Kässbohrer SWAP BODY Series User manual

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INDEX
FOREWORD................................................................................................................................3
1. GENERAL INFORMATION AND SAFETY INSTRUCTIONS .........................................................4
1.1. About the User Manual.........................................................................................................4
1.2. Meanings of Symbols Used in User Manual..........................................................................4
1.3. Personal Protective Equipments ...........................................................................................5
1.4. Terms of Use and Safety Information ...................................................................................5
2. MAIN INFORMATIONS.........................................................................................................7
2.1. Vehicle Identification Plate ...................................................................................................7
2.2. Warranty and Responsibility.................................................................................................7
3. LOWER STRUCTURE AND USAGE INSTRUCTIONS..................................................................8
3.1. Front Ramp Buffer.................................................................................................................8
3.2. Rear Ramp Buffer ..................................................................................................................8
3.2.1. V -Type Ramp Buffer ......................................................................................................8
3.2.2. V+L Type Ramp Buffer....................................................................................................9
3.3. Forklift Fork Holder ...............................................................................................................9
3.4. K-Fix .......................................................................................................................................9
3.5. Eye Bolts ................................................................................................................................9
3.6. Train Loading Points............................................................................................................10
3.7. Load Lashing Rings...............................................................................................................10
3.7.1. U-Type Lashing Rings ...................................................................................................10
3.7.2. Load Lashing Ring Embedded in Floor .........................................................................11
3.8. Floor.....................................................................................................................................11
4. UPPERSTRUCTURE COMPONENTS AND USAGE INSTRUCTIONS .......................................... 13
4.1. Overview of Trailer Superstructure Components...............................................................13
4.1.1. Front Panel...................................................................................................................13
4.1.2. Side Curtain..................................................................................................................15
4.1.3. Curtain Tensioner.........................................................................................................17
4.1.4. Train Loading Plate.......................................................................................................18
4.1.5. Middle Pillar .................................................................................................................18
4.1.6. Side Rows .....................................................................................................................20
4.1.7. Rear Pillars....................................................................................................................21
4.1.8. Rear Panel ....................................................................................................................21
4.1.9. Roofs ............................................................................................................................23
5. TRANSPORTATION PROCESS..............................................................................................29
5.1. Pre-Driving Checks...............................................................................................................29
5.2. Consideration During Loading-Unloading...........................................................................29
5.3. Coutions During the Parking and Stopping .........................................................................29
5.4. Important Technical Condiderations...................................................................................29
5.4.1. Modifications on the Trailer ........................................................................................29

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5.4.2. Considerations for Environment..................................................................................29
5.5. Cleaning The Vehicle ...........................................................................................................29
6. LOADING AND LOAD SECURITY.......................................................................................... 31
6.1. Coil Transportation..............................................................................................................31
6.1.1. Coil Transport Well ......................................................................................................31
6.2. Safety Instructions...............................................................................................................33
6.2.1. Load Security................................................................................................................34
6.3. Load Distrubition and Load Limits of Tractor-Semi Trailer Combination ...........................34
6.4. Lashing Profiles....................................................................................................................34
6.5. Load Security Sertification...................................................................................................34
7. INSPECTION AND MAINTENANCE ......................................................................................36
7.1. Safety Instructions...............................................................................................................36
7.2. Main Principles....................................................................................................................36
7.3. Cataphoresis Coating...........................................................................................................36
7.4. Galvanized Coating..............................................................................................................36
7.5. Periodic Maintenance and Controls....................................................................................36
7.6. Trouble Shooting.................................................................................................................36
7.6.1. Safety Regulations........................................................................................................36

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FOREWORD
First, thank you for purchasing a vehicle produced by us.
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 documenta-
tion belong to the manufacturer.

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1. GENERAL INFORMATION
AND SAFETY INSTRUC-
TIONS
1.1. About the User Manual
The usage and operation information given in
this manual is prepared to make sure the ve-
hicle is used in compliance with its purpose
and as desired.
The instructions here contain important rec-
ommendations to perform your operations
safely, completely, and in the most efficient
manner. Complying with these instructions,
warnings and recommendations will prevent
accidents, decrease down-time & repair costs,
and make sure you use your vehicle safely, re-
liably and problem-free.
Please read the operating instructions in this
manual carefully and completely. The manu-
facturer is not liable for the damages and defi-
ciencies caused by the failure to comply with
these instructions. The instructions herein
must be supported by local laws, rules and
regulations. Please comply with these instruc-
tions 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 instructions,
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
•Exceedingtechnicallyandlegallyper-
missible 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, accesso-
ries, spare parts and etc. by the man-
ufacturer
•Themanufacturershallnotacceptany
responsibility for the problems and
faults that occurs that are not in com-
pliance with the purpose of the vehi-
cle’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 features will
be explained in the manual. Some options
may not be available for your vehicle.
Adhere strictly to the operating
instructions when using your
vehicle. When problems occur
which can lead to dangerous
consequences, contact 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 indicated by a special
symbol. These symbols and their meanings
are as follows.
The information specified by this
warning symbol is very important
for health and human safety.
When the given information is ignored, se-
rious damage, injuries and even death may
occur.
This symbol specified in this
manual indicates that critical ac-
cidents may occur when the in-
structions do not comply.
This symbol is used when addi-
tional information is required.

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This symbol is used when chem-
icals and other substances 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 pre-
vents injuries and are determined by regional
regulations depending on the load carried.
People who will work or perform operations 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 rele-
vant protective equipment.
•As a rule, gloves and work shoes are
always used.
It is obligatory to use appropriate
personal protective equipment
during the operations.
Long hair is particularly danger-
ous 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 working on
the vehicle is strictly prohibited.
They may get caught in moving parts or
mechanisms and cause injuries and even
death.
Protective Gloves
During the operation, protective
gloves must be used. Please make
sure you are using the correct type of
gloves when you are working with hot parts or
chemicals.
Gloves should fit snugly. Other-
wise, there is a risk of them getting
caught in moving parts or mecha-
nisms.
Protective Gloves
While working on the vehicle, appro-
priate overalls must be worn.
•Overalls should not have pleats, but-
tonsor externalpocketsand their clo-
sure system should be made in such
a way that they can be opened as
soon as possible in case of an emer-
gency.
•Interior pockets should have fasten-
ingstoclosethemup.Cuffsshouldbe
adjusted to fit the wrist.
Protective Helmets
When working around the vehicle, a
lightweight helmet approved by an
accredited institution should be worn.
Protective Ear Plugs
A hearing protective device (head-
sets 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 sub-
stances that are dangerous to breathe
or in dusty environments.
1.4. Terms of Use and Safety Infor-
mation
It is necessary to keep the warranty, operating
and maintenance manual and other documen-
tation about the vehicle available on the vehi-
cle at all times.
To prevent possible accidents and environ-
mental pollution, follow the operating instruc-
tions and binding regulations.

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•Pay attention to the safety and warn-
ing 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 ve-
hicle immediately and inform the au-
thorized people or institutions.
•Donotmodifyanythingonthe vehicle
without a written manufacturer’s ap-
proval. Your vehicles guarantee
terms do not cover unapproved mod-
ifications. -
•The spare parts must meet the tech-
nical requirements set forth by the
manufacturercompany.Onlytheorig-
inal spare part/parts meet their re-
quirements.

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2. MAIN INFORMATIONS
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 thevehicle ( vehicle iden-
tification number) is located on the chassis.
Vehicle Identification Number
2.2. Warranty and Responsibility
Our trailers, semi-trailers and truck onboard
applications are manufactured in compliance
with regulations and our quality standards. It is
necessary to perform the maintenance to en-
sure our products always operate in the most
efficient manner in compliance with our latest
directives and maintenance programs. The
warranty starting date isthe registration date of
the vehicle that is stated in the registration pa-
per.The performance of maintenance and re-
pair/servicingofthevehiclewiththeuse oforig-
inal spare parts by authorized service shall as-
sure the client’s warranty rights. This warranty
is based upon the usage and maintenance
conditions described herein and in the war-
ranty book. Thus, it is important to read andun-
derstand this operation manual and warranty
book.
It is necessary to keep the warranty, always
operating and maintenance manual available
on the vehicle to allow authorized service per-
forming the servicing to see the warranty con-
ditions and maintenance records. In the re-
pairs made during the warranty period, the au-
thorized service performing the repair will de-
mand this. Purchasing one trailer or semi-
trailer is an important investment. For the high-
est return on your investment, it is necessary
to comply with the manufacturer’s procedures
and recommendations during the operation
period of the vehicle. The information provided
by the client/driver related to the warranty writ-
ten in this manual shall be kept within our da-
tabase.

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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 or-
der 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 loading
ramp, there is a V-type(1), corner welded steel
ramp buffer to protect the rear of the vehicle

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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 loading
ramp, in addition to the standard welded V-
type(1) ramp buffer, your vehicle can optio-
nally have L-type(2) steel ramp buffers at the
corners in order to protect the rear of the ve-
hicle from impacts.
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 lifted from
the forklift forks when empty.
3.4. K-Fix
K-Fix (1) allows connection from multiple po-
ints with the help of spanzets in order to carry
the load safely.
Each K-fix point has a maximum carrying ca-
pacity of 2.5 tons.
K-Fix
The pulling force of 2,500 kg sho-
uld not be exceeded for each point
on the K-Fix.
Over 1 m of K-Fix, a connection
should not exceed 6000 kg.
3.5. Eye Bolts

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Your vehicle may optionally have eyebolt at-
tachment 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 vehicle
from train loading points (1) in operations such
as train loading, loading the vehicle on a con-
tainer carrier, etc.
Train Loading Points
3.7. Load Lashing Rings
Load fastening rings areused 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 at-
tach your braces by pulling the ring upwards
with your hand.

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U Type Lashing Ring
The maximum towing capacity of
the lashing 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 Embed-
ded in Floor
Your vehicle may optionally have load lashing
rings with a capacity of 2.5 tons, which are em-
bedded in the floor, allowing 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 vehicle and tested
according to a norm. You can see this infor-
mation from the label 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 damaged, and the forklift can be
tipped.

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The accident may occur when you
are walking on a wet floor.
In cold weather, there may be
icing on the floor. Beware of slip-
ping hazard.
The original spare parts must be
used during the floor repair opera-
tion. Otherwise, the forklift front
axle load might be reduced.
Phenol Resin Coated Plywood Floor

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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 connec-
tion. 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.

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Steel Front Panel
Plywood construction for protection from impacts
4.1.1.2. Aluminum Front panel
The aluminum front panel formed of 2 alumi-
num 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 con-
nection couplings on the coupling plate. Opti-
onal 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.

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Front Pillar
4.1.2. Side Curtain
4.1.2.1. Curtain Types
Swapbody vehicles can have two types of cur-
tain 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 produced
in accordance with the relevant standards and
norms can be found.
Standard Curtain
4.1.2.1.2. Stainless Steel Intagrated
Vertical Curtain
In your vehicle, the stainless steel intagrated
vertical curtain produced in accordance with
the relevant standards and norms can be fo-
und. On both sides of the side curtain, there
are vertical stainless steel profiles determined
according to the design.
Curtain pockets are installed on the inside of
the curtain. These pockets are fixed by pas-
sing stainless steel profiles.
With this curtain:
•Provides high lateral stability.
• There is no need for a side rows, thus
allowingsideloadingtobecarriedoutfas-
ter.
Stainless Steel Intagrated Vertical Curtain
4.1.2.2. Openning The Curtain
•Turn on the curtain tension (1) by fol-
lowing the steps in the heading
4.1.2.4.

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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 thehandle and
the curtain profile at the same time
Pulling The Curtain
It is dangerous to travel with an
open, unsecured curtain. The cur-
tain can fly and injure people. Un-
secured curtain can also cause cargo go-
ods to fall. Always make sure that the cur-
tains are properly closed and secured be-
fore starting 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 fi-
nished.
•At the rear of the vehicle, attach first the
upper end of the curtain profile and then
thelowerendoftheprofiletotheclawand
place it in place.
•After making sure that the curtain profiles
are fully seated, tighten the ratchet mec-
hanism with the help of a lever until the
curtain tension is maximum.
•Put the hooks of the fasteners on the cur-
tain back into place and tighten them and
lock their mechanisms.
4.1.2.4. Rear Tensioner
Curtain stretching is made from behind the ve-
hicle.
•By pressing the upper tongue on the
curtain tensioningmechanism(1),the
big lever (2) is pulled and the curtaip-
rofile is discharged.

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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 ve-
hicles, there may be curtain tensioners with
mechanical lock.
The curtain tensioner with mechanical con-
sists of the following parts:
1 Tension Strap
2 Curtain Tension Lock
3 Hook
Curtain Tensioner with Mechanical Lock
4.1.3.1. Opening the Curtain tensio-
ner
•Pull the curtain tensioner lock upwards.

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•Remove the hook from theouter frame or
board ring after the locking system is un-
locked.
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 thelocking sound.
4.1.4. Train Loading Plate
They are structures (1) designed to prevent
the side curtain of the vehicle from being da-
maged during thetrain loading operations, due
to the requirement to color the train loading
plates as per the regulation. There are 4 pie-
ces in total, 2 on the right and 2 on the left of
the vehicle.
Train Loading Plate
4.1.5. Middle Pillar
Aracın sağ ve yol yanlarında 3 er adet kayar
orta babalar bulunmaktadır.

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Kayar baba
Orta Babaların Açılması:
Press the lever (1) down and pull it out.
Sliding Middle Pillar
Slide the pillar, which we rescued from its soc-
ket, on the rail, either forwards or backwards
according to our needs.