Kässbohrer SWAP BODY Series User manual

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1. GENERAL INFORMATION AND SAFETY INSTRUCTIONS
1.1. About the User Manual ..............................................................5
1.2. Meanings of Symbols Used in User Manual..............................5
1.3. Personal Protective Equipments.................................................6
1.4. Terms of Use and Safety Information ........................................7
2. MAIN INFORMATIONS
2.1. Vehicle Identification Plate ........................................................8
2.2. Warranty and Responsibility ......................................................8
3. LOWER STRUCTURE AND USAGE INSTRUCTIONS
3.1. Front Ramp Buffer ...................................................................10
3.2. Rear Ramp Buffer ....................................................................10
3.2.1. V -Type Ramp Buffer ........................................................10
3.2.2. V+L Type Ramp Buffer.....................................................10
3.3. Forklift Fork Holder.................................................................11
3.4. K-Fix .......................................................................................11
3.5. Eye Bolts ..................................................................................11
3.6. Train Loading Points................................................................12
3.7. Load Lashing Rings .................................................................12
3.7.1. U-Type Lashing Rings ......................................................12
3.7.2. Load Lashing Ring Embedded in Floor ............................13
3.8. Floor .........................................................................................13
4. UPPERSTRUCTURE COMPONENTS AND USAGE
INSTRUCTIONS
4.1. Overview of Trailer Superstructure Components ....................15
4.1.1. Front Panel ........................................................................15
4.1.2. Side Curtain.......................................................................16
4.1.3. Curtain Tensioner ..............................................................18
4.1.4. Train Loading Plate...........................................................20
4.1.5. Middle Pillar......................................................................20
4.1.6. Side Rows..........................................................................21
4.1.7. Rear Pillars ........................................................................22
4.1.8. Rear Panel .........................................................................23
4.1.9. Roofs .................................................................................24
5. TRANSPORTATION PROCESS
5.1. Pre-Driving Checks..................................................................30

5.2. Consideration During Loading-Unloading ..............................30
5.3. Coutions During the Parking and Stopping .............................30
5.4. Loading ....................................................................................30
5.5. Important Technical Considerations ........................................31
5.5.1. Modifications on the Trailer..............................................31
5.5.2. Considerations for Environment .......................................31
5.6. Cleaning The Vehicle ...............................................................31
6. LOADING AND LOAD SECURITY
6.1. Coil Transportation ..................................................................32
6.1.1. Coil Transport Well ...........................................................32
6.2. Safety Instructions....................................................................34
6.2.1. Load Security ....................................................................35
6.3. Load Distribution and Load Limits of Tractor Semi-trailer
Combination ..................................................................................35
6.4. Lashing Profiles .......................................................................35
6.5. Load Security Certification ......................................................35
7. INSPECTION AND MAINTENANCE
7.1. Safety Instructions....................................................................37
7.2. Main Principles ........................................................................37
7.3. Cataphoresis Coating ...............................................................37
7.4. Galvanized Coating..................................................................37
7.5. Periodic Maintenance and Controls .........................................37
7.6. Trouble Shooting......................................................................37
7.6.1. Safety Regulations ............................................................37

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. The defined options in this manual can vary according to
the vehicle specs.
Important information on how you can use your vehicle is explained in this user manual,
please be sure that you review and understand the content. We suggest keeping this user
manual available in your vehicle at all times. This information is specified in the product’s
user manual. We recommend you read this operating manual thoroughly to get the most out
of your vehicle.
* Owing to the developments in product research, the manufacturer reserves the right to
make any changes in the product, without any prior notice. The publication rights of this doc-
umentation belong to the manufacturer.

5 / 39
1. GENERAL INFORMATION AND
SAFETY INSTRUCTIONS
1.1. About the User Manual
The usage and operation information
given in this manual is prepared to make
sure the vehicle is used in compliance
with its purpose and as desired.
The instructions here contain important
recommendations to perform your oper-
ations safely, completely, and in the most
efficient manner. Complying with these
instructions, warnings and recommenda-
tions will prevent accidents, decrease
down-time & repair costs, and make sure
you use your vehicle safely, reliably and
problem-free.
Please read the operating instructions in
this manual carefully and completely.
The manufacturer is not liable for the
damages and deficiencies caused by the
failure to comply with these instructions.
The instructions herein must be sup-
ported by local laws, rules and regula-
tions. Please comply with these
instructions to prevent accidents and
protect your surroundings and the
environment.
Any usage of transportation that goes
beyond the use in accordance with the
rules will be considered improper use.
Transportation of the following is not
allowed:
•Carrying people and live animals
•Transportations that need to be car-
ried according to special instruc-
tions, e.g., dangerous good
transportations
•Transportation of unsecured goods
•Transportation of materials that are
dangerous due to their properties or
that need to be carried with special
equipment
•Exceeding technically and legally
permissible weights of the axles or
king pin load
•Exceeding of the maximum vehicle
speed
•Exceeding the permissible length,
width and height
•Unapproved parts like tires, acces-
sories, spare parts and etc. by the
manufacturer
•The manufacturer shall not accept
any responsibility for the problems
and faults that occurs that are not in
compliance with the purpose of the
vehicle’s usage. All the risks of this
issue belong to the customer.
It is necessary to keep the
user manual available on the
vehicle at all times.
The vehicle can be equipped
with a lot of different options.
The standard or optional fea-
tures will be explained in the
manual. Some options may
not be available for your
vehicle
Adhere strictly to the opera-
ting instructions when using
your vehicle. When problems
occur which can lead to dan-
gerous consequences, con-
tact the service centre
immediately.
1.2. Meanings of Symbols Used in
User Manual
Several warnings are available in this
manual to ensure maximum safety when
using your vehicle. Each warning is indi-
cated by a special symbol. These sym-
bols and their meanings are as follows.

The information specified by
this warning symbol is very
important for health and hu-
man safety. When the given in-
formation is ignored, serious
damage, injuries and even
death may occur.
This symbol specified in this
manual indicates that critical
accidents may occur when the
instructions do not comply.
This symbol is used when ad-
ditional information is
required.
This symbol is used when
chemicals and other substan-
ces can be disposed of with
precautions that will not harm
the environment.
1.3. Personal Protective Equipments
Personal protective equipments serves
the purpose of preventing injuries and
are prevents injuries and are determined
by regional regulations depending on the
load carried.
People who will work or perform opera-
tions on the vehicle must wear proper
and appropriate protective clothing.
•Depending on the load to be carried,
the eyes, ears, body, and respiratory
tract must be protected with the rel-
evant protective equipment.
•As a rule, gloves and work shoes
are always used.
It is obligatory to use approp-
riate personal protective
equipment during the
operations.
Long hair is particularly dan-
gerous when working on the
vehicle, regardless of whether
it is loose or tied up, and it
should be protected properly
to avoid tangling.
Wearing a tie, necklace and/or
dangling jewelry when wor-
king on the vehicle is strictly
prohibited. They may get
caught in moving parts or
mechanisms and cause inju-
ries and even death.
Protective Gloves
During the operation, protecti-
ve gloves must be used. Plea-
se make sure you are using
the correct type of gloves
when you are working with
hot parts or chemicals.
Gloves should fit snugly. Ot-
herwise, there is a risk of them
getting caught in moving
parts or mechanisms.
Protective Cloth
While working on the vehicle,
appropriate overalls must be
worn.
•Overalls should not have pleats,
buttons or external pockets and their
closure system should be made in
such a way that they can be opened
as soon as possible in case of an
emergency.
•Interior pockets should have fasten-
ings to close them up. Cuffs should
be adjusted to fit the wrist.
Protective Helmets

7 / 39
When working around the ve-
hicle, a lightweight helmet
approved by an accredited
institution should be worn.
Protective Ear Plugs
A hearing protective device
(headsets or ear plugs) should
always be used around self-
propelled vehicles.
Protective Goggles
Protective goggles should be
worn during all maintenance
operations.
Protective Mask
Appropriate protective masks
should be used when working
with substances that are dan-
gerous to breathe or in dusty
environments.
1.4. Terms of Use and Safety
Information
It is necessary to keep the warranty, op-
erating and maintenance manual and
other documentation about the vehicle
available on the vehicle at all times.
To prevent possible accidents and envi-
ronmental pollution, follow the operating
instructions and binding regulations.
•Pay attention to the safety and
warning signs placed on your
vehicle.
•Always keep these safety and warn-
ing signs completely visible.
•Make sure that the load carrier is se-
cured properly.
•In case of any dangerous condition
in the operation of safety, stop your
vehicle immediately and inform the
authorized people or institutions.
•Do not modify anything on the ve-
hicle without a written manufac-
turer’s approval. Your vehicles
guarantee terms do not cover unap-
proved modifications.
•The spare parts must meet the tech-
nical requirements set forth by the
manufacturer company. Only the
original spare part/parts meet their
requirements.

2. MAIN INFORMATIONS
There are vehicle identification stickers
on the vehicle.
2.1. Vehicle Identification Plate
Vehicle identification plate is located on
the right side of the vehicle.
You may find these information’s on this
plate;
Vehicle Identification Plate
1- Vehicle Type
2- Serial Number
3- Technical Total Capacity
4- Permitted Total Capacity
5- Type Approval Number
6- Production Date
The serial number of the vehicle ( vehicle
identification number) is located on the
chassis.
Vehicle Identification Number
2.2. Warranty and Responsibility
Our trailers, semi-trailers and truck on-
board applications are manufactured in
compliance with regulations and our
quality standards. It is necessary to per-
form the maintenance to ensure our
products always operate in the most effi-
cient manner in compliance with our lat-
est directives and maintenance
programs. The warranty starting date is
the date that the vehicle is delivered to
the customer.
The performance of maintenance and re-
pair/servicing of the vehicle with the use
of original spare parts by authorized
service shall assure the client’s warranty
rights. This warranty is based upon the
usage and maintenance conditions de-
scribed herein and in the warranty book.
Thus, it is important to read and under-
stand this operation manual and war-
ranty book.
It is necessary to keep the warranty, al-
ways operating and maintenance man-
ual available on the vehicle to allow
authorized service performing the servic-
ing to see the warranty conditions and
maintenance records. In the repairs
made during the warranty period, the au-
thorized service performing the repair
will demand this. Purchasing one trailer
or semi-trailer is an important invest-
ment. For the highest return on your in-
vestment, it is necessary to comply with
the manufacturer’s procedures and rec-
ommendations during the operation

9 / 39
period of the vehicle. The information
provided by the client/driver related to
the warranty written in this manual shall
be kept within our database.

3. LOWER STRUCTURE AND USAGE
INSTRUCTIONS
1.Front Ramp Buffer
2.Rear Ramp Buffer
3.Forklift Attachements Points
4.K-Fix
5.Mapa Ports
6.Train Loading Points
7.Load Lashing Rings
3.1. Front Ramp Buffer
It is positioned as welded to the chassis
in order to protect the front panel from
impacts at the front of the vehicle.
Front Ramp Buffer
3.2. Rear Ramp Buffer
Equipment that protects the rear of the
vehicle against impacts.
3.2.1. V -Type Ramp Buffer
When the vehicle approaches the load-
ing ramp, there is a V-type (1), corner
welded steel ramp buffer to protect the
rear of the vehicle against impacts and
to protect the door lock handles from
impacts.
V Type Ramp Buffer
3.2.2. V+L Type Ramp Buffer
When the vehicle approaches the load-
ing ramp, in addition to the standard
welded V-type (1) ramp buffer, your ve-
hicle can optionally have L-type(2) steel
ramp buffers at the corners in order to
protect the rear of the vehicle from
impacts.

11 / 39
V+L Type Ramp Buffer
3.3. Forklift Fork Holder
To be able to move the vehicle on the
field when the vehicle is empty, there are
fork slots in which forklift forks can be
passed, suitable for lifting by forklift.
Forklift Fork Holder
The vehicle should only be lif-
ted from the forklift forks
when empty.
3.4. K-Fix
K-Fix (1) allows connection from multiple
points with the help of spanzets in order
to carry the load safely.
Each K-fix point has a maximum carrying
capacity of 2.5 tons.
K-Fix
The pulling force of 2,500 kg
should not be exceeded for
each point on the K-Fix.
Over 1 m of K-Fix, a connec-
tion should not exceed 6000
kg.
3.5. Eye Bolts
Your vehicle may optionally have eyebolt
attachment points (1) that allow it to be
lifted with eyebolts during loading
operations.
Eyebolt Points

Eyebolt
3.6. Train Loading Points
It is a structure designed for lifting the ve-
hicle from train loading points (1) in oper-
ations such as train loading, loading the
vehicle on a container carrier, etc.
Train Loading Points
3.7. Load Lashing Rings
Load fastening rings are used to fix the
load by connecting the transported load
to the vehicle floor.
3.7.1. U-Type Lashing Rings
It is positioned on the side rave. It is
used to connect the transported load to
the ground.
To use this load lashing ring (1), you can
attach your braces by pulling the ring up-
wards with your hand.
U Type Lashing Ring

13 / 39
The maximum towing capacity
of the las-hing rings on the
front panel (1) is 1250 kg. This
pull value must not be
exceeded.
Lashing Rings At Front Panel
3.7.2. Load Lashing Ring Embedded
in Floor
Your vehicle may optionally have load
lashing rings with a capacity of 2.5 tons,
which are embedded in the floor, allow-
ing the load to be fixed.
Lashing Rings Embeded in the Floor
3.8. Floor
The floor of the vehicle can be covered
with phenol resin coated plywood.
For forklift entries into the vehicle, there
is a maximum forklift front axle load that
has been defined specifically for your ve-
hicle and tested according to a norm.
You can see this information from the la-
bel on the vehicle or from the sales
contract.
If a forklift which is heavier
than the permitted forklift
front axle load enters to the
vehicle, the floor may be da-
maged, and the forklift can be
tipped.
The accident may occur when
you are walking on a wet floor.
In cold weather, there may be
icing on the floor. Beware of
slipping hazard.
The original spare parts must
be used during the floor repair
operation. Otherwise, the fork-
lift front axle load might be
reduced.

Phenol Resin Coated Plywood Floor

15 / 39
4. UPPERSTRUCTURE COMPONENTS AND USAGE INSTRUCTIONS
1-2 Front Panel - Front Pillar
3 Side Curtain
4 Curtain Tensioner
5 Train Loading Plate
6 Middle Pillar
7 Side Rows
8 Rear Pillar
9 Rear Panel
10 Roof
4.1. Overview of Trailer
Superstructure Components
4.1.1. Front Panel
There are two type of front panels in
vehicles.
•Steel Front panel
•Aluminum Front Panel
4.1.1.1. Steel Front panel
Steel front panel is formed by combining
2 front pillars and steel panel with rivet
connection. On the inside of the front
panel there is a supporting plywood
structure to protect the front panel from
impacts. Two load securing rings with
each of 1.250 kg capacity used for load
securing are located on the inside of the
right and left pillars.
Optional fire extinguisher box, document
box and plates (ADR, etc.) can be found.
Steel Front Panel

Plywood construction for protection from impacts
4.1.1.2. Aluminum Front panel
The aluminum front panel formed of 2
aluminum front bollards and horizontally
interlocking aluminum panels fixed to the
aluminum front bollards with rivets.
There is a coupling plate on the front
panel, and there are electrical sockets
and air connection couplings on the cou-
pling plate. Optional fire extinguisher
box, document box and plates (ADR,
etc.) can be found.
Aluminum front panel
Aluminum front panel impact protection plate
4.1.1.3. Front Pillars
There are pillars connecting the side
rows and the front panel at the front of
the vehicle.
Front Pillar
4.1.2. Side Curtain
4.1.2.1. Curtain Types
Swapbody vehicles can have two types
of curtain structures depending on the
usage needs.
1.Standard curtain
2. Stainless steel intagrated Vertical
Curtain
4.1.2.1.1. Standard Curtain
In your vehicle, sliding side curtains pro-
duced in accordance with the relevant
standards and norms can be found.

17 / 39
Standard Curtain
4.1.2.1.2. Stainless Steel Intagrated
Vertical Curtain
In your vehicle, the stainless steel inta-
grated vertical curtain produced in ac-
cordance with the relevant standards
and norms can be found. On both sides
of the side curtain, there are vertical
stainless steel profiles determined ac-
cording to the design.
Curtain pockets are installed on the in-
side of the curtain. These pockets are
fixed by passing stainless steel profiles.
With this curtain:
•Provides high lateral stability.
•There is no need for a side rows,
thus allowing side loading to be car-
ried out faster.
Stainless Steel Intagrated Vertical Curtain
4.1.2.2. Openning The Curtain
•Turn on the curtain tension (1) by
following the steps in the heading
4.1.2.4.
Curtain tensioner open
•Remove the curtain profile (2)
Removing The Curtain Profile
•Pull the curtain all the way to the
front of the vehicle, holding the han-
dle and the curtain profile at the
same time.
Pulling The Curtain

It is dangerous to travel with
an open, unsecured curtain.
The curtain can fly and injure
people. Unsecured curtain
can also cause cargo goods
to fall. Always make sure that
the curtains are properly clo-
sed and secured before star-
ting to drive.
4.1.2.3. Closing and Tensioning the
Curtain
•Pull the curtain gathered to the front
back to the rear of the vehicle when
you are finished.
•At the rear of the vehicle, attach first
the upper end of the curtain profile
and then the lower end of the profile
to the claw and place it in place.
•After making sure that the curtain
profiles are fully seated, tighten the
ratchet mechanism with the help of
a lever until the curtain tension is
maximum.
•Put the hooks of the fasteners on
the curtain back into place and tight-
en them and lock their mechanisms.
4.1.2.4. Rear Tensioner
Curtain stretching is made from behind
the vehicle.
•By pressing the upper tongue on the
curtain tensioning mechanism (1),
the big lever (2) is pulled and the
curtaiprofile is discharged.
Rear Tensioning
Full Open Position
•The Curtain rosd (3) is removed.
Curtain Rod
4.1.3. Curtain Tensioner
Depending on the options selected in
your vehicles, there may be curtain ten-
sioners with mechanical lock.
The curtain tensioner with mechanical
consists of the following parts:
1Tension Strap

19 / 39
2Curtain Tension Lock
3Hook
Curtain Tensioner with Mechanical Lock
4.1.3.1. Opening The Curtain
Tensioner
•Pull the curtain tensioner lock
upwards.
•Remove the hook from the outer
frame or board ring after the locking
system is unlocked..

4.1.3.2. Tensioning and Closing The
Curtain Tensioner with Mechanical
Lock
Attach the hook (3) to the outer frame or
the door hook, then stretch the curtain by
pulling the tensioning strap (1), press the
lock (2) mechanism to close it and make
sure you hear the locking sound.
4.1.4. Train Loading Plate
They are structures (1) designed to pre-
vent the side curtain of the vehicle from
being damaged during the train loading
operations, due to the requirement to
color the train loading plates as per the
regulation. There are 4 pieces in total, 2
on the right and 2 on the left of the
vehicle.
Train Loading Plate
4.1.5. Middle Pillar
There are 3 sliding middle pillars on the
right and left sides of the vehicle.
Sliding Pillar