This document is a user manual for the Kässbohrer Tanker Series, providing comprehensive information on its operation, maintenance, and safety. The manual covers various types of tankers, including Bitumen (Tar), Chemical, Food, and Waste tankers, detailing their specific components and usage instructions.
The manual emphasizes the importance of using the vehicle in compliance with its purpose and adhering to safety instructions to prevent accidents, reduce downtime, and ensure reliable operation. It highlights that the manufacturer is not liable for damages resulting from non-compliance. The document strictly prohibits carrying people and live animals, transporting unsecured goods, or materials requiring special equipment. It also warns against exceeding permissible weights, vehicle speed, or dimensions, and using unapproved parts.
Safety symbols are used throughout the manual to indicate critical information:
- A red exclamation mark in a triangle signifies very important health and human safety information, where ignoring it can lead to serious injury or death.
- A yellow exclamation mark in a triangle indicates critical accidents may occur if instructions are not followed.
- A blue 'i' in a circle denotes additional information.
- A green recycling symbol indicates environmentally safe disposal of chemicals.
Personal protective equipment (PPE) is mandatory during operations. This includes gloves, work shoes, appropriate overalls (without pleats or external pockets, with adjustable cuffs), and lightweight helmets. Long hair must be protected to avoid tangling, and ties, necklaces, or dangling jewelry are strictly prohibited when working on the vehicle. Protective goggles are required during maintenance, and appropriate masks when working with hazardous substances or in dusty environments.
The manual stresses the importance of keeping the user manual, warranty, and maintenance documentation available in the vehicle at all times. It advises against modifying the vehicle without written manufacturer approval and insists on using only original spare parts.
Main Information
Vehicle identification stickers are present on the vehicle, including the vehicle identification plate (located on the right side) which provides:
- Type approval number
- VIN number
- Technical total capacity
- Technical king pin capacity
- Technical axle capacity
- Technical total axle capacity
- Nationally approved total capacity
- Nationally approved king pin capacity
- Nationally approved axle capacity
- Nationally approved total axle capacity
- Vehicle Type
For Stainless Chemical and Bitumen (Tar) tankers, which are pressurized/non-pressurized vessels carrying dangerous goods, compliance with ADR regulations is indicated, and the seal of approval by a 3rd organization is on the plate. Tested gross volumes are also listed.
A brake data plate (2) is present on EBS-equipped vehicles, showing information such as empty vehicle weight, loaded vehicle weight, axle lifting, brake chamber data, references, driving height, pin positions, and IN/OUT-connections.
The VIN (chassis) number is located on the right side of the vehicle, marked with a different color than the chassis.
The warranty is based on the usage and maintenance conditions described in the manual and warranty book. Maintenance must be performed by authorized services using original spare parts to ensure warranty rights.
Trailer Running Gear and Usage Instructions
Brake System
The main connection between the truck and trailer is via air couplings. Three types are generally used: Standard (Palm), Duomatic, and C (UK) Couplings, all serving the same function but with different shapes. There are two air supply lines: Brake Line (Yellow) and Supply Line (Red).
- Service Line: Pneumatic air hose feeding the brake line.
- Supply Line: Pneumatic air hose feeding the air tanks and trailer.
If equipped with two types of couplings, only one should be used at a time. The parking brake of both truck and trailer must be engaged during mounting/demounting. Only authorized services should modify brake parameters or service the brake system. Test points may be present on the chassis or above the air couplings to check air pressure. Coupling filters must be cleaned regularly. Driving with a non-suitable air connection or damaged air supply parts is dangerous and forbidden.
Compressed Air Tanks
Pressurized air is stored in air tanks, with quantities and capacities varying by vehicle specifications. In cold or high-humidity conditions, moisture can condense in the tanks. Tractors are usually fitted with air driers, but condensed water must still be drained via the drain valve. Water in the air tank can cause corrosion and brake system failure if frozen. The pneumatic system should be checked frequently in cold weather. An EBS warning lamp illuminates if air tank pressure drops below 4.5 bars, and brakes automatically lock if the service line pressure is below 2.5 bars.
EBS Socket
Trailers are equipped with an EBS (Electronically Controlled Brake System) featuring automatic load sensing braking pressure (ALB) and anti-skid systems (ABS/ABV). To activate EBS, both truck and trailer must be EBS-equipped. An EBS cable from the truck must be connected to the trailer's EBS socket. Driving without EBS connectors or with a faulty EBS system is illegal and can lead to accidents. Trailers have an additional power supply for EBS from brake lamps, activating extra safety functions if the EBS connector is damaged.
RSS is integrated into the trailer modulator, analyzing wheel speed, load, and transverse acceleration to detect rollover risk and automatically apply brakes. It helps prevent accidents but cannot override the laws of physics.
PREV (Park Release Emergency Valve)
Brake control systems are typically on the driver's side.
- Service Brake (Black button 1): Allows maneuvering the trailer without air connections. Pushing it disables the service brake; pulling it activates it. Frequent use without air connection can reduce air pressure and braking power. It activates automatically if air connections are demounted. It is not suitable for permanent braking; for longer periods, the semi-trailer must be secured with a spring-loaded park brake and wheel chocks.
- Spring Loaded Park Brake (Red button 2): Used for longer parking on flat or inclined surfaces. Pulling it activates the brake; pushing it deactivates it. It must be deactivated before driving.
Brake Chambers
Vehicles may have disc or drum brake axles. Brake chambers are chosen based on axle type and loading capacity. Maintenance, modification, or repair must be done by authorized services.
- Manually Deactivation of Parking Brake Spring: In emergencies, the parking brake spring can be deactivated by removing the release rod (2) from its slot (4), inserting it into boreholes (1), and screwing in the nut (3). This makes the brake chamber work only on service brakes, and the spring brake won't activate even if air pressure drops below 2.5 Bar. This operation should only be used until the trailer is serviced, and the vehicle must be secured with wheel chocks beforehand.
- Activation of Brake Chambers: Remove the nut (1) and release rod (2), then screw the release rod back into its place on the brake chambers (3) and close the plastic cover. Ensure the brake system works properly before driving.
Suspension System
Vehicles are equipped with an air suspension system.
- Manual Control: A control button on the driver's side allows selecting fifth wheel height (position 1 for lower, position 2 for higher).
- Auto Reset: The auto reset lever works similarly to manual control. When the EBS socket is mounted and the vehicle is driving at a producer-defined speed, the lever automatically sets the driving height.
- Electronic Controlled Air Suspension (ECAS): An optional system that electronically sets driving height. When the EBS socket is mounted and the vehicle is driving at a producer-defined speed, the lever automatically sets the driving height. Buttons allow raising or lowering the vehicle height.
Electrical System
Vehicles have 15-pin, 2x7-pin (for non-ADR tankers), or 15-pin + 2x7-pin (for ADR tankers) electrical sockets for connections between truck and trailer.
- 15 Pin Socket: Provides electricity for stop lamps, signal lamps, etc., according to ISO 12098. Pin functions are detailed (Left/Right indicator, Fog lamp, Ground, Left/Right taillight, Brake light, Reverse light, Supply line, EBS, Axle lifting).
- 2x7 Pin Socket: Provides electricity for stop lamps, signal lamps, etc., according to 24S ISO 3731 and 24N ISO 1185 norms. Pin functions are detailed (Ground, Left/Right taillight, Left/Right indicator, Brake light, Reversing lamp, Supply line, EBS, Axle lifting, Fog lamps).
Electrical sockets must be connected while driving. Ensure truck and trailer electrical systems are compatible with norms to avoid problems. Lamps must be checked regularly, and repairs must use original and approved parts. Adding or removing lamps may make the vehicle non-suitable for regulations. LED systems consume low energy, which might trigger failure lamps in older tractors.
Light System
The vehicle is equipped with a light system compliant with regulations. Components include Electrical Sockets, Stop Lamps, End Outline Markers, License Plate Lamps, Side Position Lamp, and Modulator.
King Pin
The king pin connects the truck and trailer. Vehicles may have 2” or 3.5” diameter pins. The king pin diameter must be checked before connecting. If wearing exceeds 2 mm, it must be replaced. Vehicles may have a double king pin slot, allowing the king pin to be moved by removing bolts. Total vehicle length must comply with country regulations.
Landing Gear
Front landing gears are located behind the gooseneck area, allowing the vehicle to stop without a truck.
- Working Principle: The crank handle (1) is removed from its holder (2) and brought to a perpendicular position.
- Low Speed (A): Turning the crank handle in the fully pressed position raises/lowers at low speed.
- High Speed (B): Turning the lever in the fully extended position provides high-speed lifting/lowering. This is used to quickly lower the gear until feet touch the ground when separating the semi-trailer, or to raise it quickly after connection.
The crank handle is usually on the passenger side. The semi-trailer must be secured with wheel wedges to prevent tipping. Loading/unloading without the tractor connected can cause the vehicle to raise, leading to accidents. If the tractor leaves a loaded trailer, ensure the load is homogeneously distributed to prevent the front or rear from raising. Landing gear should be in the middle (neutral) position when disconnecting. For long-term parking without a coupled tractor, lower air suspensions and adjust landing gears to keep the loading area parallel to the ground.
Side Protection Equipment (Underrun Protection)
Side protection equipment must be in the off position while driving. Some can be opened upwards for service access (e.g., spare tire). Driving with open underrun protection is dangerous and illegal.
- Removing: Open protection release pins (2) on both sides and remove the underrun protection.
- Installing: Insert protection into slots and insert pins. Ensure it is fixed properly to prevent injury.
Semi-Trailer Axle System
Vehicles use axles with disc or drum brakes. Axles must be loaded within maximum legally permissible limits indicated on the identification plate. The user is responsible for proper use and maintenance. Healthy brake system operation depends on using the semi-trailer with a compatible tractor. Brake adjustments must be made by authorized services of the tractor company.
- Self-Steering Axles: Optional, usually on the rear axle, to increase maneuverability. They have a locking mechanism. Reversing with unlocked steering axles is dangerous; ensure it's locked before backing up.
- Locking: For EBS-equipped vehicles, the self-steering axle locks automatically when reverse gear is engaged. It can also be locked manually by driving straight, ensuring the axle is straight, and closing valve (1) or turning the button to off.
- Unlocking: Automatically unlocks when the vehicle moves forward. To manually unlock, turn the valve handle 90° clockwise (2) or move the button to the open position.
- Axle Lifting: Optional feature to minimize tire wear and balance load distribution. Requires active EBS connection. Lifts automatically based on legal regulations and speed limits (if load is below maximum allowable). Manual intervention may be needed for departure or maneuvering aid. Departure aid activates below 30 km/h and if axle capacity doesn't exceed 30%. Traction help can be activated by pressing the tractor brake pedal 3 times when stationary. A spring-loaded button in the tractor cabin can also manually raise/lower the axle lift. Interference with EBS modulator parameters can void regulations.
Hubodometer
Hubodometers show the distance traveled in kilometers or miles, adjusted to tire diameter.
Tires
Tires must have appropriate carrying capacity. The manufacturer offers tires for various uses (highway, off-road, mixed). For wet roads, tires with low decibel values and close to Class A for braking and fuel efficiency are preferred. EU tire label values are available on the website.
For double/twin row wheels, tires must be matched by diameter (tread depths not differing by more than 5 mm). Newly coated and partially worn tires should not be used side-by-side. Mismatching causes excessive deformation and premature wear. Radial and crossply tires should not be used side-by-side.
Seasonal M+S (Mud and Snow) or 3PMSF (3 Peak Snowflake) tires may be mandatory in some countries. Unsuitable or worn tires can cause serious accidents. Tires are heavy; observe ergonomics and safety rules during replacement to avoid pinching, falling, or cutting. Spare wheel holder carriers are designed for specific tire dimensions; follow rules for removal/mounting.
Spare Wheel Holder
Different types are offered:
- Crane Type:
- Removing: Remove screws (2), mount lever (3) and turn counterclockwise to lower the wheel, then remove fixation parts (4).
- Placing: Mount fixation parts (4) to the tire, lift by turning handwheel (3) clockwise, mount screws (2), and store lever (3).
- Basket Type: Single or double basket types.
- Removing: Remove pin (2) from fixation cane (1), remove fixation cane (1) and pin (3), then move tire outwards.
- Placing: Slide tire into holder, attach fixation cane (1) and pin (3), then mount pin (2).
Mudguards
Vehicles have mudguards and mats compliant with legal regulations to prevent splashing. Some may have folding mats to prevent rubbing against the ground during a crash. Folding mats must be open while driving.
Wheel Chock
Two wheel chocks and holders are provided.
- The vehicle must be secured with wheel chocks when parked on a slope, during loading/unloading, or without a tractor.
- Place chocks only on fixed axles, never on idle/steer axles.
- Ensure pins are properly mounted when chocks are fixed.
- Place chocks properly after driving.
- Pin Type:
- Removing: Pull cotter pin (1), pull chock sideways from slot.
- Placing: Fit chock onto pin, replace cotter pin.
- Pocket Type:
- Removing: Push handle (1) from chock to the other side.
- Placing: Pull handle (1) to insert chock.
Boxes and Storage Units
Ensure boxes and storage units are properly closed and materials fixed before driving to prevent accidents. Observe safety measures when using cabinets.
- Stainless Steel Toolbox: For tools, usually on the driver's side.
- Steel Food Box: Usually on the passenger side, may have compartments and gas cylinders for cooking. Some may have a sliding shelf that must be locked after closing. Lamps may be equipped, connected to parking lamps, with an on/off switch.
- Plastic Toolbox:
- Unlocking: Remove lock cover, unlock with key, pull lever towards you, turn lever to open door.
- Fire Extinguisher Cabinet: Protects extinguishers from external environment.
- Opening: Open plastic latches (1), lift latch up and back to unlatch cover, open Velcro fastening, take extinguisher.
- Closing: Insert extinguisher, fix with Velcro, close cover, close latch, tighten latch.
Fire extinguishers must be maintained regularly and their expiration dates observed.
Water Tank
For general cleaning, with a faucet handle and filler neck. May have a soap dispenser.
- Ignoring hygienic rules is dangerous; wastewater must be disposed of according to regulations.
- Water is not for drinking, only cleaning.
- Empty in cold weather to prevent freezing and cracking.
Document Box
For non-valuable documentation. Round type opens by turning cover counterclockwise. Square type opens by lifting and removing a pin. Keep locking pin and door neat.
Fuel Tank
Optional diesel tank (60-80 liters) for heater unit, usually on the left side. Open by unlocking and turning cap counterclockwise. If heater/fuel tank installed by customer, red and black hoses on front panel connect to heater unit.
- Observe legal regulations for fuel tank use. Act according to legislation in case of leakage.
Armature Box
Cabinet for filling/discharging couplings, controls, hoses, and accessories. Filling/discharging can be automatic.
Components: Armature box cover, butterfly valve and dust covers, parking brake activation sensor, discharge adapter, 'Ex-proof' lamp with on-off switch, bucket, shovel, copper hammer.
- Armature Box Cover (bus type, opens upwards):
- Opening: Insert key, turn to open locks, pull buttons (1) on handles, press button to release handle, lift cover by handles (2).
- Closing: Lower cover, place into lock, pull handle forward, lock with key.
Hose Carriers and Hose Holders
Hose carriers (1) are on one or both sides of the vehicle, singly or in pairs, on the upper chassis to carry discharge hoses. Covers may be front or front and back. Keys are in the toolbox. Hose holders (2) for bitumen tankers are open pools with a drain hole at the rear.
- Close hose carrier covers before driving to prevent hoses from falling and causing injury.
- Prevent product remaining in discharge hoses from dripping; use valve to drain liquid if dripping into chamber.
Working Lamp
Located at the rear, on top of the bumper or chassis profile (1). Can be rotated up-down and left-right. Turned on/off with switch (2) on the back.
- Putting into use: Remove upper arm from lock-latch, pull lamp to desired area.
- Fixing: Push lamp into place, fold arms, lock lock-latch.
- If equipped, fold up parking sign at night before use.
- Do not drive without securing the working lamp to prevent it from being thrown and causing injury.
Rear Bumper (Rear Protection Equipment)
Compliant with legal regulations. A damaged bumper compromises traffic safety and must be replaced quickly with an original one.
- Fixed Bumper: Includes Lamp group, License plate location, License plate lighting, Side marker lamps, Reflectors.
Ladder, Walkway and Handrails
Ladder systems vary by tanker type:
- Chemical (STC) tankers: Ladder (1) usually at rear, bottom foldable.
- Food (STL) tankers: Ladder (2) fixed behind tank.
- Bitumen (STS) tankers: Ladder (3) on the side for single filling/discharging manhole access.
- Foldable Ladder:
- Opening: Hold ladder, release from latch-lock, pull towards you, push downward.
- Closing: Hold lower part, lift slowly, lock latch-lock.
- Do not drive without securing the folding ladder to prevent it from being thrown and causing injury.
- Fixed Ladder: For climbing to the top, connected to the upper walkway.
- Step Ladder: Used to enter the tank. Fixed to walkway with plastic nut (2). Unscrew nut, take ladder, hang on manhole neck (3). After use, return to walkway and fix with nut.
- Handrail: On top of vehicle, sides of walkway, for safe work. Manual, automatic via folding ladders, or pneumatic systems.
- Opening Manual Handrail: Grab handle (4), pull towards you, release from latch (5). Ensure lock bracket (6) is in slot.
- Closing Manual Handrail: Lift lock bracket, grab handle, push forward, fix latch.
- Opening via Folding Ladder: Arm (2) connects folding ladder (1) to handrail, opening it when ladder opens.
- Opening via Pneumatic System: Pneumatic piston (4) on bracket (3) connected to handrail, controlled by buttons (5,6) on tank. Turn left button (5) to open, lower to close. Turn right button (6) to open, lower to close. A rope is mounted on the handrail to prevent falls.
Lubrication System
- Central Lubrication Automatic Counter System Control Unit: Ensures central lubrication works for 45 seconds when the brake is pressed 100 times. Continuous operation is max 25 minutes, minimum waiting time 5 minutes.
Grounding Pins
During filling/discharging, grounding pins (1) (DIN 75013) prevent static electricity charges, fire, or explosion. Locations indicated by sign (2).
Warning Signs
Warning signs (1) are on different places of the vehicle. They must always be visible; replace worn, damaged, or invisible signs immediately.
Upperstructure Components and Use
This chapter explains tanker upperstructure components and their use for safe loading and unloading.
Bitumen (Tar) Tanker
- Tank: Main body, cylindrical, stainless steel. Single compartment. Breakwaters prevent material floating and center of gravity changes during braking/acceleration.
- Isolation Coating: Prevents material freezing due to heat loss. Walk only on walkway to avoid damaging coating.
- Manhole Cover: For top filling and tank entry. Stainless steel, heat resistant.
- Opening: Loosen hatch clamps (2) by turning levers, pull clamps backwards, lay on tank, hold cover by handle (3) and rest on spill box edge.
- Safety: Never tighten/loosen clamps under pressure; cover may break off. Damaged threads can't withstand pressure. Check contact surfaces are clean, tighten clamps crosswise manually (never with foot, pipe, hammer). Grease threads regularly. Tank must not be under pressure.
- Pressure Safety Valve (1): Protective equipment, prevents tank explosion by maintaining operating pressure during pressurized discharge. Located on front part of vehicle, on side air line.
- Ventilation Valves: Connected to upper ventilation line and open atmosphere. Balance pressure and provide ventilation. Left (1) open, right (2) closed: air enters tank. Left (1) closed, right (2) open: excess air released.
- Vacuum Valve (1): Protective equipment, prevents negative pressure from air pressure/temperature variations. Located inside spill box. Check with control lever (2) after each filling/discharging.
- Side Air Line (1): Supplies air to system from compressor. Check valve (2) prevents return air to compressor.
- Jet Air Line (1): Accelerates discharge by blowing air at outlet. Free blowing mechanism available to discharge remaining material in bend.
- Opening: Pull safety lock (2), open mechanism (3) by turning counterclockwise.
- Closing: Turn mechanism (3) clockwise, push safety lock (2) forward.
- Top Air Line (1): Above side air line, enters tank from front of hose carrier. Pressurizes and mixes material for easy discharge. Manual valve (2) controls air flow.
- Bottom Valve: For opening during discharge. Manual and pneumatic control.
- Handwheel Control (1): Open by turning wheel counterclockwise, close clockwise. Status indicated by (2).
- Pneumatic Control (3): Open by pulling button, close by pressing.
- Safety Valve (Gate Valve 1): Manually opens/stops flow.
- Opening: Remove pin (2), push lever (3) forward.
- Closing: Pull lever towards you, fix with pin.
- Pneumatic Butterfly Valve (4): Opens/stops flow pneumatically.
- Remote Control System: Controls top air line, bottom valve, safety valve from remote or panel.
- Turning on Remote: Rotate emergency button (1) to open, power button (2) to open. Rotate button (3) on panel to left to activate remote. Rotate emergency button (4) on remote to 'on'. LED (5) green, LEDs (6,7) red.
- Activating Remote: Press 'Oberluft' buttons (7,8) for 2 seconds. Remote connects. LED (1) flashes green, others (2,3,4,5) red.
- Bottom Valve (1): Press to open, LED (2) illuminates. Press again to close, LED (2) turns off.
- Safety Valve (2): Press 'Schnellschlussschieber' to open, LED (3) illuminates. Fluid moves to hose coupling. If hose connected, discharge starts. Press again to close, LED (3) turns off.
- PIN Code: Enter PIN (3-4-5-6) using buttons. Warning buzzer sounds, top air line valve opens.
- Turning off Remote: Press emergency button (1). All open valves close automatically.
- Panel Control: Rotate emergency button (1) to open, power button (2) to open. Rotate button (3) on panel to left to activate panel control.
- Top Air Line Valve: Rotate button (4) on panel to right to open.
- Bottom Valve: Rotate button (5) on panel to right to open. Will not open until top air line valve is open.
- Safety Valve: Rotate button (6) on panel to right to open.
- Manometer (7): Displays pneumatic system air pressure (optimally 6.5 bar). Check air tubes if pressure is low.
- Sampling Valve: Takes samples from discharge outlet. Open by rotating lever clockwise, close counterclockwise.
- Thermometer (1): Measures material temperature inside tank, located at rear, upper part of handwheel bottom valve control.
- Manometer (2): Optional, after pressure safety valve. Monitor pressure for rises/falls.
- Drain Valves: Two on spill box (1) around manhole cover, one on hose carrier (2). Drain rainwater, cleaning water, or remaining material. Discharge to ground from valves under tank (3).
- Heating Line: Heats transported material (steam or liquid).
- Steam Heating: Connect hot steam hose to inlet (1), evacuate steam from outlet (2). Close ball valve (3), supply hot steam. Max pressure 7 bar. Safety valve (4) prevents exceeding 7 bar. Manometer (5) shows pressure.
- Liquid Heating: Closed circuit with hot liquid. Heater and pump in cabinet (6) on left. Fuel tank (7) above cabinet.
- Operation: 24V energy, energized by socket (1) on front. Do not confuse (+) and (-) poles. Heater stops at 78°C, restarts at 72°C. Open ball valve (2) at heating duct inlet.
- Safety: Do not disconnect electrical connection when heater is off but still operating (after switch to '0').
- Warning Signs on Tank (1): Inform drivers/public about material and behavior.
Chemical Tanker
Similar components to Bitumen tanker, with some differences.
- Tank: Stainless steel, insulated with glass wool, coated with aluminum/stainless steel. Single or triple compartments. Wave breakers prevent material fluctuation. Walk on walkway to avoid damaging coating.
- Manhole Cover: Stainless steel, heat resistant. Opening/closing procedures and safety warnings are identical to Bitumen tanker.
- Pressure Safety Valve (1): Identical to Bitumen tanker.
- Vacuum Valve (1): Identical to Bitumen tanker.
- Blast Valve (1): Activates if pressure exceeds set value, secures tank.
- Jet Air Line: Identical to Bitumen tanker.
- Top Air Line: Identical to Bitumen tanker.
- Bottom Valve: Pneumatically controlled.
- Safety Valve: Manually or pneumatically controlled butterfly valve.
- Sampling Valve: Identical to Bitumen tanker.
- Thermometer (1): Identical to Bitumen tanker.
- Manometer (1): Identical to Bitumen tanker.
- Drain Valves: Two on spill box (1), one on hose carrier (2). Drain to ground from valve (3) under tank.
- Heating Line: Steam or liquid heating.
- Steam Heating: Identical to Bitumen tanker.
- Liquid Heating: Identical to Bitumen tanker.
- Warning Signs on Tank (1): Identical to Bitumen tanker.
Food Tanker
- Tank: Stainless steel, insulated with polyurethane and glass wool, covered with stainless steel. Usually triple compartments.
- Isolation Coating: Polyurethane and glass wool insulation to maintain temperature for perishable food. Walk on walkway to avoid damaging coating.
- Manhole Cover: For top filling. Stainless steel, heat resistant.
- Opening: Loosen screwed wing nut (2), lean nut back on spill box, hold handle (3) and lean against spill box edge.
- Safety: Damaged wing nut threads can cause material loss. Check contact surfaces, tighten wing nut by hand (never with foot, pipe, hammer).
- Breather Valve (1): On manhole cover, allows tank to breathe, eliminates vacuum risk during discharge. Plastic nut (2) on cover should be removed, top cover removed, and inside cleaned regularly.
- Cleaning Line (1): For cleaning tank interior with cleaning balls. Remove blind cap (2), connect to hot steam/water line. Open DN50 butterfly valve (3) and DN25 butterfly valves (4), spray cleaning agent through cleaning balls (5).
- Bottom Valve (1): Manually controlled for product discharge.
- Handwheel Control (2): Open by turning counterclockwise, close clockwise.
- Discharge Valves (1): At end of discharge line, standard on right/rear, optionally left. Manually open/cut flow. Rear drain valve in armature box.
- Thermometer (1): Three thermometers, one per compartment, to measure material temperature.
- Drain Valves: Two on spill box (1), drain holes behind spill box, water discharged to ground through valves (2) at bottom of tank.
Waste Tanker
- Tank: Stainless steel, for liquid waste.
- Filling Manhole: For top filling and tank entry.
- 6" Pneumatic Control Gate Valve For Ventilation (3): For tank ventilation.
- Safety Valve (4): Balances pressure.
- Vacuum Valve (5): Prevents negative pressure.
- Tank Ventilation Line: For tank ventilation.
- Pneumatic Overfill Protection For Stop The Pump (Float 7): Pneumatically controlled, indicates filling level.
- Filling Funnel (8): For filling tank.
- Filling Funnel 8’’ Pneumatic Control Gate Valve (9): Pneumatically controlled for filling.
- Tank Level Indicator (10): Visually shows filling level.
- 6" Manual Control Gate Valve (11): Controls discharge line.
- Perrot Coupling (12): Provides connection for discharge.
- Turning Joint (13): Turns discharge pipe for right/left discharge.
- Pump (14): Discharges material by sucking.
- 3 Way Ball Valve (15): Bypasses material into pump line or tank.
- Discharge Pump Outlet Line (16): Provides discharge.
- Tank Mixing Pump Inlet Line (17): Provides pump inlet for tank mixture.
- Discharge Pump Inlet Line (18): Provides pump inlet.
- Tank Mixing Pump Outlet Line (19): Provides pump outlet for tank mixture.
- Sampling Valve (20): Takes samples from product.
- Perrot Coupling Cover (21): Closes port after filling/discharging.
- Hydraulic Control Lever (22): Commissions hydraulic installation.
- Hydraulic Pressure Gauge (23): Shows pressure in hydraulic line.
- Pneumatic Valve (24): Operates product pump for 10 seconds.
- Filling Funnel Valve (25): On-off pneumatic valve.
- Pneumatic Manometer (26): Shows pressure in pneumatic line.
- Pneumatic Valve for Tank Ventilation (27): On-off pneumatic valve.
- Central Lubrication System (28): Automatic lubrication.
- Central Lubrication Electronic Counter System (29): Ensures lubrication for 45 seconds when brake is pressed 100 times.
- Central Lubrication On / Off Button (30): For operation.
- Hydraulic Quick Coupling (31): Hydraulic connection between tractor and trailer.
Transportation Process
Pre-Driving Checks
Ensure all documentation is available, adjustments and loading are proper, vehicle is coupled and secured, pneumatic and electrical connections are made, EBS is operational, structural hardware is in place and locked, load is evenly distributed and within limits, regulations are complied with, lighting/signal system is operational, tire pressures are correct, parking brake is released, all valves/manhole covers are closed, and material hoses are removed.
Semi-Trailer and Tractor Coupling
- Check kingpin and couplings for grease and contaminants.
- Lower tractor rear suspension airbags.
- Set 5th wheel locking system to "On".
- Adjust semi-trailer height with landing gear, engage parking brake, use wheel chocks.
- Move tractor slowly until 5th wheel touches top-connection plate and locks kingpin.
- Raise landing legs.
- Connect air, electrical, and EBS cables/hoses.
- Release parking brake.
- Safety: Ensure kingpin is locked by engaging first gear and slowly releasing clutch; tractor should strive to move semi-trailer. Check connection during travel.
Cautions During Parking and Stopping
- Involuntary movements, unstable posture, insufficient safety at night can cause accidents.
- Use parking brake and wheel chocks.
- Use necessary marking plate in public traffic areas.
Reversing Camera
Optional covered camera system connected to reversing signal. Solenoid valve opens/closes cover. Monitor not included.
Important Technical Considerations
- Fire Extinguisher: Check annually, refill immediately after use. Sealing materials may release corrosive gases when burned; wear protective gloves.
- Wheel Chocks: Keep in place, use during parking, remove before setting off.
- Modifications: Only authorized services for repairs/modifications to maintain warranty.
- Air Leakage: Instant drop in air pressure indicates leakage; contact authorized service. Affects braking safety and airbag lifting capacity.
- Oils: Avoid contact with vehicle oils; dangerous to health.
- Welding: Never weld on vehicle body/chassis. Disconnect electrical connection from tractor. Connect welding machine minus (-) end close to welded part. Prevent sparks/slags on bellows, air hoses, brackets. Do not weld on tankers without gas-free cleaning/measurement results.
- Spare Wheels: Keep spare tires ready.
- Environment: Collect and dispose of waste materials according to regulations. Batteries should be disposed of at appropriate service points.
- Health and Safety (Battery): Keep sparks/fire away (explosive gas). Wear eye protection and rubber gloves (sulfuric acid causes burns/blindness). Do not let children handle. Familiarize with proper use. Do not use battery if electrolyte level is low (explosion risk).
- Waste Oil: Do not discharge into channels, sewers, landfills, or soil.
Cleaning of the Vehicle
- For dangerous materials, do not enter tank for cleaning unless absolutely necessary. Perform gas measurement before entry.
- Tanker must be cleaned by authorized services specializing in tankers.
- Before Cleaning: Ensure tank is fully discharged, no product residue, tank is depressurized, potential conductors are connected.
- Product residue in air lines can contaminate subsequent loads; clean air lines if necessary.
- Use only compatible cleaning agents to avoid damaging tank/sealants.
- Air Lines: Open all valves before cleaning.
- Hot-Cleaned Tank: Ensure sufficient ventilation to prevent vacuum damage when cooling.
- Do not use inflammable/toxic substances for cleaning.
- External Cleaning:
- Newly Painted Surfaces: Clean only after 4-week paint stiffening period with cold water jet. Avoid pressurized water jets or hard brushes. After 4 weeks, avoid high-temperature water or abrasive materials.
- Wash external with water below 60°C. Avoid abrasive detergents. Maintain minimum distance for high-pressure water jet (70 cm for circular nozzle, 30 cm for flat nozzle). Do not direct water on electrical components, receptacles, seal rings, or hoses.
Transportation Solution
Dangerous Goods Transportation (ADR)
Vehicles carrying dangerous goods must display ADR identification plate in open position while driving. Location may vary. Ensure loads comply with regulations and vehicle type.
- Opening Plate: Turn latch (1) clockwise/counterclockwise by 90°, attach opened flap to latch (2).
Transportation Compliant with ATP Legislation
Vehicles may be manufactured according to ATP legislation for perishable foodstuffs. ATP certificate expiry date labels are on the upper front of the side panel. Modifications can void ATP compliance.
Chemical Substance Transportation
Tank is stainless steel. Insulated with glass wool, covered with aluminum/stainless steel. Breakwaters prevent material fluctuation. Walk on walkway carefully to avoid damaging coating.
Loading and Load Security
Loading and Discharging of Bitumen (Tar) Tanker
- Safety Instructions: Ensure cargo is properly distributed, complies with laws/regulations, and is within loading limits/capacities. Load evenly. Do not exceed maximum height.
- Loading/Unloading Safety: Tanker must be connected to tractor.
- Load Distribution: Ensure proper load distribution, considering loading limits, total weight, and axle load capacities. Axle loads may vary; comply with permissible limits. Check loads at weighing stations.
- Loading Preparation: Wear appropriate PPE, follow ADR regulations. Clean tanker if previous load was different. Get onto tank only when handrail is raised and vehicle is secured. Engage handbrake, ensure vehicle is level. Check shipper’s safety precautions, secure couplings, compatibility of product with vehicle materials/seals. Clean tank if dirty.
- Loading:
- Approach filling station, stop, engage handbrake.
- Ensure safety of surroundings.
- Ground vehicle with grounding pins (1).
- Open guardrails before climbing ladder.
- Open manhole cover (2).
- Insert hoses into manhole.
- Fill tank (avoid overfilling, fill to NET volume).
- Close manhole cover, step down, close handrails.
- Remove grounding lines.
- Vehicle ready to drive.
- Safety during Loading: Grounding pin must be connected. Avoid physical contact with load, do not breathe steam. Use PPE. If injury, consult material safety document. Do not use spark-producing tools. No smoking, cellular phones, cameras, open flames. Always connect grounding pins.
- Discharge (Compressed Air): Emptying with compressed air from external/on-board compressor.
- Factors: Product type, on-site conditions, climate.
- Preparation: Park on firm, even ground. Lower landing legs horizontally. Deflate air suspension. Check manhole cover/connections are closed. Connect air battery to compressor via side air line (1).
- Instructions for Compressor: See manufacturer's manual.
- Discharge:
- Approach filling station, stop.
- Ensure safety of surroundings.
- Ground vehicle.
- Supply air to system via side air line (1).
- Connect discharge hose to discharge port.
- After controls, open side air line valve, supply air to top air line (2).
- Open bottom valve (3).
- Apply jet air (4), supply material flow from discharge port (5).
- In emergency, use rapid shut off valve (6).
- After discharge, use free blowing mechanism for residuals.
- Close bottom valve, jet air, top air line.
- Stop compressor.
- Remove connections. Vehicle ready to drive.
- Safety during Discharge: Tanker material is hot; beware of burning. Avoid direct contact, wear PPE. Do not open manholes/connections under pressure. Ensure tank is depressurized.
- Discharge (Free Discharge): Without auxiliary equipment, by gravity.
- Safety: One manhole cover must be opened.
- Procedure:
- Approach filling station, stop.
- Ensure safety of surroundings.
- Connect discharge hose to discharge port (1).
- Open handrails, climb ladder.
- After controls, open filling manhole cover.
- Open bottom valve (1).
- Open rapid shut off valve (2).
- Close bottom valve, manhole cover.
- Remove connections. Vehicle ready to drive.
- Warnings for Filling and Discharging: Park close to station, short connections. Stop engine, apply park brake, use chocks. Follow transporter safety instructions. No smoking. Turn off electrical appliances. Avoid conducting shoes/hard hats, wear PPE. Do not carry spark-producing items. Do not thaw frozen manhole covers with open flames. Check all connections.
- Checks After Loading/Unloading: Ensure tanker is properly filled, all valves/covers closed, hoses removed, danger signs visible. Check equipment per manufacturer's manual.
Loading and Discharging of Chemical Tanker
- Safety Instructions: Identical to Bitumen tanker.
- Load Distribution: Identical to Bitumen tanker.
- Loading Preparation: Identical to Bitumen tanker.
- Loading: Identical to Bitumen tanker.
- Discharge (Compressed Air): Identical to Bitumen tanker.
- Discharge (With Pump):
- Approach filling station, stop, engage handbrake.
- Ensure safety of surroundings.
- Ground vehicle.
- Connect hydraulic pressure/return hoses to couplings (2,3).
- Connect discharge hose to connection coupling (4).
- Open bottom valve (5).
- Open butterfly valve (6) on pump inlet line.
- Open hydraulic control valve (7).
- Close hydraulic valve after discharge.
- Close bottom valve.
- Remove connections. Vehicle ready to drive.
- Discharge (Free Discharge): Identical to Bitumen tanker.
- Warnings for Filling and Discharging: Identical to Bitumen tanker.
- Checks After Loading/Unloading: Identical to Bitumen tanker.
Loading and Discharging of Food Tankers
- Safety Instructions: Identical to Bitumen tanker.
- Load Distribution: Identical to Bitumen tanker.
- Loading Preparation: Identical to Bitumen tanker.
- Loading:
- Approach filling station, stop, engage handbrake.
- Ensure safety of surroundings.
- Open guardrails.
- Open manhole cover (1).
- Insert hoses.
- Fill tank (avoid overfilling, fill to NET volume).
- Close manhole cover.
- Step down, close handrails.
- Vehicle ready to drive.
- Discharge (Free Discharge):
- Safety: One manhole cover must be opened.
- Procedure:
- Approach filling station, stop.
- Ensure safety of surroundings.
- Connect discharge hose to discharge port (1).
- Open handrails, climb ladder.
- Open bottom valve (2) with handwheel.
- Open butterfly valve (3) at discharge port.
- Perform discharge.
- Close bottom valve and butterfly valves.
- Step down, close handrails.
- Remove connections. Vehicle ready to drive.
- Discharge (Compressed Air):
- Preparation: Park on firm, even ground. Lower landing legs horizontally. Deflate air suspension. Check manhole cover/connections. Connect air battery to compressor via side air line (1).
- Starting Discharge:
- Connect compressor to side air line (4).
- Start compressor.
- Tank pressure increases. Do not start discharge before 2 bar.
- Visually check manometer; start discharge at 2 bar.
- Procedure:
- Disconnect air line from compressor.
- Close bottom valve and butterfly valves.
- Step down, close handrails.
- Remove connections. Vehicle ready to drive.
- Warnings for Filling and Discharging: Identical to Bitumen tanker.
- Checks After Loading/Unloading: Identical to Bitumen tanker.
Loading and Discharging of Waste Tankers
- Safety Instructions: Identical to Bitumen tanker.
- Load Distribution: Identical to Bitumen tanker.
- Loading (Top Filling):
- Approach filling station, stop, engage handbrake.
- Fix vehicle with wheel chocks.
- Open manhole cover (2).
- Insert filling hose, perform filling.
- Close manhole cover.
- Loading (Bottom Filling):
- Approach filling station, stop, engage handbrake.
- Fix vehicle with wheel chocks.
- Remove perrot coupling cover (21).
- Connect perrot coupling to fill/discharge hose.
- Open 6" manual control gate valve (11.1) on pump outlet line.
- Close 6" manual control gate valve (11.2) on tank mixing pump inlet line.
- Set 3-Way Ball valve (15), discharge pump inlet line (18) to "On", tank mixing pump outlet line (19) to "Off".
- Open pneumatic valve for tank ventilation (27).
- Connect hydraulic quick couplings (31) to tractor.
- Activate tractor PTO, pump oil into system.
- Move hydraulic control lever (22) to filling position.
- Filling starts.
- Float (10) rises, presses pneumatic roller valve, hydraulic motor signals pump to stop.
- For foamy product, press pneumatic valve (24) for 10 seconds to operate pump and fill completely.
- Close 6" gate valves, remove hose, connect perrot coupling blind cap.
- Safety: Pump will not run until tank ventilation valve is opened.
- Discharge: Gravity, pump, or vacuum discharge.
- In-Tank Mixing: Before discharge, mix product with pump (waste manure is dense).
- Open 6" manual control gate valve (11.2) on tank mixing pump inlet line.
- Close 6" manual control gate valve (11.1) on pump outlet line.
- Set 3-Way Ball valve (15), discharge pump inlet line (18) to "Off", tank mixing pump outlet line (19) to "On".
- Open tank ventilation on-off pneumatic valve (27).
- Connect hydraulic quick couplings (31) to tractor.
- Activate tractor PTO, pump oil into system.
- Move hydraulic control lever (22) to discharge position.
- Product mixes.
- Gravity Discharge:
- Approach filling station, stop, engage handbrake.
- Fix vehicle with wheel chocks.
- Remove perrot coupling cover (21).
- Connect perrot coupling to fill/discharge hose.
- Open pneumatic on-off valve for tank ventilation (27).
- Open 6" manual control gate valve (11.2) on pump inlet line.
- Open 6" manual control gate valve (11.1) on pump outlet line.
- Perform discharge.
- Discharge With Pump:
- Approach filling station, stop, engage handbrake.
- Fix vehicle with wheel chocks.
- Remove perrot coupling cover (21).
- Connect perrot coupling to fill/discharge hose.
- Open pneumatic on-off valve for tank ventilation (27).
- Close 6" manual control gate valve (11.2) on pump inlet line.
- Set 3-Way Ball valve (15), discharge pump inlet line (18) to "On", tank mixing pump outlet line (19) to "On".
- Connect hydraulic quick couplings (31) to tractor.
- Activate tractor PTO, pump oil into system.
- Move hydraulic control lever (22) to filling position.
- Perform discharge.
- Vacuum Discharge From Tank Rear Upper Funnel:
- Approach filling station, stop, engage handbrake.
- Fix vehicle with wheel chocks.
- Open manhole cover.
- Open pneumatic on-off valve for tank ventilation (27).
- Open filling funnel 8’’ pneumatic control gate valve (25).
- Place pumping system head from another vehicle in filling funnel (8).
- Vehicle ready for discharge by pumping (vacuum).
- Perform discharge.
- Warnings for Filling and Discharging: Identical to Bitumen tanker.
- Checks After Loading/Unloading: Identical to Bitumen tanker.
Inspection and Maintenance
Safety Instructions
Read safety instructions carefully. Obey traffic laws, environmental regulations. Act according to rules when removing residues. Check and service equipment (axles, landing gears, pump, counter, hose reel) per manufacturer's manual. Refer to pump/compressor manuals for usage/warranty. If EBS warning lamp comes on, park immediately and contact authorized service.
Main Principles
Maintenance ensures semi-trailer operating status, prevents breakdowns, extends life, maintains value, and reduces repair time. Vehicle should be regularly cleaned.
Check electrical system, lighting, brake, signal lamps. Check vehicle documents. Grease wheel plate and king pin. Check wheel nut tightness. Check landing gear in both speed ranges.
Manhole Covers
- Leak tightness: Small amounts of hissing air are normal. No load should escape.
- Seals: Check when silo vehicle is depressurized and manhole cover is open. Must be in good condition and clean. Replace damaged seals.
Cataphoresis Coating
Chassis/components may be cataphoresis coated. Damage must be repaired quickly by authorized service.
Galvanized Coating
Chassis/components may be galvanized. White mottling on new vehicles in winter is normal. Galvanized surfaces can be washed with water up to 50°C for the first 3 months.
Periodic Maintenance and Controls
Refer to warranty and maintenance manual. For warranty validity, first and annual periodic maintenance must be done at authorized services.
Important Warning!
- Brake Lining/Discs: Check lining thickness periodically; if below half, check more frequently and replace before finished. Check brake discs for deformation/cracks; contact authorized service if found. Visually check caliper piston/bellows, check operability.
- Axles: Follow manufacturer's service/maintenance instructions meticulously. Failure can affect service life and void warranty.
- Brake System: Healthy operation depends on using compatible tractor. Buyer must ensure brake adjustment at authorized service for matched tractor. Responsibility for malfunctions due to unmatched tractor lies with buyer.
Trouble Shooting
Safety Instructions
Identical to 8.1.
Spare Tire Replacement
- Safety: Improperly tightened wheel nuts can loosen and cause accidents. Tighten to specified torque (in "Axles" manual). Check tightness after each tire change.
- Removing Tire:
- Park in safe place, away from traffic.
- Secure vehicle with wheel chocks.
- Apply spring-loaded parking brake.
- Loosen wheel nuts one turn.
- Place lever jack under axle, raise until tire is off ground.
- Remove wheel nuts.
- Take damaged wheel off axle (grab by cheeks, not top/bottom).
- Remove spare tire from holder (see spare wheel holder section).
- Fitting Spare Tire:
- Position spare tire close to wheel hub.
- Lightly oil nut threads.
- Insert bar under tire, push wheel bolts into rim holes (leverage). Avoid damaging threads.
- Hand-tighten wheel nuts.
- Tighten nuts with wrench in order shown in picture.
- Lower jack, tighten wheel nuts in same sequence with required torque. Repeat after first 80 km and daily for first week.
- Check wheel nuts for torque every week.
- Safety: Check bolt holes on rims for ovalization regularly. Excessive tightening or insufficient tightening can cause deformations. Follow all maintenance instructions. Manufacturer not responsible for wear/defects from excessive force or unauthorized modifications. Rectify brake system irregularities immediately.
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