couplings are normal . Make sure that there is 5.1. Pre-Driving Checks an adequate amount of grease oil on the fifth wheel, top-connection • Make sure that all necessary docu- plate and kingpin that will prevent mentation is available at the vehicle, damage when coupling and that it does not contain any dust and...

  • Page 84: Cautions During The Parking And Stopping

    If your vehicle is driven at the To ensure that that the king wrong 5th wheel height, mal- pin is locked properly, engage functions may occur in the ve- the first gear of the tractor, hicle. You may have height and press the gas pedal, when problems..

  • Page 85: Important Technical Considerations

    The camera is active after reversing. It provides extra protection against rain and theft. The monitor is not included in the system. Reversing camera 5.5. Important Technical Fire Extinguisher Box Considerations 5.5.2. Wheel Chocks 5.5.1. Fire Extinguisher Keep the wheel chocks in their place and Have fire extinguishers checked periodi- place them under the wheels during cally every year and if necessary, fill...

  • Page 86: Welding

    5.5.6. Welding Never do any welding work on the ve- hicle body and chassis. Disconnect the vehicle’s electrical connection from the tractor before welding on the parts. It is recommended that you disconnect the tractor as well. Connect the minus (-) end of the welding machine as close as Health and Safety possible to the welded part in order to...

  • Page 87: Cleaning Of The Vehicle

    This rule also applies to empty contain- Damaged and invisible signs and labels ers in contact with oil, chemical materi- should be replaced as soon as possible. als, and waste of cleaning cloths. Take Make sure that the tanker is these wastes to the relevant authorities cleaned by authorized servi- or the most appropriate service point for...
  • Page 88 When cleaning the external of the When a tank that has been vehicle: hot-cleaned cools down, va- cuum damage can occur if the • Clean the outpouring load as soon tank is insufficiently vented. as possible. Make sure that there is suffi- cient ventilation via the man- •...

  • Page 89: Transportation Solution

    6. TRANSPORTATION SOLUTION Dangerous substances that can be transported in the ve- 6.1. Dangerous Goods Transportation hicle vary according to the ve- (ADR) hicle structure and options. For this reason, make sure Vehicles carrying dangerous goods that the loads that comply should keep this plate in open position with the regulations and your while driving.
  • Page 90 stainless steel sheet quality specified in or starting up, preventing the vehicle's the contracts. center of gravity from shifting to a large extent. A change in the vehicle's center After insulating the tank with glass wool, of gravity can affect the braking distance, it is covered with aluminum or stainless handling and control of the vehicle.

  • Page 91: Loading And Load Security

    7. LOADING AND LOAD SECURITY • All danger signs are in place and visible. 7.1. Loading and Discharging of Bitumen (Tar) Tanker • In addition to these checks, some of the equipment in the vehicle must 7.1.1. Safety Instructions also be checked in their manufactur- er's manual.

  • Page 92: Loading Preparation

    material to be loaded. Follow ADR regu- • Ensure that you have performed the lations and material safety instructions. loading in compliance with the laws and regulations of all countries Depending on the previous load that was where you drive the vehicle. transported, get the tanker vehicle prop- erly cleaned before you make a new The axle loads of the tractor/semi-trailer...
  • Page 93 2. Provide necessary safety on the sur- 9. Close manhole cover after the tank is roundings before starting the filling filled. process. 10. Step down from ladder and close the 3. Perform grounding process with the handrails carefully. help of grounding pins (1) on the right 11.

  • Page 94: Discharge

    3. Perform grounding process with the Emergency buttons are push help of grounding pins (1) on the right type. When pressed, it stops and left sides of vehicle. filling or discharging in an emergency. 4. Supply air to the system by connecting the side air line (1) of the vehicle to the 7.1.5.
  • Page 95 If you open the manholes or loading connections while the tank is under pressure, these equipment may explode. In this case, you and those around you can be seriously or even fatally injured. • Before emptying, check if the tank is under pressure. •...
  • Page 96 7.1.5.2. Free Discharge Keep available and wear the appropriate protective equipment, depending on the material to be discharged. Follow ADR regulations material safety instructions. Only get onto the tank when the folding handrail is raised and if the vehicle is se- cured against accidental movement.

  • Page 97: Loading And Discharging Of Chemical Tanker

    • Do not carry items that may cause sparks (keys, lighters, etc.) in the pockets of the clothes. Do not wear clothes that may cause static elec- tricity during operation. • Do not attempt to thaw frozen man- hole covers with open flames. •...
  • Page 98 distributed evenly on the load car- Loading and unloading the riage surface and the calculations tanker vehicle that is not con- are done accordingly. Thus, the load nected to the tractor may cau- up to the maximum carrying ca- se the vehicle to overturn. Fill pacity of your vehicle must be dis- or unload the tanker vehicle tributed to ensure that equal weights...

  • Page 99: Load Distribution And Load Limits Of Tractor-Semi-Trailer Combination

    along with how and how much of the ton- Follow the correct order du- nage and dimensions of these loads are ring the filling and unloading to be secured. operations. This is especially important if several loading 7.2.2. Load Distribution and Load sections are being filled at the Limits Tractor-Semi-trailer...

  • Page 100: Loading

    • Make sure of the compatibility of the product that is to be loaded with the materials of the vehicle and its seals. Product residues in the tank can contaminate the products in the subsequent loading and makes them unusable. •...

  • Page 101: Discharge

    compressed air. The compressed air is If the grounding pin is not supplied from an external or on board connected, statical load may compressor. cause sparks and explosions. When selecting an unloading procedure, • Connect the grounding pin while please take the following factors into filling and dicharging processes.
  • Page 102 section “Components and Use of Upperstructure”). Grounding pin Top air line ball valve 4. Supply air to the system by connecting the side air line (2) of the vehicle to the 7. Open the bottom valve (5) (See sec- compressor. tion “Components Upperstructure”).
  • Page 103 9. After the discharge of the material is completed, take off the material resid- uals inside the bend with free blowing mechanism (7) (See section “Compo- nents and Use of Upperstructure”). 10. Close bottom valve and free blowing mechanism when discharge is complete. 11.
  • Page 104 6. Open bottom valve (5) (See section “Components Upperstructure”). Hydraulic control valve Pneumatic actuator 9. Close the hydraulic valve after the dis- charging process is complete. 7. Open the butterfly valve (6) on the pump inlet line. 10. Close bottom valve. 8.

  • Page 105: Warnings For Filling And Discharging Operations

    When free discharge (by gra- The material transported in vity, without giving compres- the tanker may be hot. During sed air into the tank), one of the filling and discharging the manhole covers must be processes, care must be taken opened before starting the against the danger of burning.

  • Page 106: Checks After Loading And Unloading

    cell phones and auxiliary heaters. identification plate. Comply with all Headlamps of the vehicle are un- national/international laws, rules necessary, too. and regulations about loading and occupational safety. • Avoid conducting shoes and hard • hats, wear additional protective While all vehicles are being de- clothes, too, if required.

  • Page 107: Load Distribution And Load Limits Of Tractor-Semi-Trailer Combination

    Loading and unloading the Follow the correct order du- tanker vehicle that is not con- ring the fil-ling and unloading nected to the tractor may cau- operations. This is especially se the vehicle to overturn. Fill important if several loading or unload the tanker vehicle sections are being filled at the only when the vehicle is con-...

  • Page 108: Loading

    6. Vehicle is ready for filling. • Make sure of the compatibility of the product that is to be loaded with the 7. Avoid overfilling and fill each compart- materials of the vehicle and its ment max. to its NET volume. seals.
  • Page 109 vehicle with the necessary equipment 7. Perform the discharging operation. (adapter etc.). 8. Close the bottom valve and the butter- fly valves. 9. Step down from ladder and close the handrails carefully. 10. After the connections between the station and the vehicle are removed, the vehicle is ready for drive.
  • Page 110 2. Provide necessary safety on the sur- 6. Open the butterfly valve (3) located at roundings before starting the filling the discharge port on the side where you process. will discharge. (See section “Compo- nents and Use of Upperstructure”). 3. Connect the discharge hose of the station to the discharge port (1) of the ve- Starting discharge hicle with the necessary equipment...

  • Page 111: Warnings For Filling And Discharging Operations

    • When the tanker air pressure All valves and manhole covers are exceeds 2 bar, the safety valve closed and secured. automatically evacuates the • excess air. All material hoses are safely removed. 6. After the discharge process is fin- •...

  • Page 112: Load Distribution And Load Limits Of Tractor-Semi-Trailer Combination

    • • All valves and manhole covers are Ensure that you have performed the closed and secured. loading in compliance with the laws and regulations of all countries • All material hoses are safely where you drive the vehicle. removed. The axle loads of the tractor/semi-trailer •...

  • Page 113: Loading

    7.4.3. Loading 7.4.3.1. Top Filling 1-) Draw near the filling station. Stop the vehicle. Engage the tractor handbrake. 2-) Fix the vehicle with the help of wheel chocks. 3-) Open the manhole cover (2) on the tank. 4-) Connect the perrot coupling to fill/dis- charge hose.

  • Page 114: Discharge

    14-) Since the product that fills in the tank is foamy on top, some more product can still be filled into the tank. In order to make this, press the pneumatic valve (24) to operate the product pump for 10 seconds and bring the hydraulic control lever to the filling position.
  • Page 115 Manual control gate valve Hydraulic quick coupling 2-) Close the 6" manual control gate valve (11.1) on the pump outlet line. 6-) Activate the tractor PTO and pump oil into the system. 3-) Set the 3-Way Ball valve (15), the dis- charge pump inlet line (18) to the "Off"...
  • Page 116 When free discharge (by gra- vity, without giving compres- sed air into the tank), one of the manhole covers must be opened before starting the discharge. 1-) Draw near the filling station. Stop the vehicle. 2-) Fix the vehicle with the help of wheel chocks.
  • Page 117 Manual control gate valve Hidrolik quick coupling 7-) Set the 3-Way Ball valve (15), the dis- charge pump inlet line (18) to the "On" 9-) Activate the tractor PTO and pump oil position and the tank mixing pump outlet into the system. line (19) to the "On"...

  • Page 118: Warnings For Filling And Discharging Operations

    • Before and during filling operation, follow the safety instructions of the transporter. • Do not smoke ! • To prevent the risk of explosion, turn off any electrical appliances that are not used. These include the radio, cell phones and auxiliary heaters. Headlamps of the vehicle are un- necessary, too.

  • Page 119: Inspection And Maintenance

    8. INSPECTION AND MAINTENANCE • To prevent permanent damage to the semi-trailer, 8.1. Safety Instructions • To ensure that the semi-trailer main- There is a risk of accident that tains its value, may arise in terms of a vehicle that is not built or built insuffi- •...

  • Page 120: Cataphoresis Coating

    The seals can only be checked when the For the validity of the warranty silo vehicle is depressurized. The man- period, the first maintenance hole cover must be open. and annual periodic mainte- nance must be done at autho- Seals; rized services.

  • Page 121: Trouble Shooting

    adjustment of the semi-trailer is not Please refer to the pump made or cannot be made, the mal- manufacturer's manual functions and damages that may oc- pump usage and warranty cur in the brake system or the conditions. tractor and the semi-trailer are out- side the responsibility of our com- Please refer to the compres- pany, and all responsibility in this...
  • Page 122 • Possible problems that may Place the lever jack under the axle arise in the future can be pre- as close as possible to the tire to be vented by checking all the bolt replaced. holes on the rims against ova- •...

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