Novatech 11.569.00-B User manual

Revision: 0
Release date: 28.10.2021
OWNER’S MANUAL 1.0
ROLL TRAILER 100T 60FT
For transporting evenly distributed loads on the trailer
PROJECT NUMBER:11.569.00-B

NOVATECH ApS - Skudehavnsvej 30 - DK 9000 Aalborg. P.O.Box 540
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Revision History
REVISION
DATE
DESCRIPTION
PAGE
CHANGED BY

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Table of Contents
1. Product information................................................................................................................. 4
2. Terms and units ....................................................................................................................... 6
3. Safety....................................................................................................................................... 8
4. General description................................................................................................................ 13
5. Operating rules ...................................................................................................................... 15
6. Working with the trailer ........................................................................................................ 16
6.1. Before first use............................................................................................................... 16
6.2. Connecting the tugmaster............................................................................................... 16
6.3. Loading the trailer.......................................................................................................... 17
6.4. Driving with the trailer................................................................................................... 19
6.5. Driving on the ramp ....................................................................................................... 20
6.6. Disconnecting the tugmaster.......................................................................................... 20
6.7. Trailer transport and stacking storage............................................................................ 21
7. Maintenance........................................................................................................................... 24
7.1. Maintenance manual ...................................................................................................... 24
7.2. Grease points.................................................................................................................. 26
7.3. Bolts ............................................................................................................................... 27
7.4. Old tire replacement....................................................................................................... 27
7.5. Bearings replacement..................................................................................................... 27
7.6. Maintenance schedule .................................................................................................... 28
7.7. General safety................................................................................................................. 28
8. Spare parts ............................................................................................................................. 28
9. Warranty regulations ............................................................................................................. 29

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1. Product information
Manufacturer:
NT Industry Sp. z o.o.
(subsidiary of Novatech Aps.)
Fabryczna 1
43-180 Orzesze /Poland
Vendor:
Novatech Aps.
Skudehavnsvej 30
9000 Aalborg / Denmark
Phone no: [phone]
Fax no: [phone]
Type: Transport equipment
Name: Roll Trailer 100t 60ft
Project number: 11.569.00-B
Production year: 2021
Weights and loads
Capacity [kN]
1000
Tare weight [kg]
12000
Axle load [kN]
820
4 x 205
5th wheel load (without gooseneck) [kN]
305
Dimensions
Total length [mm]
18500
Total width [mm]
2790
Total height [mm]
900
Rear overhang [mm]
5000
Length of the loading area (ft)
60
Running gear
Number of axle lines
2
Number of wheels
8
Tire size (solid rubber) (inch)
22x16x16
Loading platform
Steel deck
5mm checker plate
Max surface pressure 19,4kN/m2
Speed and distance
Speed max. (km/h)
6
With load
10
Without load
Distance with max. speed (m)
2000
Min. 3 hours break between driving
cycles
Accessories
D-rings
Equipped
50 pcs 50t BL
Lashing eye
Equipped
2 pcs on each longbeam
Forklift pockets
Equipped
2050 mm distance in between
Finish
Shoot blasting
Sa 2½
EN ISO 8501
Top coat
C3
EN ISO 12944-6

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Road requirements
Max ramp angle (deg)
6
Max allowable transverse slope (deg)
4
Max tugmaster angle (deg)
±70
Other requirements
Ambient temperature (°C)
MIN. -20; MAKS +40

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2. Terms and units
Table 1. Unit conversion table
SI / METRIC SYSTEM
US UNITS
1 mm
0.03937 in
1 m
3.281 ft
1 km
0.6214 mi
1 km/h
0.6214 mph
1 kg
2.205 Ib
1 t
2205 Ibs
1 N
0.2248 Ibf
1 Nm
0.7376 Ibf*ft
1 bar
14.5 psi
1 liter
0.264 gal
Table 2. Definitions table
Cargo deck
The area within the CTU boundaries onto which packages may be placed and
secured.
Cargo transport unit (CTU)
A freight container, swap body, vehicle, railway wagon or any other similar
unit in particular when used in intermodal transport.
Clean CTU
A CTU free from:
Any previous cargo residues;
Any securing materials used from previous consignments;
Any marks, placards or signs associated with previous
consignments;
Any detritus (waste) that may have accumulated in the CTU;
Visible pests and other living or dead organisms, including any part,
gametes, seeds, eggs or propagules of such species that may survive
and subsequently reproduce; soil; organic matter;
All other items covered by contamination, infestation and invasive
alien species that can be discovered upon visible inspection.
COG
Center of gravity
Contamination
Visible forms of animals, insects or other invertebrates (alive or dead, in any
lifecycle stage, including egg casings or rafts), or any organic material of
animal origin (including blood, bones, hair, flesh, secretions, excretions);
viable or non-viable plants or plant products (including fruit, seeds, leaves,
twigs, roots, bark); or other organic material, including fungi; or soil, or
water; where such products are not the manifested cargo within the CTU.
Overloaded
Load (kN) placed on the trailer is greater than the maximum capacity.
User
Whoever uses the Roll Trailer or has it operated by suitable trained personal
is considered to be the user (employer/company)
Trained personnel
Trained personnel are persons who have been instructed and trained in the
duties with which they are entrusted and risks which may arise from
incorrect behaviour, have been advised on the necessary protective devices,
precautions, applicable regulations, accident prevention regulations and
prevailing conditions and have proven their ability.
Qualified person
(specialist)
A qualified person is one with the necessary qualification, based on
theoretical and practical knowledge of trailers, for the required activities as
listed in the manual. Person with the authority to undertake certain
maintenance work on our products include service engineers of
manufacturer and trained fitters with the corresponding certification.

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SWL
Safe Working Load (SWL) is the maximum safe force that a piece of lifting
equipment, lifting device or accessory can exert to lift, suspend, or lower,
a given mass without fear of breaking.
TARE
Tare is unladen weight of a device.
Remarks
DANGER
Highest danger level
Immediate danger of death or severe injury
The action is forbidden
WARNING
High danger level
Possible danger of death or severe injury
Measures to be taken for preventing specific danger
CAUTION
Hazardous situation
Danger of injury or property damage
Measures to be taken for preventing specific danger

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3. Safety
This section contains general safety instructions for supplied machine. This manual should
be reviewed very carefully by all persons working on or with supplied machine.
Conditions
REMEMBER: YOU are the best to prevent YOU from getting injured if you think about
it before you come near the machine.
You should think about your own safety first. Various errors must be corrected as soon
as possible.
Operators should think twice before they do anything with the machine not to get
injured.
Machine should not be started until the operator is satisfied that there are no persons
or unwanted things close by, in or on the machine and start-up can be done without
risk to life and injury and damage to the machine.
There are not always more persons in the immediate vicinity, so it requires that operators
are extra careful in their use since help is not in the immediate vicinity.
General safety instructions for maintenance personal.
Maintenance and service personnel must remember to disconnect the power supply
for machine, when maintenance, repair works, troubleshooting, cleaning etc are performed.
Put a sign on the machine indicating that "Do not start, work in progress" and "This energy
source is locked." The service worker writes his name on the sign, so the third party can see
who is working on the machine.
As long as the desired power is connected, it is incumbent for the service employees to make
sure that others cannot get injured by / in / on machine.
After repairs, troubleshooting etc. is completed, the service employees ensure that
all connections, guards etc. are properly installed, secured and connected before the machine
is start up again.
CAUTION
Risk of injury
Read the instructions

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General safety information
CAUTION
Risk of injury
Read the instructions
CAUTION
Danger when assembling of components and risk of cuts due to sharp edges.
Use safety gloves
CAUTION
Danger of flip over components due to insufficient stability or if it falls down
during transportation
Never work under suspended components
Always use suitable, undamaged and tested cranes and load
attachment gear for the respective load
Wear safety shoes.
Use safety helmet
CAUTION
Danger from sliding, rolling or falling components due to improper use
of trailer
Ensure transport equipment has sufficient capacity
Wear safety shoes.
Use safety helmet
CAUTION
Danger of grease and oil. Risk of slipping!
Immediately remove grease and oil residues
It is recommended for operators to use non-slip footwear, safety vest
and helmet when working near machine
CAUTION
Danger due to high working areas. Risk of falling down!
Work only in safe areas.
Use safety helmet
Use safety harnesses
Entrance on gooseneck is forbidden

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CAUTION
Movement/rotation of different components can result in the danger
of injury.
Never reach between moving parts with your hands or other body
parts
Use safety gloves and helmet
NOTICE
Before starting, ensure that all devices are in place and functional.
Take into account the capacity limits (especially lifting capacity).
Use appropriate safety equipment when working under special
temperature conditions.
You should not use medicines that affect reaction and perception,
when working with it.
It is the user and NOT Novatech ApS, which is responsible for all
personal and property damages, arising due to non-proper use.
Safe operation is not guaranteed if the machine is not used according
to specifications.

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Use protective equipment appropriate for the work when you operate or maintain
machine.
The following safety equipment must be available:
Safety Gloves
Shoes according to DIN EN ISO 2045, category S3 or in accordance with local
regulations.
Safety helmet.
Safety glasses.
Hearing protection.
Safety Vest
Mask
Always obey the local laws and regulations regarding safety.
All safety equipment must be visually inspected prior to use by the user.
The user is responsible for:
The use of the necessary personal safety equipment.
Regular cleaning and care of equipment.
Timely replacement of damaged or defective equipment or components.
DANGER
It is forbidden to use trailer with construction defects or damages without
service personnel permission, except emergency drive for repairs.

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CAUTION
Noise Impacts during machine operation.
Wear ear protection
Exhaust gases from TUGMASTER. Danger of suffocation!
See TUGMASTER manual for indoor use
Danger at the start of the machine while people are in the danger zone.
Visual inspection before starting that no person is in the danger area
Use safety vest for better visual contact
NOTICE
Operators should be trained in usage of machine.
Ensure that there are no unwanted components or the like on / in
or around the machine before start-up.
Only use approved and tested lifting equipment and accessories
which are CE marked.
The Tugmaster operator must have a valid certificate.
Avoid exceeding max gooseneck angle (±70°) to increase service life
of tyres.

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4. General description
Roll Trailer is designed as steel structure with running gears (Fig. 1). It is designed to work
with tugmaster for transporting general cargo.
Fig. 1 Roll trailar ready to work
Frame
The Roll Trailer is constructed as a skeletal frame steel S355J2 acc. To EN 10025 with
following features:
Longitudinal IPE main beams and between these cross members made of either IPE
or U-profiles;
Wheel beam made as box profile above running gear;
Forklift pockets made of bended C-shape profile with reinforcement;
Reinforced gooseneck tunnel;
Rear crossbeam square profile;
Special arrangement of crossbars above running gear.
Platform
Platform is constructed from checker plate resting on IPE cross members;
Steel checker plate above wheels and support in front for empty stacking;
Running Gear
2 rocker arms, box construction, type: straight;
4 axles, EN 10025 Steel S355 J2, dimension 140x140 mm;
Axle bolt in steel C45;
8 steelband reinforced solid rubber tires 22x16x16;
Bronze bushings for axle and rocker arm;
Novatech standard bearings;
Cover of bearing house made by pressed steel cover;

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Lubrication nipple placed in wheel and bolts for service;
Additional
40 pcs of D-rings 50t BL (6 at front end, 4 at rear end, 15 at each main beam);
Lashing eyes (2 at the end of each main beam)
All screws, nuts and washers are galvanized;
Stacking support.

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5. Operating rules
General remarks
The Roll trailer is intended for internal use only.
The Roll trailer is not equipped in braking system. Required braking force should be
generated by the tugmaster.
Prohibited activities
Do not step under the trailer when it is not empty.
Do not drive with forklift on the deck.
Do not pull/push the load on the deck.
Do not smoke, eat or drink during packing, securing or unpacking.
Do not concentrate heavy cargo on small areas of the floor.
Do not load with eccentric load distribution.
Do not use securing or protection equipment which is incompatible with the cargo.
Do not secure the cargo with devices overstressing the structure of the trailer/cargo.
Do not overstress securing devices.
Do not over tighten securing devices so that the packaging or goods are damaged.
Do not fasten web lashings by means of knots.
Required activities
Do use blocking or lashing or a combination of these methods to prevent the cargo
from sliding and tipping in any direction.
Do secure the cargo in a way that forces are distributed over an appropriate area
of a unit.
Do secure each single loaded item independently where necessary.
Do use non-slip surface material to refrain packages from sliding where appropriate.
Do use hooks or shackles to fasten lashings where applicable.
Do check that the CTU and any cargo securing equipment are in good condition.
Do select the securing methods best adapted to the characteristics of the cargo, the
mode of transport and the properties of the CTU.
Do load with the center of gravity correctly located in the CTU.

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6. Working with the trailer
6.1. Before first use
Due to the fact that after production the roll trailer was stored and transported, which means
that it was out of use for a long time. Before the first use, service activities should be
performed, including:
visual inspection whether the product has not been damaged during its transport;
check that trailer is complete, there are no loose parts and all bolts are properly
tightened (due to transport, the trailer may be delivered with disconnected elements
that should be installed after delivery);
lubrication of all greasing points (for complete description of lubrication, see section
7.2 "Greasing points").
6.2. Connecting the tugmaster
Lower/raise 5th wheel approximately to the coupling height of the trailer.
Drive tugmaster (equipped with gooseneck) into mid line of the trailer, adjust 5th wheel
height, drive until gooseneck is locked in the tunnel of the trailer. Slowly lift the trailer to see
if the connection is rigid.
Perform daily inspections (daily inspection is limited to a check for visual damage).
NOTICE
During coupling and uncoupling operation all personnel have to wear
safety equipment.
DANGER
When coupling the Roll Trailer to the Tractor, ensure that no other
persons are near. Roll Trailer do not have EMERGENCY STOP.
HIGH DANGER of crushing.

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6.3. Loading the trailer
Trailer is made for transport of general cargo evenly distributed over the length of the trailer.
For special load cases please contact Novatech.
Other types of cargo has to be placed on the trailer and secured by suitable securing
equipment like lashings so no danger can appear.
The COG of the load should be placed as close to the COG of the trailer as possibly.
Loading the trailer
Before loading, make sure that Roll Trailer is parked horizontally
The total load of the roll-trailer must not exceed its maximum load capacity;
All cargo needs to be secured in the way that while driving no movement can occur.
CAUTION
Trailer may not be used for anything other than specified purposes, unless
Novatech ApS has given written permission.
Consequences:
Loss of warranty;
Exclusions of liability claims.
NOTICE
The user and not Novatech ApS. is responsible for all personal injury
and property damage that occurs due to non-proper use.
Safe operation is not guaranteed if the machine is not used according
to specifications.

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Uniformly Distributed Load
UDL as shown in the diagram below (Fig. 2) so that the centre of gravity of the load
is in the appropriate areas of the diagram;
Other loading methods may result in overloading and damaging the trailer;
Fig. 2 Load diagram for evenly distributed load

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6.4. Driving with the trailer
When transport driving, you can either pull or push the Roll Trailer along a pre-planned
route. We recommend pulling the Roll Trailer. When backing up the Roll Trailer, you must
have unimpeded rear visibility.
The driver must always carefully observe the driving route and drive at the speed required
by the situation.
Drive with load only on previously checked driving route.
Never exceed the recommended driving speed. According to technical specification of solid
rubber tyre 22x16x16 speed limit is 6km/h with load and 10km/h with empty trailer. Do
not exceed max distance limit 2000m due to the risk of overheating tires and bearings and
respect required standstill time at least three hours between driving cycles.
Keep COG of cargo as low as possible. Avoid exceeding max gooseneck angle (±70°) to
increase service life of tyres. When performing turns always observe outer turning circle
of tugmaster and inner turning circle or trailers rear part.
Cross bumps and another uneven terrain drive very slowly.
Sharp turns drive very slowly.
The issues listed below may have a detrimental effect on the manoeuvrability of the Roll
Trailer and require that you lower your speed:
• load weight
• the location of the centre of gravity in the vertical direction
• the location of the centre of gravity in the horizontal direction
• aisle widths
• road inclinations
• speed bumps, railroads and other uneven spots
• underpasses
• lighting and visibility
• other traffic
• road condition
• slipperiness of road surface
• bends.

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6.5. Driving on the ramp
Do not approach ramp sideways. Trailer is capable of going on ramps up to 6 deg.
Fig. 3 Info graphic for ramp angle
Keep in mind that height of the Roll Trailer body must be adjusted accordingly, using
the terminal tractor’s fifth wheel.
when driving the rear end of the trailer onto the ramp, the tractor saddle should be
lowered as much as possible to achieve about 30-50 mm distance between front foot
and ground in order to obtain the maximum clearance at the rear;
when the trailer suspension is on the upper edge of the ramp, raise the tractor's
saddle as much as possible to obtain the maximum clearance between the ground and
bottom surface of the longbeams.
6.6. Disconnecting the tugmaster
Adjust 5th wheel height, until gooseneck is unlocked from the tunnel of the trailer. Slowly
lower the gooseneck to see if the connection has been released. Make sure that gooseneck
is disconnected with trailer, then drive out the tugmaster straight forward. Perform daily
inspections by checking for visual damage.