Operating manual. Curtainsider. Trailer Services Technology

Transcription

1 Operating manual Curtainsider GB Trailer Services Technology

2 Please take a few minutes to read this note... This manual tells you about the Schmitz Cargobull curtainsider semitrailers. It contains important information on working with the semitrailer. Please read the information in this manual very carefully. Take particular note of the sections dealing with your safety. Make sure that the manual is always with the vehicle, especially if you lease or sell it. Schmitz Cargobull is continuously developing our products. For this reason the descriptions in the text and the pictures in this manual may differ from the equipment on your semitrailer. If you have any questions that you cannot answer by reading this manual, please contact a Schmitz Cargobull service centre or the Schmitz Cargobull customer service: Schmitz Cargobull AG Siemensstraße 50 D Altenberge Outside normal business hours: CARGOBULL or Altenberge Centre customer service: Telephone +49 (0) / Fax +49 (0) / Internet

3 Vehicle identification Keywords Chassis Driving Superstructure Operation Transport solutions Safety Vehicle identification 1 Vehicle Identification Number (VIN) 2 Vehicle name plate 3 ALB name plate The Vehicle Identification Number (VIN) (1) is stamped into the vehicle frame. The vehicle identification number can also be read on the name plate (2). ALB name plate on front panel The "ALB" name plate contains the test pressures for the automatic load sensing brake control, depending on the axle loads. Vehicle name plate on the front panel Maintenance The "vehicle" name plate includes the following information: axle and fifth wheel load, approved gross mass, external length and width, Vehicle Identification Number. 1 Data

4 Graphics Safety instructions This manual includes various safety instructions with the following meanings: DANGER! Text with this symbol warns you of potential hazards to health and life. If these instructions are not observed accidents and injuries that can result in fatalities may occur. Observe the instructions provided for avoiding hazards. Direction indicators Direction indicators in this manual always refer to the direction of travel. Therefore "on the left side of the chassis frame links" means "in direction of travel on the left vehicle side". "Forward" means" in the direction of travel", "backwards" means "against the direction of travel". Optional equipment* Text marked with an asterisk* identifies optional equipment. For this reason text and illustrations in this manual show different equipment from that of your semitrailer. Property damage Text with this symbol warns you of potential property damage. Observe the instructions provided for avoiding property damage. Supplementary information Note Text with this symbol provides tips or supplementary information. Directions/procedures Text with this symbol identifies a procedure that should be carried out. Text with this symbol describes the expected result of the above procedure. 2

5 Vehicle overview This operating manual applies to the following Schmitz Cargobull semitrailers. S.CS Mega Curtainsider semitrailer with sliding tarpaulins in volume design. Also available with Varios superstructure. S.CS Universal Curtainsider semitrailer with sliding tarpaulins. Also available with side boards and sliding tarpaulin. S.CS Light Curtainsider semitrailer with sliding tarpaulins. Reduced empty weight due to weight-optimised frame longitudinal members and other measures. S.PR Mega Platform semitrailer with side boards and conventional tarpaulins in volume design. Also available with Varios superstructure. S.PR Universal Platform semitrailer with side boards and conventional tarpaulins and a choice of sliding roof or bow-type structure (Hamburg model). Transport solutions In addition to the above basic types, specially equipped semitrailers, referred to as transport solutions, are available for specialised transport: Paper transport (S.CS Paper), Beverage transport (S.CS Drink), Coil transport (S.CS Coil, S.PR Coil), Intermodal transport (S.CS, S.PR). Keywords Safety Chassis Driving Superstructure Transport solutions Maintenance Operation 3 Data

6 Contents An overview of the contents of this manual is given below. You can find specific topics with the index at the front of the manual. There is a list of topics in that chapter at the beginning of every chapter. 1 Index The index is a fast way to find a specific topic. Terms are listed in alphabetical order. 2 Safety Here you can find important instructions for safe working with the semitrailer. 3 Chassis Here you can find information and instructions on the basic operation of the chassis and its attached components, Such as the air suspension, or landing legs and spare wheel holder. 4 Driving Here you can find information and instructions for driving with the semitrailer, such as coupling and uncoupling, ferry transport or the electronic brake system (EBS). 5 Superstructure Transport solutions Here you can find information and instructions on equipping and operating specialised superstructures. such as for paper or beverage transport. This chapter only describes the equipment that deviates from the basic types. You can find the description of the basic equipment in the chapters on chassis and superstructure. 7 Operation Here you can find information and instructions for working with the superstructure. such as loading and unloading and securing loads. 8 Maintenance, care Here you can find information on the care and maintenance of the semitrailer, service charts with the specified service intervals and instructions on the required test work. 9 Specifications Here you can find the most important specifications, required fuels and an overview of the most important warning stickers. Here you can find information and instruction on all aspects of the superstructure. such as sliding tarpaulins or side boards and top. 4

7 A B Index Keywords * (optional equipment) Actuation function Additional sideposts* , 141 Air reservoir Air suspension Auto-reset Axle guide Driving instructions Lift Lower Stroke limit Support block Air suspension bump stop Air suspension stroke limit Air suspension systems Air suspension valve , 39 Air vessel ALB Test pressures Attached forklift , 174 Lowering Pick up Attaching wheels Automatic load sensing brake control Auto-reset function , 79 Axle guide Type Axle hub odometer* Axle lift Manual lowering Operating console Socket assignment Starting aid Switching from the tractor Axle load , 69 Forklift , 208 Axle load indicator* Electronic Pneumatic Axle load pressure gauge* Axle load table Basket-type model Bow hooks Brake adjustment , 72 Brake light Brake pads Wear check Wear indicator* Brake shoe Brake system Braking power , 72 Breakdown Brief overview Bumper Attached forklift C Care CEKON socket For tail lift* Certificate EN XL Load securing gear Chapter Chassis Driving Maintenance Operation Safety Specifications Superstructure Transport solutions Chassis Chassis number Cleaning agents , 211 Closing Sliding tarpaulin Coil Load centre of gravity Safety supports SIDMAR standard Coil safety supports Coil transport Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 5 Data

8 Index Coil well Safety supports Well cover Combination safety support Combination valve Compressed air tank Connections Brake , 25 EBS Electrical Connector 5-pin ABS pin EBS Contents Chassis Driving Index Maintenance, care Operation Safety Specifications Superstructure Transport solutions Conventional tarpaulin Corner sideposts turning to the outside* Corner sideposts, turning to the outside Coupling Coupling heads C Duo-Matic Standard Crane loading Cross beam Cross tube Current NATO socket REALS socket Customer Service D Danger symbols Datasheet DCE Directive Dead man's switch Departure Departure inspection Designated use Dimensions , 206 Drawing S.CS / S.CS BS S.PR Direct clamps Direction indicators Direction of travel Directive DCE Disc brake Brake adjustment Distributed load , 208 Document compartment* Document tube* Drain valve Draining Driving Driving dynamics program Driving height Adapting Automatic Fifth wheel height High Low Manual Overview Setting , 139 Standard Driving position Air suspension Bumper E EBS Axle load indicator* Connection connector Notes Plug connector Warning displays Warning sign ECE-R Edges Electrical connections Emergency braking function Emergency release

9 EN EN XL Entry aids Extension ladder Ladder Steps Euroservice , 19 Extension ladder Eyelets F 5-pin ABS connector Ferry lashing rings Movable Rigid Ferry transport Accompanied Unaccompanied Fifth wheel heights Fifth-wheel load Fire extinguisher * Flat spray nozzle Flexible corners (13.73 m)* , 140 Flexible load securing gear* Industrial wiremesh boxes Flexos Description Offset front wall tarpaulin Floor load capacity Folding Guard Foot control for tail lift* Forklift axle load , 208 Forklift rack* Forklift supports Forklift rack* Front tension ratchet* G Grease and oil Guarantee. See warranty H Hamburg top Hazards Height coding Height-adjustable superstructure High speed Holdback stay Hook section* Hooks Hot-galvanised surfaces Hub odometer Hub odometer* Hydraulic lifting roof Hydraulic oil Hydraulic pump Manual Pneumatic* I Increasing Load height Load width Increasing load height Increasing load width Indicators Information on operation Inspection Before departure Interior length m Intermodal transport Intermodal transport identification letter ISO 1726 Rotation radius Tilt angle Turning angle ISO ISO J Joloda roller See pallet roller Joloda tracks See perforated rails Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 7 Data

10 Index K Kilometre counter Digital Mechanical Kilometre counter* Kilometre reading King-pin Limit dimensions KLV L Ladder , 109 Landing leg , 42 Landing leg Length compensation Notes Rear* Lashing eyelets In the outside frame Reinforced* Lashing holes* Lashing rings, see ferry lashing rings Lashing winches* Layout of rear lights Length Inside Outside Lift axle* Lift height Lifting roof Hydraulic Hydraulic oil Hydraulic, manual Hydraulic, pneumatic Important notes Lift height Mechanical Light system Circuit diagram Light system circuit diagram Lights Line load , 208 Lines Wendelflex Load centre of gravity Coil Load distribution Load distribution plan Load height Load pressure indicator Load safety Load securing certificate Maintenance Transport conditions Load securing gear At front At rear Cross beam Securing sideposts With partial load Load securing gear in accordance with EN XL Load securing wedge Load securing wedges Loading Loading and unloading bulky goods Loading on train Corner height Loading/unloading bulky goods Locking belts Longitudinal member Installing Removing Low speed Lubricants M Maintenance , 177 Air suspension system Batteries Compressed air system Door hinges Front wall Hydraulic pump King-pin Landing legs Load securing certificate Pallet stop strips Rubber bushings Shock absorbers Sidepost locks Sidepost pockets Skid plate

11 Sliding tarpaulin Tarpaulin locking gearbox Tarpaulin roller Technical qualifications Tension locks Threaded connections Threaded fasteners Manual control for tail lift* Manual lowering of lift axle* Meaning of safety instructions Mechanical lifting roof Moveable bulkhead* Multifunction floor N Name plate NATO socket , 64 O Offset front wall tarpaulin Flexos Open box (S.PR) Opening Semitrailer Sliding tarpaulin Opening the semitrailer Operating console Air suspension , 32 Brake Operating instructions Brake adjustment Changes Service and maintenance Operation Original spare parts Outside dimensions Outside frame Installing Removing Overall adjustment , 72 Overall weight Overview Air suspension systems Chassis Driving heights P Superstructure Warning sticker Pallet box Loading diagram Pallet box* Pallet roller Pallet stop strip* Paper transport Parking brake Parking/manoeuvring valve Perforated rails Pivoted foot Plug connector 5-pin pin EBS Electrical Pocket wagon Pressure advance Pressure washer Q Quick-tension lock* R REALS socket , 64 Rear door High Small Rear lights Rear wall Release unit Front tarpaulin* Release valve Releasing Tarpaulin with tarpaulin locking gearbox Tarpaulin with tension ratchet* Removable sideposts* Reserve wheel holder. See spare wheel holder Reset-to-ride Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 9 Data

12 Index Residual hazards Coupling and uncoupling Entering and leaving superstructure. 17 Load in danger of tipping Load pressure Opening and closing superstructure Resistance Additional sideposts* Load securing wedge Moveable bulkhead* Reversing light Revolving rod lock , 102 Rigging board holder* Rigging boards* Handling Stowing Roof Hydraulic lifting/lowering Mechanical lifting/lowering Roof opening tool Roof retain. See Strap retainers in the roof Rotating nozzle Rotation radius ISO RREG 71/ Rubber strap S 7-pin EBS connector pin socket Axle lift pin socket Axle lift S.PR "open box" Safe floor load , 208 Safety Safety inspection Safety instructions Symbols Safety supports for coils Section information Section number Service intervals , 180 Service items , 180 Service partner Service schedules , 180 Setting Driving height Settling processes Side board lock Side boards Sideguard Sidepost holder Sideposts Fixed Removable sideposts* Sliding sideposts Sideposts* Stowing SIDMAR standard Sliding roof S.CS SPR Sliding tarpaulin Closing Opening S.CS S.CS BS Slotted bar Socket CEE/CEKON NATO , 64 REALS , 64 Socket assignment charts Spare parts Operating permit Purchasing Spare wheel Removing , 53 Replacing , 54 Spare wheel holder Basket-type model Models Winch-type model Specifications Spiral lines Splitter (Loading on train) Spring bellows pressure Spring-actuated pressure accumulator parking brake Actuation Emergency release Stability Stability program

13 Standard EN , 170 EN XL ISO , 78 ISO ISO SIDMAR VDI (association of German engineers) 2700 ff, Starting aid* Stickers Storage compartment For additional sideposts For pallets For tools In the front wall Paper transport Strap retainers in the roof Superstructure Height-adjustable Supply lines Layout Wendelflex lines Support block Surfaces Hot-galvanised Suspension Type Swivel radius Symbols Explanation T Tail fog light Tail lift batteries Tail lift charging cable* Tail lift* Charging cable Direct connection Foot control Manual control Operation Spare battery Tail light Tailboard Tarpaulin S.CS S.CS BS S.PR Tension ratchet* , 92 Tightening gear Tarpaulin locking gearbox , 92 Tarpaulin rope S.PR Tarpaulin tension Tarpaulin tension rod Front Rear , 92 Telescopic Tarpaulin tightener DB Miederhoff Standard Tyride Technical datasheet Technical qualifications Telephone Customer Service Euroservice , 19 Spare Parts Centre Telescopic tarpaulin tension rods Tension bracket Quick-tension lock* Tension of tarpaulin Tension ratchet* , 92 Tension straps on outside frame Tensioning Superstructure when driving without load Tarpaulin with tarpaulin locking gearbox Tarpaulin with tension ratchet* Tensioning superstructure Tensioning when driving without load Test pressures ALB Tightening torques Tilt angle TIS Tool box* Torque values Bolt sizes Chassis bolts King-pin Mounted parts Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 11 Data

14 Index Strength classes Wheel nuts Torques. See Torque values TPMS Trailer EBS Transport solution Coil transport Industrial wiremesh boxes Paper transport Transport solutions Travelling empty Tensioning superstructure Turnbuckle see Tarpaulin tightener Turning angle Turning circle Type Axle guide Suspension Tyre pressure monitoring system Tyres U Uncouple Uncoupling , 74 Unloading Up/down valve Drive Lift Lock position Lower Stop Use Designated Use, designated W Wagon Warning notes Warning sign Landing legs Wheel nut seating Warning sticker , 212 Warning symbols Warranty Wash additives Water tank* Wear Brake pads , 190 Wedges for load securing Well cover Coil Wendelflex lines , 76 Wheel chocks Wheel nuts First drive Tightening Wheels Width Inside Outside Winch-type model Working with residual hazards V VDI VDI (association of German engineers) 2700 ff, Vehicle identification Vehicle Identification Number

15 Safety Operating instructions 14 Residual hazards 16 Departure inspection 18 Warranty 19 Maintenance Safety Keywords Operation Transport solutions Superstructure Driving Chassis 13 Data

16 Operating instructions Operating instructions Designated use Schmitz Cargobull curtainsider semitrailers are approved exclusively for operation behind tractors with brake systems approved by road traffic regulations or EC Directive 98/12 EC or ECE Regulation No. 13. Operation of the semitrailer is only approved with properly connected compressed air and electrical supply lines and the EBS connection cable. The tractors must be fitted with either an ISO plug connector, 7-pin, 24 V, or an ISO plug connector, 5-pin, 24 V. Transport of the following is not permitted: Livestock Food controlled under the ATP agreement, Persons Transport of dangerous goods under GGVS/ADR is only permitted with the specified supplementary equipment. The load must be secured properly with the supplied equipment, such as lashing eyelets and supplementary equipment such as tension straps, before starting travel. Unsecured or insufficiently secured loads can cause serious accidents with personal injury by moving or falling from the load area. Load the semitrailer so the axles and drawbars are neither overloaded and the approved gross weight of the semitrailer is not exceeded. With partial load, make sure the load is evenly distributed. Otherwise the driving characteristics will deteriorate and the risk of accident will be higher. Do not exceed the legally approved length, width and height dimensions. Always drive with tarpaulins, rear wall and side boards closed. Flapping tarpaulins and open side boards may cause accidents with personal injuries. Always drive with the lifting roof lowered and screwed sideposts. Overwidth and overheight may cause accidents with personal injuries. Do not modify the semitrailer in any way. This can negatively affect the safety of the semitrailer. The operating permit will also be cancelled. Schmitz Cargobull does not accept liability for damage caused by modifications to the semitrailer. Designated use also includes following the directions of this Owner's Manual and the test and service intervals with the service conditions specified by Schmitz Cargobull. Brake adjustment Unlike the drum brake the disc brake shows no perceptible loss of braking power when overloaded. The overload is noticeable more by overheated brake discs, which can result in damage to wheel bearings and brakes and also increased brake pad wear. To distribute the braking force evenly over all brakes in the combination, all wheel brakes should be adjusted to operate evenly after the first 2,000 to 5,000 km as per RREG 71/320. Warranty claims resulting from premature wear can only be considered when the results of the semitrailer brake adjustment are submitted. 14

17 Service and maintenance All service and maintenance work must be carried out by qualified workshops only. Schmitz Cargobull recommends the Schmitz Cargobull service centres for all service and maintenance work. They have all the required tools and the knowledge required for this work. Have all inspections and services done at the specified intervals. The service book documents all inspections and forms the basis for any warranty claims. Warning sticker The warning stickers on the semitrailer are part of the operating manual. Observe the stickers in the same way as the operating manual. Keep the stickers readable and replace illegible or lost stickers immediately. An overview of the warning stickers attached to the vehicle can be found in "Warning sticker overview" on page 212. Keywords Safety Chassis Changes to the semitrailer Vehicle frame, wheels, axles and the wheel brakes are safety-relevant components that must not be modified, repaired or converted in any way. The following in particular are prohibited: welding, alignment, drilling and heat treatment of any safety-relevant components. Protect electronic controllers for ABS/EBS, ECAS etc. by disconnecting them before doing any welding on components that are not relevant to safety. Cover plastic lines before carrying out welding, drilling or grinding work. Driving Superstructure Transport solutions Operation Maintenance 15 Data

18 Residual hazards Residual hazards Schmitz Cargobull curtainsider semitrailers are designed to the state of the art in technology and the generally accepted safety engineering requirements. However, hazards to life and limb of persons or damage to the curtainsider semitrailer and other property may occur when working on the curtainsider semitrailer. Please find below an overview of the residual hazards when working with the curtainsider semitrailer. Hazard source Coupling and uncoupling Opening and closing superstructure Load in danger of tipping Hazard/consequences FATALITY HAZARD! Persons in the danger zone between the tractor and the semitrailer may be crushed or run over. Direct all persons away from the danger zone when coupling or uncoupling. No person is permitted to remain at the fifth-wheel lock of the tractor while coupling or uncoupling. Persons directing the tractor driver must stand well away from the vehicles. INJURY HAZARD! You may slip and fall if you climb up parts not designed for the purpose. Do not climb up on wheels, bumpers or other attached parts. Always use a ladder with antislip feet. FATALITY HAZARD! If the load has fallen it may fall out when the body is opened and cause personal injury. Do not release lashings if you see that the load may tip. Secure the load to prevent its tipping before releasing the lashings. 16

19 Hazard source Load pressure Entering and leaving superstructure Hazard/consequences INJURY HAZARD! Load pressure occurs when loads press on side boards, gates or doors and move suddenly with great force when they are opened. You or other persons may be crushed or struck under such circumstances. Always open the superstructure very cautiously. Note the load pressure indicator on the locks on side boards, gates or doors. Proceed with great care when opening tarpaulins. Do not open tarpaulins if shifted loads are pressing on them. In such a case leave the tarpaulin tightener tensioned and the tarpaulin rope threaded. Remove the pressure from the load before opening the relevant sides of the superstructure. When opening side boards, gates or doors always stand outside the swing area. INJURY HAZARD! You may slip and fall if you climb up parts not designed for the purpose. Do not jump down from the superstructure. Use the accesses provided. Do not climb up on wheels, bumpers or other attached parts. Superstructure Driving Chassis Safety Keywords Maintenance Operation Transport solutions 17 Data

20 Departure inspection Departure inspection The departure inspection is an important contribution to road safety. Carry out a pretrip inspection before every trip. Walk around the semi-trailer truck after trip interruptions, such as rest stops on the highway or after the weekend, inspect the most important points and repair any defects if necessary. Before departure Is the fifth wheel correctly locked and secured? Are all landing legs retracted and the cranks secured? Are all supply lines connected? Are the compressed air connections and lines sealed? Is the up/down valve in the "DRIVE" position? Are the compressed air tanks free of condensed water? Are all mounted parts such as ladders, wheel chocks, roof opening tools etc. secured with spring clips, split pins or padlocks? Are the spare wheels fixed and secured? Are the sideguards unfolded and secured? Is the rear folding guard* unfolded and secured? Are the covers of storage compartments, such as toolboxes or pallet boxes closed and secured with spring clips, split pins or padlocks? Are all tarpaulin tighteners of the sliding tarpaulin attached and secured? Are all tyres in good condition? Is the tyre pressure correct? Are the air spring bellows free of folds and undamaged? Does the lighting system function? Weather-dependent Check the following points depending on the weather: Remove water from the roof. Do not endanger yourself. Remove ice or snow accumulations from the top if applicable. Do not endanger yourself. Before loading Clean the load area before loading for safety. After loading or unloading After loading or unloading or after picking up the semitrailer check the following points: Is the semitrailer correctly loaded and the load sufficiently secured? Are all side boards and rear doors closed and secured? Are all rigging boards securely stowed? Is the top closed and secured? Is the lifting roof lowered? Are the sideposts completely retracted? Is the tarpaulin closed everywhere and tensioned? Are the locking belts and the tarpaulin rope of the conventional tarpaulin correctly threaded and secured? 18

21 Warranty Terms and conditions The contents and scope of warranty claims conform to the Schmitz Cargobull new vehicle supply terms and conditions (purchase contract between Schmitz Cargobull and the customer). Damage caused by the following is not covered by the warranty: Overloading Non-designated and improper use Unapproved modifications Wear is also of course excluded from warranty coverage. The warranty coverage is as follows: If the semitrailer is operated as specified and only with components approved by Schmitz Cargobull, If spare parts approved by Schmitz Cargobull are used. Spare parts Schmitz Cargobull recommends the exclusive use of Schmitz Cargobull original spare parts. Schmitz Cargobull original spare parts undergo regular tests for safety and function. The use of Schmitz Cargobull original spare parts guarantees road and operating safety and the operating permit is retained. Spare parts that have not been approved by Schmitz Cargobull cannot be assessed by Schmitz Cargobull with regard to their suitability, safety and reliability. Warranty The operating permit and the warranty will be cancelled if spare parts that are not approved by Schmitz Cargobull are used. Have the information on the vehicle name plate (see page 1) ready when ordering spare parts: Vehicle type Vehicle Identification Number (VIN) Spare parts sales Schmitz Cargobull Parts & Services GmbH Spare Parts Center Siemensstraße Altenberge Telephone: +49 (0) 2558 / Fax: +49 (0) 2558 / Fax: +49 (0) 2558 / Ersatzteil-Center@cargobull.com Internet: or at one of our authorised service partners. In the event of breakdown you can contact the Cargobull Euroservice at: CARGOBULL or Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 19 Data

22 20

23 Chassis Overview 22 Brake system 24 Air suspension 32 Landing legs 41 Wheel chocks 45 Sideguard 46 Ladder* 47 Roof opening tool 48 Rigging board holder* 49 Sidepost holder* 50 Spare wheel holder 51 Pallet box* 55 Tool box* 56 Water tank* 57 Fire extinguisher * 58 Document compartment* 59 Hub odometer* (Axle hub odometer) 60 Forklift rack* 61 Tail lift* 63 Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 21 Data

24 Overview Overview Overview of controls on chassis Item Name Page 1 Connections for compressed air and electrical supply lines, EBS plug connector 2 Fire extinguisher * 58 3 Document compartment* 59 4 King-pin Left wheel chock 45 6 Ferry lashing rings* 80 7 Left sideguard 46 8 Pallet box* 55 Ladder* 47 Roof opening tool 48 Rigging board holder* 49 Sidepost holder* 50 9 Spare wheel holder (S.CS Mega) Lift axle* (country-specific) Spring-actuated pressure accumulator emergency release Brake/air suspension controls

25 Item Name Page 13 Rotary switch for axle lift* Axle load indicator* Rotary switch for second driving height Brake pad wear indicator* Compressed air reservoir/drainage valves Water tank* Forklift rack* 61 Tail lift* Folding guard* Rear landing leg* Tool box* Spare wheel holder Hub odometer* Right sideguard Winch (landing leg) Right wheel chock 45 Superstructure Driving Chassis Safety Keywords Maintenance Operation Transport solutions 23 Data

26 Brake system Brake system Schmitz Cargobull semitrailers are fitted with the Electronic BrakeSystem EBS as standard equipment (see "EBS" on page 68). EBS Standard coupling heads The EBS system also includes the ABS function (Antiskid Braking System) and the ALB function (automatic load sensing braking pressure regulation). All supply lines are combined at the front wall. The following types of coupling heads may be installed: Standard coupling heads (production) with integrated line filters Duo-Matic connector* C-coupling heads* with separate line filter Coupling heads Different types of coupling heads can be installed simultaneously for specialised applications. Wendelflex lines Wendelflex lines that are tangled may come off in very tight curves. Separate them before connecting them. 1 Supply coupling head (red) 2 Brake coupling head (yellow) Connecting to the tractor Prerequisite: the parking brake of the tractor must be set. Check sealing surfaces of the coupling heads and clean if necessary. Always connect the brake coupling head (2) first. The semitrailer is braked. Connect the supply coupling head (1). Check coupling heads for leaks and replace leaking rubber seals. Disconnecting from the tractor Prerequisite: The parking brake of the tractor is set. Always disconnect the supply coupling head (1) first. The semitrailer is braked. Disconnect the brake coupling head (2). Close dust caps of coupling heads. 24

27 Duo-Matic coupling head* C-coupling heads Keywords Chassis Maintenance Safety Duo-Matic connection 1 Duo-Matic coupling head Driving Superstructure Transport solutions Operation Connecting to the tractor Prerequisite: the parking brake of the tractor must be set. Check sealing surfaces of the connections and clean if necessary. Pull lever of coupling head (1) down and insert counterpart. The semitrailer is braked. Check connections for leaks and replace leaking rubber seals. Disconnecting from the tractor Prerequisite: the parking brake of the tractor must be set. Pull lever of coupling head (1) down and remove counterpart. The semitrailer is braked. C-coupling heads 1 Supply coupling head 2 Brake coupling head 3 Line filter Connecting to the tractor Prerequisite: the parking brake of the tractor must be set. Check sealing surfaces of the coupling heads and clean if necessary. Always connect the brake coupling head (2) first. The semitrailer is braked. Connect the supply coupling head (1). Check coupling heads for leaks and repair leaks. Disconnecting from the tractor Prerequisite: the parking brake of the tractor must be set. Always disconnect the supply coupling head (1) first. The semitrailer is braked. Disconnect the brake coupling head (2). 25 Data

28 Brake system ABS/EBS connection ACCIDENT HAZARD! The EBS and thus the ABS and the automatic load sensing brake control will not operate without the ABS/EBS plug connector. This can cause the semitrailer to overbrake and skid and may result in accidents. Always connect the ABS/EBS plug connector between the tractor and semitrailer. Use only approved ABS/EBS plug connectors registered in the vehicle registration. The "EBS" warning sign is part of the operating manual. Observe the sticker and keep it readable. Replace the "EBS" warning sticker if it is lost or becomes illegible. Approved plug connectors 1 EBS socket Power supply Vehicles built from 2002 have an additional power supply for the EBS system. This is ensured by the 7-/15*-pin socket of the light system. This means that the ABS and ALB will still operate even if the ABS/EBS plug connector is disconnected. The power supply through the 7-pin socket is only provided as a supplementary power supply, in the event of a fault in the ABS/EBS plug connector! Schmitz Cargobull semitrailers may only be operated behind tractors with the following ABS/EBS plug connectors: Enhanced ISO plug connector, 7-pin, 24 V, on tractors with CAN data line (with EBS) ISO plug connector, 5-pin, 24 V, on tractors without CAN data line (tractors without EBS, with ABS plug connector) ABS/EBS warning sticker 7-pin socket (EBS system) "EBS" warning sign on the front wall 26

29 Brake/air suspension controls Keywords Chassis Driving Superstructure Transport solutions Operation Maintenance Safety 5-pin socket (ABS system) Electrical connections Electrical connections 1 7-pin socket 2 7-pin socket 3 15-pin socket* Schmitz Cargobull semitrailers have two 7-pin sockets as standard equipment (1 and 2). The 15-pin socket (3) is available as optional equipment. For the terminal assignment of the sockets see page 199. Controls for brake and air suspension on chassis 1 Operating console The operating console (1) is installed behind the left axle. The following functions are operated with the operating console (1): Service brake, Parking brake, Air suspension up and down function, second driving height *, Axle lift*, Axle load indicator*, Test connections, Diagnostics connection (depending on the system manufacturer), Reversing lock for a trailing steering axle*, Brake pad wear indicator (see "Brake pad wear indicator" on page 190), Tyre pressure indicator (see "Tyre pressure monitoring system* (TPMS)" on page 196), TIS (Trailer Information System). 27 Data

30 Brake system Trailer Information System* (TIS) The Trailer Information System is available on request. It offers a fast way to access the following information: Total kilometre reading, Trip meter reading, Axle loads, Brake pad wear indicator (with additional sensors), Tyre pressure gauge for each wheel (with additional sensors), EBS fault diagnosis. Operating console with parking/ manoeuvring valve 1 Red button, parking valve 2 Black button, manoeuvring valve TIS by Knorr or Wabco The TIS control unit the is installed on the operating console. For further information on the operation please contact the manufacturer. Parking/manoeuvring valve When the supply line is uncoupled the semitrailer is automatically braked. The emergency braking and actuation function is ensured in accordance with ECE-R13. Release ad actuate the brake for manoeuvring the uncoupled semitrailer with the black button (2). Actuate the spring-actuated pressure accumulator parking brake with the red button (1). The red button (1) has a lock to prevent accidental release of the brake. Parking/manoeuvring valve The black button (manoeuvring valve) can only be pressed in when the semitrailer is uncoupled. Always pull the red button (parking valve) out on an uncoupled semitrailer! When the supply line is coupled the black button (manoeuvring valve) is automatically pressed out in driving position. The spring-actuated pressure accumulator parking brake is automatically actuated and cannot be released if the pressure is less than 2.6 bar. 28

31 The spring-actuated pressure accumulator parking brake can only be released if the pressure in the semitrailer compressed air system is at least 5.2 bar. Manoeuvring uncoupled semitrailer Requirement The semitrailer is uncoupled. Press red button (parking valve) in. Press black button (manoeuvring valve) in. The brake is released, and the semitrailer is unbraked. Pull black button (manoeuvring valve) out. The brake is actuated, the semitrailer is braked. Parking the semitrailer: Pull red button (parking valve) out again. Release/actuate spring-actuated pressure accumulator parking brake With uncoupled semitrailer Press red button (parking valve) in. Press black button (manoeuvring valve) in. The spring-actuated pressure accumulator parking brake is released, and the semitrailer is unbraked. Pull red button (parking valve) out. The spring-actuated pressure accumulator parking brake is set, and the semitrailer is braked. With coupled semitrailer Press red button (parking valve) in. The spring-actuated pressure accumulator parking brake is released, and the semitrailer is unbraked. Pull red button (parking valve) out. The spring-actuated pressure accumulator parking brake is set, and the semitrailer is braked. Actuating the red button 1 Lock 2 Red button A Release position B Unlocked C Actuation D Brake position To actuate the red button Pull lock (1) and pull or press red button (2). Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 29 Data

32 Brake system Spring-actuated pressure accumulator emergency release ACCIDENT HAZARD! The unbraked semitrailer may roll away and run over you or other persons. Secure the semitrailer to prevent its rolling before releasing or setting the spring-actuated pressure accumulator parking brake with the emergency release. Emergency release Spring-actuated pressure accumulator brake cylinder 1 Hole 2 Release rod 3 Nut The emergency release must be disabled as soon as the operating pressure of the semitrailer is at least 5.2 bar. Only then will the semitrailer be braked by the parking brake again. Emergency release It is easier to screw in the emergency release with vented spring-actuated pressure accumulator brake cylinders. ACCIDENT HAZARD! The parking brake does not operate when the emergency release is actuated. The semitrailer may roll away and run over you or other persons. Disable the emergency release in before driving the semitrailer. Prerequisite: the semitrailer must be secured to prevent movement. Remove release rod (2) from the brake cylinder and insert it in the hole (1). The release rod (2) is fastened to the side of the brake cylinder. Rotate release rod (2) 90 and screw in the nut (3) until it contacts the brake cylinder. Screw in the nut (3) completely with a screwdriver. The spring-actuated pressure accumulator parking brake is released, and the semitrailer is unbraked. Deactivation Prerequisite: the semitrailer must be secured to prevent movement. On all wheels with spring-actuated pressure accumulator brake cylinders: Unscrew the nut (3) completely. Remove release rod (2) and fasten to brake cylinder again. The emergency release is deactivated, and the semitrailer can be braked with the spring-actuated pressure accumulator parking brake again. 30

33 Compressed air tank Compressed air tank 1 Drain valve The compressed air reservoirs are installed in the frame behind the rear axle. Modern tractors are fitted with air driers that largely prevent the accumulation of condensation in the compressed air. For safety reasons regularly check whether there is water in the compressed air tanks. ACCIDENT HAZARD! Condensation in the compressed air reservoir may cause brakes to freeze and failure of the brake system! Check the drain valve of the compressed air reservoir for condensation regularly, particularly during cold weather. Drain any condensation completely. Drain condensation completely from the compressed air reservoir by pulling the drain valve (1). Superstructure Driving Chassis Safety Keywords Maintenance Operation Transport solutions 31 Data

34 Air suspension Air suspension Function You can lift and lower the level of the parked semitrailer with the up and down valve (1), e. g. for coupling and uncoupling or to adjust the height for a ramp. If the up/down valve is not in "DRIVE" position during loading or unloading, the level of the semitrailer will change as the load changes! The up and down valve returns automatically to driving position when the speed exceeds 16 km/h (Auto-Reset). Operating console 1 Up/down valve 2 Selector lever (shown in "DRIVE" position) The operating console (see page 27) is installed on the left side of the semitrailer behind the rear axle. In "DRIVE" position the air suspension continuously maintains the driving level at the same height regardless of the load. After changing the height for loading or unloading the basic level is reset. ACCIDENT HAZARD! If the air suspension is not set to "DRIVE" position before starting a trip, poor driving properties or a high level setting may cause to vehicle to be caught at an underpass and cause an accident. Always set the Up and Down valve to "DRIVE" position before starting atrip. Stroke limit Raise/Lower If the service or parking brake is set, it may be difficult to lift or lower the vehicle because the springs will not be able to pivot freely. The shock absorbers act as stroke limiters, therefore cables or other types of stroke limit are not required. To lower the air suspension completely a stop is mounted on the axle ties. The stop allows the semitrailer to be driven a short distance at low speed without air on the bumper to the nearest workshop if the air suspension system fails. However, make sure that the tyres rotate freely. Up/down valve Use the up/down valve for height adjustment while loading and unloading, before uncoupling, during ferry transport, during intermodal transport. 32

35 Always set the up/down valve to driving position before starting a trip. Driving with the up and down valve set to "Up" or "Down" may damage the load, the semitrailer, the brake and the air suspension system and will overload and destroy the shock absorber. The up and down valve (1) has a safety function, the "dead man's switch". This safety function ensures that when the selector lever (2) is released the spring bellows are not supplied with air or vented and the lift and lower process is stopped immediately. In the lock position "UP" or "DOWN" the selector lever locks. The lift and lower process is not interrupted when the selector level is released. The RtR function(auto-reset) is effective also in the lock positions. The selector lever (2) has the following positions: "DRIVE" position The selector lever (2) is pulled out in the centre position and cannot be moved. "STOP" position "STOP" position Leave the selector lever in "STOP" position or lock position "DOWN" to leave the semitrailer lowered (e.g. on the ferry) or lifted (e.g. on a ramp). "STOP" position Press selector lever in from "DRIVE" position. It can now be moved. To restore the driving position pull the selector lever (2) out from the "STOP" position to the "DRIVE" position. "UP" position "UP" position Move selector lever (2) to the right from the "STOP" position (anticlockwise). The semitrailer is lifted while you hold the selector lever. When the selector lever is released it automatically returns to the "STOP" position and the lift procedure is stopped. Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 33 Data

36 Air suspension Lock position "UP" Lock position "UP" Move selector lever (2) to the right from the "STOP" position (anticlockwise). Press the selector level (2) again. The semitrailer is lifted up to the maximum height. To end the lock position "UP", pull the selector lever (2) to "STOP" position. "DOWN" position Move selector lever (2) to the left from the "STOP" position (clockwise). The semitrailer is lowered while you hold the selector lever. When the selector lever is released it automatically returns to the "STOP" position and the lowering procedure is stopped. Lock position "DOWN " Move selector lever (2) to the left from the "STOP" position (clockwise). Press the selector level (2) again. The semitrailer is completely lowered. To end the lock position "DOWN", pull the selector lever (2) to "STOP" position. Auto-reset function ACCIDENT HAZARD! If you lower the semitrailer to drive through a low underpass, it will automatically be lifted to driving position if the speed exceeds 16 km/h and it may be caught. When you lower the semitrailer to drive through a low underpass always drive at a speed well under 16 km/h. The Auto Reset function (also called RtR function = Reset to Ride) is a safety function that adjusts the driving level automatically when the EBS connecting cable is plugged in. The auto-reset function moves the selector lever from the "STOP" position to the "DRIVE" position from a speed 16 km/h, which automatically sets the driving position. From the lock positions "UP" or "DOWN", the selector level is also pressed to the "DRIVE" position. For this reason the semitrailer can only be driven lowered or raised at a speeds of less than 16 km/h. 34

37 Axle lift system* The following lift axle types and functions are available for 3-axle semitrailers: Axle lift at the first axle Axle lift at the first and third axle For both axle lift variants, the lift axle automatic device can be switched off by a switch mounted on the vehicle as standard. Travel through curves When the lift axle is lifted the wheel base between the tractor and semitrailer increases. This means that the semitrailer moves further in when travelling through curves! Switching axle lift on/off Keywords Safety Axle lift with ABS/EBS In older vehicles with ABS the lift axle remains lifted when the ignition in the tractor is switched off. In newer vehicles with EBS the lift axle is lowered when the ignition in the tractor is switched off regardless of the load status. Lower the lift axle when you park the semitrailer unsupervised. In the event of air loss the axle will lower uncontrollably. Axle loads The lift axle lowers only when the axle on the floor exceeds the approved axle load. Depending on the load distribution the vehicle may be driven with the axle lifted with payloads up to 18 t. Starting aid For the starting aid, please note that the maximum load of the axles on the floor is 1.3 times their capacity. Furthermore, the starting aid is active only at speeds lower than 30 km/h. Operating console 1 Axle lift rotary switch (shown at an/on position) The axle lift is switched on or off with the axle lift rotary switch (1). When it is switched off the axles are not lifted. CRUSHING HAZARD! The lift axle may crush feet when lowered quickly. Switch off the axle lift before loading the semitrailer quickly with a high tonnage (e.g. coils). Chassis Driving Superstructure Transport solutions Operation Maintenance 35 Data

38 Air suspension Switching on axle lift Rotate axle lift rotary switch (1) to "an/on" position (clockwise). Automatic operation is enabled. The lift axle is lowered with EBS as soon as the axle loads of the two other axles have reached the maximum approved value. If the load falls below this value while unloading, the lift axle is automatically lifted. Second driving height*, manual Switching off axle lift Rotate axle lift rotary switch (1) to "aus/off" position (anticlockwise). Automatic operation is disabled. The lift axle remains permanently lowered, even if the semitrailer is empty or partially loaded. The axle lift can now no longer be operated by the switch in the tractor cab. Switching the axle lift from the tractor The Axle lift of the semitrailer can also be switched from the tractor, via a key. The key must be installed tractor-side and it should be assigned to pin 14 of the 15-pin socket or to pin 2 of the white 7-pin socket as plus signal. Press the key for less than five seconds. The starting aid is activated. Press the key for five seconds or longer. The lift axle automatic device is disabled. Operating console 1 Driving height rotary switch (showing low driving height) For the operation with tractors of different fifth-wheel heights two driving heights can be set. Low (standard) driving height for fifthwheel heights of 965 mm. High driving height for fifth-wheel heights of 1,050 mm to 1,150 mm. Setting low driving height Set driving height rotary switch (1) to vertical position. The low (standard) driving height is set. Setting high driving height Set driving height rotary switch (1) to horizontal position. The high driving height is set. 36

39 Second driving height*, automatic Based on the connected coupling heads, the brake system sets automatically the low or high driving height. Setting low driving height Connecting standard coupling heads or Duo-Matic* coupling head. The low (standard) driving height is automatically set. Setting high driving height Connect C-coupling heads*. The high driving height is automatically set. Axle load indicator* Axle load table on vehicle frame 2 Axle load scale in kg 3 Pressure scale in bar Calculating axle load Read spring bellows pressure on the pressure gauge (1). Example: 3.5 bar spring bellows pressure. Find the value that you have read on the pressure scale (3) in the axle load table. The value in the axle load scale (2) shows the axle load in kg. Example: the 3.5 bar spring bellows pressure that you have read correspond to an axle load of 5510 kg per axle. Keywords Safety Chassis Driving Superstructure Pressure gauge on the operating console 1 Pressure gauge (example: 3.5 bar) The pressure gauge (1) displays the current spring bellows pressure,which depends on the load status. The higher the pressure the higher the axle load. Axle load control Check the axle load before starting a trip to make sure that overloads can be detected early. Max. axle load The actual (read) axle load must never be higher than the maximum approved axle load. This can be found on the "vehicle" name plate (see page 1). Note the following: In Europe, the approved axle load can be different in each country. When it supports the tractor, axle load can also be determined and displayed via the trailer EBS (see "Axle load indicator" on page 69). Transport solutions Operation Maintenance 37 Data

40 Air suspension Combined with Trailer Information System (TIS), the load of each axle is shown on the display near the operating console. For further information on the operation please contact the manufacturer. Setting driving height The driving height is changed by adjusting the top rubber coupling of the link rod. See the table for the adjustable driving height ranges. Do not exceed or fall below the specified values. The driving height limits in the table (MIN and MAX) apply to every axle on the vehicle. Note the legal limit of the overall vehicle height (4,000 mm as specified by the EC Directive). Axle tube 1 Axle guide 2 Axle tube 3 Bottom of frame 4 Link rod air suspension valve The driving height is set directly at the link rod of the air suspension valve. The air suspension valve is installed behind the left axle, under the superstructure. Vehicles with trailing steering axle and axle lift on the third axle have the air suspension valve on the second axle. The driving height is measured from the centre of the axle tube to the underside of the frame. The driving height depends on the installed axle guide. Axle guide You receive a technical datasheet with your new semitrailer. This datasheet contains the model of your "suspension type" axle guide and the factory-set driving height in mm. Datasheet example: Suspension type: MRH3-EO30 Driving height mm: rear 370 Air suspension system The air suspension system should be set by an authorised Service Partner only. Driving height A tilted semitrailer will have poor driving and braking characteristics. Match the driving height to the fifth wheel height of the tractor. 38

41 Measuring driving height Cargobull air suspension system MRH2 and MRH3 Driving height Fh MIN MAX Keywords EO HO HO Safety Driving height ranges Fh in mm 1 X-link Axle guide Fh Driving height 1 Axle guide 2 Axle tube 3 Bottom of frame Measure driving height (Fh) between the centre of the axle tube (2) and the bottom of the frame (3). Note the driving height ranges Fh in the table. Air suspension systems overview Cargobull air suspension system MRH2 and MRH3 Driving height Fh MIN MAX KX35 ME M-link 3 O-link X-link (deep offset) M-link (medium offset) Chassis Driving Superstructure Transport solutions DX35 ME KM KM NM NM EO O-link (slightly offset) Operation Maintenance 39 Data

42 Air suspension Changing driving height ACCIDENT HAZARD! The non-braked semitrailer may roll away and cause personal injury. Adjust the driving height on flat horizontal ground only. Always secure the semitrailer with the wheel chocks to prevent its moving. INJURY HAZARD! When setting the driving height the chassis may lower and cause personal injury. Keep all parts of the body out of the danger zone between the axle and chassis. Make sure that there are no other persons in the danger zone. Air suspension valve 4 Valve lever 5 Rubber coupling 6 Link rod Increasing driving height: Slide rubber coupling (5) upwards. Reducing driving height: Slide rubber coupling (5) down. Tighten clamp screw of rubber coupling (5). Release main brake of the semitrailer. If the brake is set it is more difficult to lift and lower the vehicle. As required slide rubber coupling (5) until the measured driving height matches the table value. Loosen clamp screw of rubber coupling (5). 40

43 Landing legs ACCIDENT HAZARD! The semitrailer may cant over and cause personal injury. Before uncoupling make sure that the semitrailer is loaded so it will not tip. Load the uncoupled semitrailer so it will not tip during loading. Do not exceed the maximum approved support load of the landing legs. Loading and unloading The landing leg may be damaged if it is loaded across the direction of travel. Avoid longitudinal and shear forces while loading or unloading an uncoupled semitrailer. Load or unload semitrailer from the side only when coupled. The notes above apply to the front landing leg and to any rear landing leg*. Keywords Safety Chassis Supplementary information See the instructions on landing legs in the following sections: "Coupling and uncoupling" on page 73 "Rotation radius" on page 77 Property damage The landing leg can be damaged by overloading if you attempt to lift or lower the semitrailer at high speed. Use the landing leg in low speed only after setting the support foot on the ground; whether the semitrailer is empty or loaded. Switch to high speed only after the foot is lifted and relieved of all load. Uncoupling The semitrailer may be damaged during the uncoupling. During uncoupling, the support feet must always contact the floor to prevent the semitrailer from falling. If necessary, use a suitable base plate under the support feet. Driving Superstructure Transport solutions Operation Maintenance 41 Data

44 Landing legs Front landing leg Retract support foot (2) completely and place crank (1) in the retainer. Landing leg with switch between low and high speed (arrow) 1 Crank 2 Support leg The landing leg supports the uncoupled semitrailer and adjusts the height while coupling and uncoupling. The landing leg has a high speed and a low speed mode. Lowering support foot Remove crank (1) from retainer. Set high speed by pulling the crank out. Lower landing leg (2) until it touches the ground. Set low speed by pushing the crank in. Extend support foot (2) to desired length and attach crank (1). Retracting support foot Remove crank (1) from retainer. Set low speed by pushing the crank in. Lift foot (2) until it no longer touches the ground. Set high speed by pulling the crank out. Crank retainer on the landing leg Crank retainer on the chassis frame at 32 pallet box Pivoted foot 42

45 As the air suspension loses pressure the semitrailer lowers and simultaneously moves forwards (when the air suspension is lifted it moves forwards). Landing legs with length compensation (pivoted foot) compensate for these movements and protect the landing leg from deformation. Pivoted feet can move approximately 20 cm forward and back. Keywords Safety Rear landing leg* Left support with crank 1 Support 2 Crank 3 Lock Chassis Instructions for landing leg See the instructions for the landing leg at page 41! Driving Landing leg at rear of vehicle, driving position When loading the semitrailer from the rear with heavy warehouse transport vehicles (forklifts, lift trucks, manual lift trucks,...), the rear of the vehicle must be supported with the rear landing leg. Tipping loads Note the specified torques on page 164. Unfolding supports ACCIDENT HAZARD! The support swings down suddenly when the lock is released and can cause injury. Lower the support slowly and cautiously. Keep clear of the swing area. Hold the support (1) with one hand so it does not swing uncontrollably. Release lock (3) on handle and lower support slowly. Allow the lock (3) to click in at the bottom position. Lift and lock the support on the other side in the same way. Superstructure Transport solutions Operation Maintenance 43 Data

46 Landing legs Lifting supports Retract support feet with the crank. Stow crank (2) in the crank rack. Release lock (3) on handle and swing support (1) up. Allow lock (3) to click into place. Lift and lock the support on the other side in the same way. Right support, unfolded 1 Support 2 Crank 3 Lock Remove crank (2) from retainer and lower support feet to the ground with the crank. Property damage The landing leg can bend or tear. Before starting a trip, raise and lock the landing leg! Left support 3 Lock 44

47 Wheel chocks Wheel chocks on chassis Two wheel chocks are supplied for additional safety when working with the parked semitrailer. Note that regulations require two wheel chocks to be carried on the semitrailer at all times. Always secure the semitrailer with the wheel chocks in addition to other measures: on up or down slopes, while loading and unloading and while uncoupled. Rigid axles Always place the wheel chocks at wheels on rigid axles, never before wheels on lift or steering axles. Removing wheel chock Pull out spring clip (1). Pull wheel chock out against the resistance of the retaining bracket (4). 3 Pipe 4 Retainer bracket Stowing wheel chock Insert wheel chock with the hole (2) on the pipe (3). Slide it back until it clicks into place against the resistance of the retaining bracket (4). Lock with the spring clip (1). Keywords Safety Chassis Driving Superstructure Transport solutions Operation 1 Spring clip 2 Hole Maintenance 45 Data

48 Sideguard Sideguard INJURY HAZARD! The sideguard can fall down and injure persons kneeling underneath it. Secure the raised sideguard with the lock. Sideguard, driving position 1 Lock The sideguard must be raised to access the spare wheel holder. In driving position the sideguard is secured on the right and left with a lock (1) on the left and right. Lifting Turn locks (1) about 90 against the resistance and pull them out. Raised and locked 1 Lock Secure the raised sideguard with the lock (1). Lowering (driving position) Lower in reverse order. Rotate both locks (1) until they snap in. Always lower the sideguard and lock it before driving! Sideguard, raised Swing sideguard up. 46

49 Ladder* Ladder 1 Spring clip The ladder is stowed at the side of the chassis frame. The ladder has rubber antislip feet on both sides. INJURY HAZARD! You may slip and fall if you climb up parts not designed for the purpose. Do not climb up on wheels, bumpers or other attached parts. Always use a ladder with antislip feet. Use the ladder for opening and closing the conventional tarpaulin. Make sure that the ladder is securely seated in use. Do not exceed the maximum load of the ladder. After use secure the ladder with the two spring clips (1). Superstructure Driving Chassis Safety Keywords Maintenance Operation Transport solutions 47 Data

50 Roof opening tool Roof opening tool Removing roof opening tool Pull front and rear spring clips (1) out. Slide roof opening tool a hand's width to the right and remove. After use secure the roof opening tool with the two spring clips (1). Roof opening tool 1 Spring clip The roof opening tool is stowed on the left side of the chassis frame. You can use the roof opening tool: to open and close the sliding roof, to remove and install the longitudinal members of the top of S.PR, to adjust the superstructure height of S.CS Mega. 48

51 Rigging board holder* Keywords Chassis Driving Superstructure Operation Transport solutions Safety Rigging board holder on chassis frame Rigging boards that are not required can be stowed in the rigging board holders on the left and right side of the vehicle. Each side holds 16 rigging boards. Secure the stowed rigging boards with the securing lashing and the snap-hooks. Pull the securing lashing down or thread it up from below Pull the securing lashing downwards as shown in the picture / insert it from below. 1 Securing lashing 2 Snap-hook Maintenance Always stow the rigging boards edge up in the rigging board holder. Always position the securing lashing as close as possible to the rigging boards. 49 Data

52 Sidepost holder* Sidepost holder* Sidepost holder on the chassis frame Unused removable sideposts can be stored in the sidepost holder. A sidepost holder includes eight removable sideposts with a length of 2 metres and a cross-section of 70 x 70 mm. Secure the stored removable sideposts with security lashings and snap-hooks. Pull the securing lashing down or thread it up from below Lift the securing lashing slightly and pull it down. Follow the above procedure in reverse order to insert the security lashing. 1 Securing lashing 2 Snap-hook Always position the securing lashing as close as possible to the removable sideposts. 50

53 Spare wheel holder General The following spare-wheel holders are installed depending on the requirements and tyre sizes: basket-type model 1, for one spare wheel, basket-type model 2, for two spare wheels (a locking kit for a second spare wheel is supplied), winch-type model, for one spare wheel. The basket-type models are installed at the rear of the vehicle in front of the bumper or behind the landing leg. The winch-type model is installed in the S.CS Mega and the S.PR Mega from a tyre size of 435/50 R 22.5 or 445/45 R The basket-type model is installed for tyre size 385/55 R If the spare wheel holder is installed in front of the axle assembly, the sideguard must be raised before removing the spare wheel (see page 46). Basket-type model Basket-type model 1, rear installation Basket-type model 2, rear installation Removing spare wheel Spare wheel, driving position 1 Safety bracket 2 Nut 3 Spring clip Spare wheels are removed and replaced in the same way with basket-type model 1 and 2. Remove spring clip (3). Use safety bracket (1) to unscrew the two nuts (2). Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 51 Data

54 Spare wheel holder 4 Retaining bracket, nut unscrewed CRUSHING HAZARD! The heavy spare wheel may crush hands and feet. Keep your feet away from the danger area when removing the spare wheel. "Mounting spare wheel" instructions Remove retaining bracket (4) downwards. Remove spare wheel. Replacing spare wheel Follow the directions for mounting the spare wheel: Position spare wheel centrally on traverse. Place retaining bracket on traverse as shown. Lock safety bracket with the spring clip. 4 Retaining bracket (installed) 5 Traverse Position spare wheel centrally on traverse. Insert the two retaining brackets (4) through the traverse (5) from below and pass through the spare wheel rim. 52

55 Winch-type model Keywords Chassis Driving Superstructure Safety 4 Retaining bracket vertical, view from below Make sure that the retaining brackets (4) are vertical as shown. Winch-type model, behind landing leg 1 Spring clip 2 Nut 3 Winch 1 Safety bracket 2 Nut 3 Spring clip Position nuts (2) and screw tight with the safety bracket (1). Insert safety bracket (1) through the two nuts (2) and secure with the spring clip (3). INJURY HAZARD! The heavy spare wheel may fall and injure you. Do not remain under the spare wheel when lifting and lowering the spare wheel with the winch. Removing spare wheel Transport solutions Operation 4 Cross member 5 Spring ring 6 Spacer ring with sleeves Remove spring clip (1). Maintenance 53 Data

56 Spare wheel holder Unscrew the two nuts (2) (spanner size 27). Lower spare wheel to the ground with the winch (3). Pull spare wheel out to the side away from the traffic. Replacing spare wheel 7 Disc holes Slide cross member (4) through the holes in the rim and the sleeves on the spacer ring (6). Make sure that the two spring rings (5) are seated on the cross member threads (4). Wind spare wheel up with the winch (3). Guide the two threads of the cross member (4) through the disc holes (7) while winding. Tighten the two nuts (2). Secure nuts (2) with the spring clip (1). 54

57 Pallet box* Keywords Chassis Driving Superstructure Operation Transport solutions Safety Pallet box The pallet box can be locked and is accessible from both sides. Depending on the size it holds 24, 30, 32 or 36 euro pallets. Opening Fold lock (2) forward and unhook the retainer bracket (3). Open the other side in the same way. Open cover (1) and slide under the pallet box. Place the tab (4) of the cover in the slot (5) in the pallet box. 4 Tab on cover 5 Slot Closing Pull cover (1) out from under the pallet box and close. Attach retaining bracket (3) and press lock (2) back. If necessary, secure with a lock. Loading diagram A loading diagram is attached to the inside of the cover. Maintenance Loading diagram for pallet box 1 Cover 2 Lock 3 Retainer bracket 55 Data

58 Tool box* Tool box* Opening Remove spring clip (3). Press latch (2) up against the resistance with both hands. Open cover (1) look out for falling objects. Tool box 1 Cover 2 Latch 3 Spring clip The toolbox is installed in the rear section, but can be attached at other positions. Max. load Do not place a load of more than 50 kg in the toolbox (evenly distributed load). Drawers in toolbox. Carry the operating manual in the tool box Closing Close cover (1). Press latch (2) down against the resistance until it clicks into place. Always secure latch (2) with the spring clip (3). Opening 56

59 Water tank* Health information Keywords POISON HAZARD! Water tank on chassis 1 Filler funnel 2 Tap Impure or contaminated water may cause poisoning or damage to health. Use only fresh water from the public water supply. Replace the water at frequent intervals to prevent the growth of microbes. Do not use standard cleaning agents to clean the water tank. Safety Chassis FATALITY HAZARD! Chemicals, fuels, cleaning agents and other substances can seriously damage health on contact or if swallowed. Fill the water tank with water only. The water tank can be attached to various points on the chassis. It has a capacity of 30 l. Winter operation The full water tank may be damaged by freezing. Make sure that the water tank is empty or only partly filled in winter. Follow the instructions below if you want to use the water tank to hold drinking water. Do not use water from springs, rivers or any other open water. Use sterilising agents if you have any doubts about the cleanliness of the water. Standard cleaning agents may cause poisoning or damage to health. Use only specially prepared sterilising agents to clean the water tank. Rinse the water thoroughly with clean water before refilling it. Clean the water tank regularly and allow it to dry completely after cleaning. Driving Superstructure Transport solutions Operation Maintenance 57 Data

60 Fire extinguisher * Fire extinguisher * Fire extinguishers on front wall The fire extinguisher is located on the front wall or on the landing leg. Before starting a trip locate the fire extinguisher. A fire extinguisher is required when transporting dangerous goods. 6 kg dry-powder extinguisher Test intervals Have the fire extinguisher checked regularly as required by law. Check that it is still in place every day. Fire extinguisher on the landing leg 58

61 Document compartment* Maintenance Operation Keywords Chassis Driving Transport solutions Superstructure Safety Document compartment on front wall The document compartment holds freight documents. It is attached to the front wall. Document tube on front wall The document tube holds freight documents. It is attached to the front wall or the chassis. 59 Data

62 Hub odometer* (Axle hub odometer) Hub odometer* (Axle hub odometer) Mechanical hub odometer 1 Approved tyre diameter The hub odometer (kilometre counter) counts the distance travelled by the semitrailer in kilometres. The hub odometer must be calibrated for the installed tyre size. The wheel diameter (1) of the approved tyre size is printed on the hub odometer. Tyre size Have the hub odometer replaced if you change the tyre size. Digital kilometre counter Digital kilometre counter 1 Sensible area In the digital kilometre counter, the wheel diameter is set once before mounting and it cannot be changed. Reading the distance travelled in km Bring a metallic object over the sensible area (1). The kilometre reading is displayed. The set wheel diameter is displayed. When the kilometre reading indicator flashes, the kilometre counter battery must be replaced. Operating instructions Detailed operating instructions are available at the manufacturer BPW. 60

63 Forklift rack* Forklift in driving position Requirements Forklifts for attachment to the Schmitz Cargobull forklift rack must meet the following requirements: Weight max. 2,000 kg, Width max. 2,150 mm, Wheel arm distance min. 1,500 mm Fork distance 380 mm Tyre diameter max. 585 mm (23x8.5-12). Combined with a trailing steering axle and a center distance of 1,980 mm, attached forklifts can weigh up to 2,300 kg. The makes listed below or other makes with the same dimensions are suitable: Kooi aap Z 2-1, Z 2-3, W2-1 Moffett Mounty M2003 STM, M1503 Moffett-Kooi M2.20.1, M2.20.3, M3.20.3, M4.20.1, M4.20.3, M Manitou TMT 317 SI The procedure for mounting and removing a forklift can be found in chapter "Operation" in "Attached forklift" on page 174. Forklift rack rear view 1 Forklift supports 2 Pockets for forks 3 Socket 2x 7-pin 4 Bumper Running empty When travelling empty always lift the first axle for weight compensation. Remember that the vehicle has a wider turning circle with the axle lifted. Keywords Safety Chassis Driving Superstructure Transport solutions Operation Attached forklift 1 Overall width max. 2,150 mm 2 Wheel arm distance min. 1,500 mm 3 Fork distance 380 mm Bumper To move the semitrailer without attached forklift, the bumper must be mounted first. Maintenance 61 Data

64 Forklift rack* Bumper Installation (driving position) Press retainer claw (2) and pull sliding section (3) out of the hollow tube (4). Rotate sliding section (3) so the retainer claw (2) points up. Slide sliding section (3) into the centre section (1) of the bumper. Make sure that the retainer claw (2) clicks on to the centre section (1). Forklift supports Removing the bumper 1 Bumper (centre section) 2 Retainer claw 3 Bumper (sliding section) Removal The bumper must be removed to carry an attached forklift. Press retainer claw (2) and pull sliding section (3) out of the centre section (1). Rotate sliding section (3) so the retainer claw (2) points down. 1 Retainer claw 2 Forklift support Lower the attached forklift on the forklift supports. Press retainer claw (1) and pull the forklift support (2) slightly. Pull out second forklift support (2) in the same way. Hollow tube behind the rear axle 2 Retainer claw 3 Bumper (sliding section) 4 Hollow tube Slide sliding section (3) into the hollow tube (4) under the superstructure. Make sure that the retainer claw (2) clicks on to the hollow tube (4). Forklift supports Pull the forklift support (2) out only a little. When the forklift is attached, the forklift supports can be pulled out completely, e.g. with the roof opening tool. 62

65 Tail lift* Separate battery system Keywords Safety Folding tail lift Power supply There are three options for the tail lift power supply: Spare battery system with CEE socket ("CEKON") to tractor, Direct supply from the tractor with 2-pin circular socket ("NATO"), Direct supply from the tractor with 2-pin flat plug ("REALS"). Linguistic usage CEKON NATO REALS Standard designation 4-pin CEE socket in accordance with DIN pin circular socket in accordance with VDA A 2-pin flat plug SRE160, EN Standard designations of the plug connectors CEE socket ("CEKON") Separate battery system with fuse box Two 12 V batteries in the semitrailer power the tail lift. The batteries are charged when the tractor engine is running and the vehicle voltage is greater than 26.5 V. The batteries are not charged: when the engine is not running and the vehicle voltage is less than 25.5 V, when the tail lift is operating. The electronic charging cable is connected to the tractor and semitrailer CEE sockets and must remain connected while driving. Chassis Driving Superstructure Transport solutions Operation Maintenance 63 Data

66 Tail lift* Instructions for servicing the batteries can be found in "Tail lift batteries" on page 202. Direct connection The tractor batteries power the tail lift. FIRE DANGER! If the charging cable is torn off or worn faire may be caused by short circuit. If the charging cable must be connected while driving: Use only charging cables that are designed as Wendelflex lines. 2-pin circular socket Unsuitable charging cables may disconnect or break. Use only Wendelflex lines. Exception: if the charging cable runs over a swing arm a Wendelflex line is not required. Remove the charging line before driving as follows: you do not have a Wendelflex line and your tractor does not have a swing arm. 2-pin flat plug ("REALS") with main switch Plug charging cable into the socket. The tail lift is supplied with power. Current Maximum approved current: 2-pin circular socket: 160 A 2-pin flat plug: 160 A 2-pin circular socket ("NATO") with main switch 64

67 Operation Operating manual Read and follow the manufacturer's operating manual before working with the tail lift. Keywords Safety Tail lift in operating position Switch on tail lift at the manual control with the keyswitch. The tail lift is ready for operation. Move the tail lift with the manual control, the foot control or the remote control. Chassis Manual control with keyswitch (example DHOLLANDIA) Driving Maintenance Operation Transport solutions Superstructure 65 Data

68 66

69 Driving EBS 68 Stability program 70 First drive 71 Brake adjustment 72 Coupling and uncoupling 73 Clearance zones 76 Air suspension 79 Ferry transport 80 Chassis Safety Keywords Maintenance Operation Transport solutions Superstructure Driving 67 Data

70 EBS EBS The Electronic Brake System for trailers, trailer EBS, is standard equipment on all Schmitz Cargobull semitrailers manufactured since EBS is an electronically controlled brake system, which is fitted with automatic antiskid systems (ABV/ABS) and automatic load sensing braking pressure regulation (ALB). Older vehicles or customised vehicles may still have an ABS system: You can recognise an EBS system by the 7-pin socket. You can recognise an ABS system by the 5-pin socket. Approved connectors To ensure that the EBS operates, semitrailers with trailer EBS may only be towed by tractors that are fitted with one of the following connectors: Extended ISO connector (ABS + CAN), 7-pin, 24 V, on tractors with CAN data line (tractors with EBS) ISO connector, 5-pin, 24 V, on tractors without CAN data line (tractors without EBS, with ABS connector) ACCIDENT HAZARD! 7-pin socket (EBS system) Without an ABS/EBS connector the semitrailer will overbrake, which may cause it to skid and can result in accidents. Always connect the ABS/EBS connector between the tractor and semitrailer. Use only approved connectors included in the vehicle registration. Only tow semitrailers with trailer EBS with tractors that have a connector compliant with ISO In case of a short drive without EBS connector or cable break, a safety function is activated. In this case, the EBS is powered by the brake light voltage, ensuring the ALB function (automatic load sensing braking pressure regulation) and the ABV function (Antiskid Braking System). 68

71 Advantages of trailer EBS Trailer EBS offers a number of advantages over conventional brake systems: The braking forces between tractor and semitrailer can be optimally matched, resulting in even wear of the brake pads. Even application of all wheel brakes in the entire semi-trailer truck, which improves the driving stability of the complete semi-trailer truck during braking. The electrical actuation of valves and the electronic pressure regulation reduce the response times, resulting in shorter braking paths. Automatic axle lift control and starting aid function* can be shown. For information on the function and operation of the axle lift and starting aid see "Axle lift system*" from page 35. ACCIDENT HAZARD! Trailer EBS is not a system that can cancel the laws of physics. Trailer EBS optimises braking operations within the physical limits and in emergency situations may help to prevent accidents. Do not allow the extra safety of trailer EBS tempt you to drive faster and take more risks. Warning displays The tractor has warning lights that display the status of the trailer EBS and any faults. The red light must not be on continuously while driving. Any faults in the EBS must be repaired at a qualified workshop as soon as possible. Axle load indicator The trailer EBS allows to calculate the semitrailer axle load based on the air spring bellows pressure. When it supports the tractor, axle load can be displayed in the driver's cab. The display precision is around +/- 3 %. The calculated value is transmitted through pins 6 and 7 of the 7-pin EBS socket (24-V-CAN; CAN messages in accordance with ISO ). Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 69 Data

72 Stability program Stability program The (driving dynamics) stability program is an enhanced function of the trailer EBS and is standard equipment in all Schmitz Cargobull semitrailers. The stability program uses specific braking operations to bring the semitrailer to a stable position in critical driving situations such as swerving to avoid accidents or excessive speed in curves. In many cases it can prevent the vehicle from tipping over. But this also applies: the stability program cannot cancel the laws of physics; it simply exploits all the options offered by those laws. The stability program can prevent the semitrailer from tipping over in many emergency situations if the stabilisation process remains within the physical limits. If you exceed these limits, such as with excessive speeds around tight curves, even the stability program will not be able to prevent the trailer from tipping over. ACCIDENT HAZARD! The stability program is not a system that can cancel the laws of physics. The stability program optimises driving characteristics within the physical limits and in emergencies may help to prevent accidents. Do not allow the extra safety of the stability program tempt you to drive faster and take more risks. Stability program The stability program of the trailer EBS operates completely independently of the make, model and equipment of the tractor. 70

73 First drive ACCIDENT HAZARD! Loose wheel nuts will cause wheels to shear off, which can cause accidents with personal injury. Tighten the wheel nuts on all wheels to the specified torque during the first trip with a load, and in any case no later than after 50 km of driving. Tighten the wheel nut to the specified torque after every wheel change and after no more than 50 km of driving. The specified torques for installing and tightening the wheel nuts can be found on page 209. Follow the directions of the axle manufacturer. Keywords Safety Superstructure Chassis Driving "Wheel nut seating" warning sign Transport solutions Operation Maintenance Because of settling processes the wheel nuts will loosen during the first few kilometres of driving the new semitrailer. For this reason the wheel nuts must be tightened to the specified torque after 50 km of driving. The wheel nuts of the changed wheel must also be tightened to the specified torque after every wheel change. 71 Data

74 Brake adjustment Brake adjustment Unlike the drum brake the disc brake shows no perceptible loss of braking power when overloaded. The overload is noticeable more by overheated brake discs, which can result in damage to wheel bearings and brakes and also increased brake pad wear. To distribute the braking force evenly over all brakes in the combination, all wheel brakes should be adjusted to operate evenly after the first 2,000 to 5,000 km as per RREG 71/320. The brake systems of Schmitz Cargobull vehicles are designed so the towing vehicle does not require a pressure advance. Warranty claims resulting from premature wear can only be considered when the results of the brake adjustment are submitted. 72

75 Coupling and uncoupling When coupling and uncoupling no person is permitted to be in the danger zone between the tractor and the semitrailer. FATALITY HAZARD! Persons in the danger zone between the tractor and the semitrailer may be crushed or run over. Direct all persons away from the danger zone when coupling or uncoupling. No person is permitted to remain at the fifth-wheel lock of the tractor while coupling or uncoupling. Persons directing the tractor driver must stand well away from the vehicles. Note the sequence: Vent the air suspension before parking on the landing leg. When coupling release the load on the landing legs first, then vent the air suspension. Before coupling Check the following before coupling: Is the wear on the king-pin still within approved limits? Is the king-pin tight? Are all fastening bolts present? Is the semitrailer correctly loaded? Is the load secured? Do the coupling heights of the tractor and semitrailer match? Is rotation radius sufficient? See "Rotation radius" on page 77. Is the parking brake on the semitrailer set? Never couple the semitrailer unless all the above items have been checked. Coupling Keywords Safety Chassis Driving Superstructure Transport solutions Operation "Landing legs" warning sign Height difference when coupling A Height difference approx. 5 cm 1 Fifth-wheel plate 2 Semitrailer skid plate Maintenance 73 Data

76 Coupling and uncoupling When coupling and uncoupling no person is permitted to be in the danger zone between the tractor and the semitrailer. Back tractor as straight as possible to the semitrailer. Open fifth wheel. Set height difference so the skid plate (2) is approx. 5 cm lower than the contact surface of the fifth wheel (1). Set the height difference either with the air suspension of the tractor or the landing leg of the semitrailer (see page 42). Reverse the tractor slowly until the fifth wheel locks. Set the parking brake on the tractor. After coupling Tractor parking brake Make sure that the parking brake of the tractor is activated! Check that the fifth wheel is correctly locked and secure it. Follow the manufacturer's operating manual. The skid plate must not have a visible air gap between it and the fifth wheel. Release spring-actuated pressure accumulator parking brake of the semitrailer. Bring air suspension to driving position. Check that the supply lines move freely by slowly driving around a tight curve. Carry out departure check. Uncoupling ACCIDENT HAZARD! The semitrailer will tip if it is loaded so it is head or tail heavy and may cause personal injury. Only uncouple the semitrailer if it is loaded so that it cannot tip forwards or backwards. See also the information on "Stability" on page 164. Coupling If the skid plate is not correctly positioned or if the fifth wheel cannot be locked, repeat the coupling process. Connect compressed air and electrical supply lines. For information on connection the supply lines see chapter "Brake system" from page 24. Connect EBS connector cable. Raise landing leg and lock crank. Collect and stow wheel chocks. Warning sticker "Stability with uncoupled semitrailer" 74

77 Avoid tension Before uncoupling vent the air spring bellows of the semitrailer and then move the semi-trailer truck forward or back slightly. This prevents any tension from damaging the chassis and the landing legs when the uncoupled semitrailer sinks on to the air suspension after loss of pressure. Keywords Safety Select a suitable parking area (level hard ground). Actuate the parking brake of the tractor and the semitrailer. Place wheel chocks under semitrailer (not at lifting or steering axles). Place suitable steel plates under landing legs if required by the quality of the ground. Raise the semitrailer with the air suspension of the tractor and then extend the landing legs or Raise semitrailer with the landing legs at low speed (tractor without air suspension). Disconnect compressed air and electrical supply lines and EBS connector (first red coupling head supply, yellow brake coupling head). Unlock and open fifth wheel. Slowly drive tractor forward. Chassis Driving Superstructure Transport solutions Maintenance Operation 75 Data

78 Clearance zones Clearance zones Supply lines Check the layout of the supply lines. They must not hang down too much and wear and they must not be too tight for driving around curves. Wendelflex lines Wendelflex lines that are tangled may come off in very tight curves. Separate them before connecting them. Swivel radius (turning circle) The swivel radius is the distance from the king-pin to the front trailer corner. If the distance from the centre of the fifth wheel to the rear of the driver's cab or any attached equipment is less than the swivel radius, the semitrailer must not be coupled. The tractor and the semitrailer would contact each other at the latest when driving around a curve. Semitrailers have a front swivel radius of 2040 mm. Collision hazard! When loaded the swivel radius is larger than with standard semitrailers and the trailer may collide with the tractor if space is restricted. Make sure that there is sufficient space available when you hitch a semitrailer with m interior length. Swivel radius A Standard semitrailer (or flexible corner unloaded) B m* semitrailer (flexible corner loaded) Semitrailers with flexible corners* (13.73 m overall length loaded) have a swivel radius of 2150 mm loaded (see diagram). Information on the flexible corner can be found in "Flexible corners (13.73 m)*" on page 140. The swivel radius is reduced if the semitrailer is tilted forward (see page 78, position B). 76

79 Rotation radius Property damage During coupling or when driving around a curve, the rear part of the tractor can be caught on the semitrailer. Tractor and semitrailer may be seriously damaged. Never couple semitrailers with reduced rotation radius to three-axle tractors. Some models (Mega model) or equipments (32 pallet box) reduce the rotation radius (r 3 ) up to 1,850 mm. Keywords Safety Chassis Warning sticker "reduced rotation radius" r 3 Rotation radius The rotation radius (r 3 ) is the distance from the king-pin to the crank of the longitudinal beam (or mounted parts set forwards). In accordance with ISO 1726 the rotation radius (r 3 ) is 2,300 mm. Semitrailers with reduced rotation radius (r 3 ) are marked on the front wall with the warning sticker "Reduced rotation radius" (see "Warning sticker overview" from page 212). Operation Driving Superstructure Transport solutions Rotation radius reduced by the landing leg Maintenance 77 Data

80 Clearance zones Turning angle Supply lines If the maximum turning angle is exceeded, the supply lines will be torn off. Always be aware of the approved turning angle when driving around curves and manoeuvring. A Tilt angle to rear B Tilt angle to front Turning angle maximum 90 Tilt angle Property damage If you exceed the maximum approved tilt angle, you risk damaging the semitrailer and the tractor. Be aware of the approved tilt angle when driving over obstacles. The values are reduced for the semitrailer when turning. The tilt angle should be at least 6 to the front (B) and 7 to the rear (A) (in accordance with the ISO 1726 standard for two-axle vehicles). The actually possible tilt angles depend on the tractor and is influenced by the wheel base, coupling height and mudguard layout. Three-axle tractors frequently do not confirm to DIN ISO When using three-axle tractors note particularly the rear radius and the free space to the landing leg! 78

81 Air suspension Driving instructions A stop on the axle allows a semitrailer with defective air suspension (no air in the spring bellows) to be driven at low velocity (max. 25 km/h) to the nearest workshop. Tyre damage Tyres may be damaged if they contact the semitrailer frame while driving. When driving with faulty air suspension make sure that the tyres do not contact the semitrailer frame. Driving with the semitrailer raised or lowered may cause accidents because of poor driving properties and may result in damage to the semitrailer and its load. Pay particular attention to the position of the Up and Down valve: after driving on to a ferry, after railway transport in intermodal transport, after height adjustments, such as at a ramp, after breaks in driving. Always set the Up and Down valve to "DRIVE" position before starting a trip. Axle lift ACCIDENT HAZARD! If the air suspension is not set to "DRIVE" position before starting a trip, poor driving properties or a high level setting may cause to vehicle to be caught at an underpass and cause an accident. Always set the Up and Down valve to "DRIVE" position before starting atrip. Auto-reset On vehicles with an auto-reset function (see page 34) the driving position is automatically reset when the speed exceeds 16 km/h. Travel through curves When the lift axle is lifted the wheel base between the tractor and semitrailer increases. This means that the semitrailer moves further in when travelling through curves! Keywords Safety Chassis Driving Superstructure Transport solutions Maintenance Operation 79 Data

82 Ferry transport Ferry transport ACCIDENT HAZARD! The semitrailer may tear loose if improperly lashed and cause accidents with personal injury. Vent the spring bellows of the air suspension completely when you park the semitrailer on the ferry. Do not lash the semitrailer until the air suspension has completely lowered. If the spring bellows have air in them the semitrailer must not be lashed to the deck of the ferry. The lashing may become loose as the semitrailer air suspension settles (e.g. loss of air in the spring bellows). Lower the semitrailer completely before lashing it down. Leaving the ferry Return the air suspension to driving position before driving off the ferry. Follow the directions in the chapter on "Chassis" below "Up/down valve" on page 32, "Auto-reset function" on page 34. Accompanied ferry transport During accompanied ferry transport the semitrailer is loaded on the ferry without a tractor and supported on a support block. Unaccompanied ferry transport During unaccompanied ferry transport the semitrailer is loaded on the ferry without a tractor and supported on a support block. Arrangement of the ferry lashing rings Avoid tension Do not actuate the spring-actuated pressure accumulator parking brake of the semitrailer until the semitrailer has been fully lowered by the air suspension. This will prevent tension in the body and landing leg. Semitrailers used for ferry transport have four pairs of ferry lashing rings (fastening rings) for lashing the semitrailer to the ferry. The ferry lashing rings are painted bright yellow. The first two pairs are rigid, the other two pairs are movable. First and second pair of ferry lashing rings on the front of the longitudinal member 80

83 Safety Keywords Third and fourth pair of ferry lashing rings on the rear of the longitudinal member Ferry lashing rings on the lamp bracket The fourth pair of ferry lashing rings can be mounted on the longitudinal member or on the lamp bracket, according to the mounted parts. Maintenance Chassis Driving Operation Transport solutions Superstructure 81 Data

84 82

85 Superstructure Overview 84 Tarpaulin tightener 85 Sliding tarpaulin (S.CS) 89 Sliding tarpaulin (S.CS BS) 95 Conventional tarpaulin (S.PR) 97 Rear wall 99 Side boards 105 Ladder 109 Rigging boards 111 Sideposts 113 Corner sideposts turning to the outside* 117 S.PR "removable sideposts*" 119 Sliding roof (S.CS) 120 Sliding roof (S.PR) 123 Hamburg top 126 Lifting roof 128 Height-adjustable superstructure 134 Flexos 137 Flexible corners (13.73 m)* 140 Additional sideposts* 141 Load securing gear 142 Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 83 Data

86 Overview Overview Overview of superstructure controls Item Name Page 1 Tarpaulin tightener 85 2 Sliding tarpaulin (S.CS, S.CS BS) 89 Conventional tarpaulin (S.PR) 97 3 Side boards (S.PR, S.CS BS) Lifting roof / height-adjustable superstructure Drive gear for sliding tarpaulin 89 Sliding tarpaulin tension ratchet 89 6 Ladder Rear door 99 8 Tailboard Flexible corners Sliding tarpaulin quick-tension lock 93 Front tension ratchet* Rigging boards* Sideposts Supplementary sideposts Hamburg top Sliding roof (S.CS) 120 Sliding roof (S.PR) Corner sideposts turning to the outside* Load securing gear

87 Tarpaulin tightener General According to requirements, three different tarpaulin tighteners are installed in Schmitz Cargobull curtainsider semitrailers: Standard tarpaulin tightener, Direct clamp DB tarpaulin tightener (see "DB tarpaulin tightener" on page 159). The hooks of the tarpaulin tightener are attached to the outside frame or on the tarpaulin hook section*. Standard tarpaulin tightener Keywords Safety Chassis Tarpaulin hook section* The tarpaulin hook section* allows tiedown straps to be inserted in the perforated rail of the outside frame even when the tarpaulin is closed (see page 143). The hooks are available as flat hooks or claw hooks. INJURY HAZARD! The load can fall off the semitrailer and injure you or other persons. Before opening the tarpaulin tightener, make sure that no load can fall off the semitrailer. Bulges in the tarpaulin indicate that the load has moved. If this is the case, do not slacken the tarpaulin tightener. Carefully open the semitrailer from behind to get an overview of the situation. Tarpaulin tightener 1 Tension strap 2 Lock 3 Hook Opening the tarpaulin tighteners Pull the tension strap (1). The lock (2) springs open. Driving Superstructure Transport solutions Operation Maintenance 85 Data

88 Tarpaulin tightener Hooking to tarpaulin hook section* (flat hook) 5 Tarpaulin hook section Tarpaulin tightener, opened 4 Outside frame 5 Tarpaulin hook section Pull the tension strap (1) down and release the hook (3) from the outside frame (4) or tarpaulin hook section* (5). Tightening and closing the tarpaulin tightener Tightening tension strap Hooking to outside frame (claw hook) 4 Outside frame Pull tarpaulin as far as possible under the outside frame or the tarpaulin hook section* (5). 86

89 Damaged tarpaulin! The tarpaulin may be damaged if with too much tension. Tension the tarpaulin as described below. Attach the tarpaulin tightener to the outside frame (4) or attach it to the tarpaulin hook section* (5). Set the tarpaulin tightener to horizontal position (90 to tarpaulin). Tighten tension strap by hand and pull turnbuckle down another 90. Keywords Safety Chassis Attaching belt loops Insert the long tension straps through the tarpaulin tightener (before it clicks into place) and form a loop. Driving Transport solutions Superstructure Securing tarpaulin tightener Press down the tarpaulin tightener until it can be heard and seen to click into place. Operation Maintenance 87 Data

90 Tarpaulin tightener Direct clamps Adjustment of length/tension The tarpaulin is tensioned with the threaded rod (3). Rotate lock (1) clockwise or anticlockwise: This increases or decreases the tension of the tarpaulin. Direct clamps 1 Lock 2 Hook Unhooking direct clamp Pull on lock (1) and swing down. Hooking to the tarpaulin hook section* 4 Tarpaulin hook section* Closing direct clamp Attach direct clamp hook (2) to tarpaulin hook section* (4). Press lock (1) in until you hear it click into place. Direct clamp unhooked 3 Threaded rod 88

91 Sliding tarpaulin (S.CS) The sliding tarpaulin is closed and locked horizontally by the rear tarpaulin locking gearbox or the tension ratchet and vertically by the tarpaulin tightener. Superstructure strength! The superstructure only acquires the necessary rigidity when the sliding tarpaulin is tightly closed. Do not drive with sliding tarpaulin open. Releasing tarpaulin with tarpaulin locking gearbox Keywords Safety Chassis Opening sliding tarpaulin INJURY HAZARD! If the load slides it can fall off the semitrailer and injure you or other persons. Before opening the tarpaulin tightener, make sure that no load can fall off the semitrailer. Bulges in the tarpaulin indicate that the load has moved. If this is the case, do not slacken the tarpaulin tightener. Carefully open the semitrailer from behind to get an overview of the situation. Releasing tarpaulin 1 Rear tarpaulin tension rod 2 Crank 3 Tarpaulin locking gearbox Turn crank (2) anticlockwise until the tarpaulin is completely released (unwound from the tarpaulin tension rod (1). The tarpaulin is released and can be unhooked at the rear and/or front. Releasing the tarpaulin with the tension ratchet Driving Superstructure Transport solutions Open and remove the tarpaulin tighteners. Operation Releasing tarpaulin 1 Rear tarpaulin tension rod 2 Tension ratchet lever 3 Sleeve Maintenance Pull sleeve (3) and turn anticlockwise. The lever (2) is unlocked. 89 Data

92 Sliding tarpaulin (S.CS) Press the lever (2) over the stop (in the direction of the arrow). The tarpaulin tension rod (1) is unlocked. Unwind tarpaulin by pulling it from the tarpaulin tension rod. Removing rear tarpaulin Threading tarpaulin tension rod out at top 5 Retainer rail (under the rubber sealing strip) Thread tarpaulin tension rod (1) at top out of the retainer profile (5). The tarpaulin can be pulled up from behind. Unhooking at front Lifting bottom tarpaulin tension rod 4 Loop Hold tarpaulin at the loop (4) and lift up. Tension ratchet The tension ratchet can be damaged when opening the side board (type S.CS BS). Pull out the lever of the tension ratchet before opening the side board. Pulling out tarpaulin tension rod at front 1 Loop 2 Front tarpaulin tension rod Hold tarpaulin at the loop (1) and lift up. Thread tarpaulin tension rod (2) at top out of the retainer profile. 90

93 The tarpaulin can be pulled open from the front. Opening tarpaulin Slide tarpaulin tension rod (1) under the rubber sealing strip and position on retainer bar. Place tarpaulin tension rod (1) on the square pin (2) while turning tarpaulin tension rod (1) until it slides completely over the square pin (2). Attaching rear tarpaulin Keywords Safety Driving Superstructure Transport solutions Operation Chassis Tarpaulin pulled to the front Open tarpaulin on the tarpaulin tighteners. The tarpaulin can be pulled completely forward and back. Closing sliding tarpaulin Care Keep the tarpaulin tension rod and square pin clean at all times. Attaching front tarpaulin Attaching rear tarpaulin 1 Rear tarpaulin tension rod 2 Square pin Slide tarpaulin tension rod (1) under the rubber sealing strip and position on retainer bar. Place tarpaulin tension rod (1) on the square pin (2) of the drive gear or the tension ratchet; while turning tarpaulin tension rod (1) until it slides completely over the square pin (2). Maintenance Attaching front tarpaulin 1 Front tarpaulin tension rod 2 Square pin 91 Data

94 Sliding tarpaulin (S.CS) Correct tarpaulin tension Marks are on the front and back of the tarpaulin. Tensioning tarpaulin with tarpaulin locking gearbox Tarpaulin tension too loose 1 green area 2 red area Note the marks (1) and (2) on the tarpaulin. The tarpaulin is too loose if the green area (1) is visible. The tarpaulin is too tight if the red area (2) is no longer visible. Tensioning tarpaulin 1 Rear tarpaulin tension rod 2 Crank 3 Tarpaulin locking gearbox Turn crank (2) clockwise to tension the tarpaulin. Note: "Correct tarpaulin tension" on page 92. Attach, tension and secure tarpaulin tighteners. Tensioning tarpaulin with the tension ratchet Tarpaulin tension OK 1 green area 2 red area The tarpaulin is correctly tightened if the green area (1) disappears and the red area (2) only is visible. 92 Tensioning tarpaulin 1 Rear tarpaulin tension rod 2 Tension ratchet lever 3 Sleeve Turn the sleeve (3) clockwise until it clicks into place.

95 Tension tarpaulin by moving the lever (2) back and forth. Note: "Correct tarpaulin tension" on page 92. Store lever (2) completely so it does not extend beyond the side of the superstructure. Front release unit* Slowly release tension bracket (1). Hold tarpaulin at the loop (1) and lift up. Thread tarpaulin tension rod (2) at top out of the retainer profile. The tarpaulin can be pulled open from the front. Chassis Keywords Safety Quick-tension lock on front wall You can use the front release unit* to open and close the tarpaulin from the front wall. The tarpaulin tighteners must be unhooked before releasing the tarpaulin. Releasing tarpaulin Releasing quick-tension lock 1 Tension bracket 2 Lock Press tension bracket (1) toward front wall and turn locking ring (2). Releasing tarpaulin 3 Tarpaulin tension rod 4 Square pin Fold in tension bracket (1) and secure for safety. Tensioning tarpaulin Fold out tension bracket (1) completely as shown. Thread tarpaulin tension rod (3) at top into the retaining profile. Place tarpaulin tension rod (3) on the square pin (4) while turning tarpaulin tension rod until it slides completely over the square pin. Swivel tension bracket (1) completely to the front wall. Put the lock (2) through the tension bracket while doing this. Turn lock (2) and release tension bracket (1). Driving Superstructure Transport solutions Operation Maintenance 93 Data

96 Sliding tarpaulin (S.CS) Tarpaulin tension If the tarpaulin is not sufficiently tensioned: wind the tarpaulin about half a turn around the tarpaulin tension rod before placing the tarpaulin tension rod on the square pin. Note: "Correct tarpaulin tension" on page 92. Front tension ratchet* Front tension ratchet* On request, an additional front tension ratchet* can be installed. Operation of the tension ratchet: "Releasing the tarpaulin with the tension ratchet" on page 89 "Tensioning tarpaulin with the tension ratchet" on page 92 "Correct tarpaulin tension" on page 92 94

97 Sliding tarpaulin (S.CS BS) Opening and closing the side boards: "Opening side board" on page 107 "Closing side board" on page 108 Opening sliding tarpaulin Keywords Safety Driving Chassis S.CS BS with short tarpaulin and rubber straps S.CS BS (Bordwand und Schiebeplane, side board and sliding tarpaulin) is available in two models: with short tarpaulin and rubber straps, with long tarpaulin and tarpaulin tighteners. For both models, the sliding tarpaulin is tensioned and released by a tarpaulin locking gearbox or a tension ratched. Model with short tarpaulin INJURY HAZARD! If the load slides it can fall off the semitrailer and injure you or other persons. Before detaching the rubber straps make sure that no load can fall off the semitrailer. Bulges in the tarpaulin indicate that the load has moved. If there are do not detach the rubber straps. Carefully open the semitrailer from behind to get an overview of the situation. Rubber strap unhitched 1 Rubber strap 2 Snap-hook 3 Combination bow hooks Unhook snap-hooks (2) and remove rubber straps (1) from the hooks (3). Release tarpaulin and pull up. ("Releasing tarpaulin" on page 89) Closing sliding tarpaulin Secured tarpaulin Superstructure Transport solutions Operation Maintenance 95 Data

98 Sliding tarpaulin (S.CS BS) Pull tarpaulin closed and tighten. ("Closing sliding tarpaulin" on page 91) Hook rubber straps (1) to the hooks (3) and lock snap-hooks (2). Tarpaulin rope If necessary, you can also pull a tarpaulin rope through the combination bow hooks. Model with long tarpaulin Flat hook attached to the tarpaulin hook section Attach the flat hook of the tarpaulin tighteners in the tarpaulin hook sections to the bottom of the side boards. Opening and closing the side boards: "Opening side board" on page 107 "Closing side board" on page 108 S.CS BS with long tarpaulin and tarpaulin tighteners Tarpaulin hook section on the bottom of side boards Opening and closing the tarpaulin: "Opening sliding tarpaulin" on page 89 "Closing sliding tarpaulin" on page 91 96

99 Conventional tarpaulin (S.PR) General The conventional tarpaulin is attached to the hooks with the eyelets on the side board and then secured with the tarpaulin rope. Opening tarpaulin Keywords Safety INJURY HAZARD! If the load slides it can fall off the semitrailer and injure you or other persons. Before undoing the tarpaulin rope make sure that no load can fall off the semitrailer. Bulges in the tarpaulin indicate that the load has moved. If you see any bulges, do not remove the tarpaulin rope. Carefully open the semitrailer from behind to get an overview of the situation. INJURY HAZARD! You may slip and fall if you climb up parts not designed for the purpose. Do not climb up on wheels, bumpers or other attached parts. Always use a ladder with antislip feet. Tarpaulin with tarpaulin rope 1 Tarpaulin rope 2 Locking belts 3 Eyelets 4 Hooks (bow hooks) 5 Cover Unhook tarpaulin rope (1) under the cover (5) and pull out of hooks (4). To open the side, pull tarpaulin rope (1) out over the complete superstructure length and attach to the front wall with a loop. Pull locking belt (2) up and out of the hooks (4). To open from the rear pull locking belts (2) out on both sides. Chassis Driving Superstructure Transport solutions Operation Maintenance 97 Data

100 Conventional tarpaulin (S.PR) Throwing tarpaulin over the top Throw tarpaulin over the top with a suitable object, such as a rigging board. Opening tarpaulin to the side Pull rigging board (1) out of the strap (2) before throwing the tarpaulin up. Strap The strap (2) in the front wall prevents the wind from blowing and flapping the tarpaulin. Closing tarpaulin Pull tarpaulin down from top, leaving it offset to the side. Caution in freezing or snowy weather. Insert front rigging board through the strap (2) in the tarpaulin. Thread locking belt through. Press tarpaulin on the hooks into the eyelets and thread tarpaulin rope through the hooks. Secure tarpaulin rope and close cover. Strap 1 Rigging board (2nd from below) 2 Strap 98

101 Rear wall Schmitz Cargobull curtainsider semitrailers can be fitted with various rear walls: High rear door for S.CS and S.PR, Small rear door for S.PR Tailboard for S.PR. For instructions for the tailboard, see chapter "Side boards" on page 105. High rear door Keywords Safety Superstructure stability Driving with the tailboard open may cause damage. Do not drive with rear doors or tailgate open or unlocked. The rear doors open 270. The holdback stays are used to hold the door halves open (see also "Holdback stay" on page 103). The revolving rod locks can be locked. Locks Doors and side boards with damaged locks will not remain closed reliably. Do not operate the locks on doors and side boards with tools. Have damaged locks and fittings repaired. High rear door Each door wing is opened and closed with two revolving rod locks. For each revolving rod lock, one locking cam at the top and one locking cam at the bottom keep the door closed. Chassis Driving Superstructure Transport solutions Maintenance Operation 99 Data

102 Rear wall Opening door wing INJURY HAZARD! The rear door can open suddenly by pressure from the load, parts of the load can fall out of the superstructure and cause injury. When opening the doors keep clear of the swing area of the door wings. Open the door wing cautiously by unlocking only one revolving rod lock at a time. If the load is pressing against the door, leave the second revolving rod lock secured and closed. Remove the pressure from the load before opening the rear wall. Opening revolving rod locks simultaneously Open both revolving rod locks completely at the same time and swing the door open. Secure the right door wing with the holdback stay. ("Holdback stay" on page 103) If necessary open the left door wing and secure with the holdback stay. Opening revolving rod lock 1 Revolving rod lock 2 Handle 3 Locking cam Always open the right-hand door wing first: Release left revolving rod lock (1). To do this press the handle (2) down with your thumb. Open revolving rod lock (1) slightly. If you cannot feel any pressure from the load, release the right revolving rod lock. Door wing open slightly and secured 1 Handle 2 Locking lever with locking cam Holding door wing open The door wing can be secured with the revolving door lock to open or close the sliding roof or to raise or lower the lifting roof. 100

103 Attach locking lever to the handle (1) with the locking cam (2). Closing door wing Top locking cam If the top locking cams do not catch, the superstructure may be damaged by movement while driving. Make sure that the two top locking cams (1) are also inserted in the locks. If they are not, open the door wing again and close it again. Maintenance Driving Keywords Safety Chassis Locking cam 1 Locking cam (one for each revolving rod lock) 2 Support 3 Locking cam Superstructure Transport solutions Operation Always close the left-hand door wing first: Remove any objects from the door frame to prevent them from being jammed. Close door wing and insert the two locking cams (3) into the support (2) at the same time. Revolving rod lock secured 1 Locking lever 2 Handle Press locking lever (1) closed until the handles (2) click into place. Close the right-hand door wing in the same way. 101 Data

104 Rear wall Small rear door Small rear door 1 Revolving rod lock 2 Locking pin Locks Doors and side boards with damaged locks will not remain closed reliably. Do not operate the locks on doors and side boards with tools. Have damaged locks and fittings repaired. Opening revolving rod lock 3 Lever retainer 4 Locking lever Opening door wing Open tarpaulin. Turn lever retainer (3) up. Open locking lever (4). Swing the two door wings open and secure with the holdback stay. ("Holdback stay" on page 103) INJURY HAZARD! The rear door can open suddenly by pressure from the load, parts of the load can fall out of the superstructure and cause injury. When opening the doors keep clear of the swing area of the door wings. Open the door wings cautiously. Close the revolving rod lock again if you see the load pressing on the door. Remove the pressure from the load before opening the rear wall. 1 Support 2 Locking pin 102

105 Top locking pin If the top locking pin is not caught, the superstructure may be damaged by movement while driving. Make sure that the top locking pin (2) also engages in its lock. If they are not, open the door wing again and close it again. Holdback stay Keywords Safety Closing door wing Always close the left-hand door wing first: Remove any objects from the door frame to prevent them from being jammed. Close left door wing. Close right door wing and insert the locking pins (2) into the support (1). Revolving rod lock secured 3 Lever retainer 4 Locking lever Attach locking lever (4) and close lever retainer (3). Open door wing, secured 1 Holdback stay Insulating curtains Insulating curtains on ramps may contact the holdback stays. After leaving the ramp check the holdback stays! ACCIDENT HAZARD! Open door wings can cause injury if they swing unexpectedly, such as when blown by the wind. Always secure the door wings with the holdback stays after opening, even if you do not move the semitrailer. When the doors are open and secured, do not drive at a speed above walking pace. Chassis Driving Superstructure Transport solutions Operation Maintenance 103 Data

106 Rear wall Securing door CRUSHING HAZARD! The spring-loaded holdback stay can crush fingers and hands. Wear work gloves. Grip the holdback stay as far down as possible, slightly above the bend, when securing the wing doors. The holdback stay will hold the open rear doors open when the vehicle is stopped. Pull holdback stay under the superstructure out and swing it up. Grip holdback stay as far down as possible, slightly above the bend, to avoid crushing your fingers. The door wing is secured. Holdback stay in home position 1 Holdback stay Move the holdback stay (1) to the horizontal home position when it is not needed. 104

107 Side boards General The side board locks of the tailboard and side boards are fitted with a load pressure indicator. Load pressure indicator The "behaviour" of the side board lock indicates whether the load is pressing on the side board: When opening the lock first unlock the side board by releasing the closing lever. The closing lever can be moved easily. If the closing lever can only be moved with great force in the second step, the load is pressing against the side board. In this case do not open the side board any further. Close the side board lock again immediately and remove the pressure from the load. Tailboard Locks Doors and side boards with damaged locks will not remain closed reliably. Do not operate the locks on doors and side boards with tools. Have damaged locks and fittings repaired. Opening the tailboard INJURY HAZARD! The tailboard can open suddenly by pressure from the load, parts of the load can fall out of the superstructure and injure you and other persons. When opening the doors keep clear of their swing area by standing to the side. Close the side board lock again immediately if you see pressure from the load. Remove the pressure from the load before opening the tailboard. Keywords Safety Chassis Driving Superstructure Transport solutions Tailboard Operation Maintenance 105 Data

108 Side boards Side board lock, closed 1 Hand lever 2 Lock Press lock (2) and open lever (1). Open tailboard slightly and close side board lock again immediately. Open the other side in the same way. Open tailboard. INJURY HAZARD! Persons can be caught and injured on open side board locks. When the side board is open close the side board locks again immediately. Side board lock, open 3 T-piece 4 Sidepost Closing tailboard Close tailboard after first opening the two side board locks. Make sure that the T-piece (3) clicks completely into the sidepost (4). Press lever (1) completely closed until the lock (2) clicks. Close the other side in the same way. Side board lock pre-load The pre-load of the side board lock can be set by turning the T-piece (3). Removing/attaching the tailboard Open tailboard. Remove split pin from the hinge pin. Pull tailboard to the left off the hinge pins with two persons. Replace in reverse order. Secure tailboard with the split pin. 106

109 Side boards Side board open, side board lock closed Locks Doors and side boards with damaged locks will not remain closed reliably. Do not operate the locks on doors and side boards with tools. Have damaged locks and fittings repaired. Superstructure stability The stability of the superstructure will suffer when driving with side boards open or released. Opening side board INJURY HAZARD! The side boards can open suddenly by pressure from the load, parts of the load can fall out of the superstructure and injure you and other persons. When opening the side boards keep clear of their swing area by standing to the side. Close the side board lock again immediately if you see pressure from the load. Remove the pressure from the load before opening the side boards. Side board lock, closed 1 Hand lever 2 Lock Keywords Safety Chassis Driving Superstructure Transport solutions Press lock (2) up and open lever (1). Maintenance Operation 107 Data

110 Side boards Removing/attaching the side board The side boards are secured to prevent accidental opening by positive locks on the hinges. To remove: Open side board. Pull side board to the left off the hinge pins with two persons. Replace in reverse order. Close lock again immediately 1 Locking wedge 2 Sidepost Open side board slightly and close lock again immediately. Side board lock Close the side board locks again immediately so no one will hit them or catch on them with the side board open. Open the other side in the same way and swing the side board out. Closing side board Closing range Keep the closing area of the side boards clean to ensure that they can close properly. Open the two side board locks and close the side board. Make sure that the locking wedge (1) clicks completely into the sidepost (2). Press lever down completely until the lock clicks into place. Close the other side in the same way. 108

111 Ladder General Schmitz Cargobull vehicles are fitted with ladders for safe access: Extension ladders on vehicles with rear doors, Steps on vehicles with tailboard. Extension ladder Keywords Safety Climbing up and down Hold on to the superstructure when entering and exiting. Climb down from the superstructure backwards. Chassis INJURY HAZARD! You may slip and fall on unsuitable ladders. Do not climb up on wheels, bumpers or other attached parts. Always use the ladders on the vehicle, such as extension ladders or steps when you want to enter or exit the superstructure. INJURY HAZARD! Jumping down from the superstructure may cause injury by slipping or falling. Do not jump down from the superstructure. Use the ladders on the vehicle for exiting the vehicle, such as extension ladders or steps. Extension ladder at rear 1 Bottom section 2 Top section The extension ladder can be pulled out in two steps. The first rung forms a step that is clearly visible when climbing down from the superstructure. Pull the bottom section of the extension ladder out completely. Pull out the top section and fold down. Driving Superstructure Transport solutions Operation Maintenance 109 Data

112 Ladder Steps Folding steps Folding steps are installed on the tailboard. Hold on to the rear opening After use slide the ladder back completely. 110

113 Rigging boards General Rigging boards for Schmitz Cargobull curtainsider semitrailers are available in aluminium or wood as required. The rigging boards are primarily intended to protect the tarpaulins. They also prevent the tarpaulins from bulging. Do not rely on the rigging boards alone to secure the load. The load must also be secured with suitable equipment. Rigging boards that are not required can also be stored in the rigging board holder* (see also "Rigging board holder*" on page 49). The aluminium rigging boards have grooves and springs to increase their stability when they are in place as a "side board". "Side board" of rigging boards Removing/replacing rigging boards Follow the directions below when you install or remove rigging boards. There is a very high accident hazard if you stand outside the superstructure when removing or installing rigging boards. INJURY HAZARD! You may slip and fall if you climb up parts not designed for the purpose. Do not climb up on wheels, bumpers or other attached parts. Always use a ladder with non-slip feet when you install or remove rigging boards. Keywords Safety Chassis Driving Superstructure Transport solutions Four rows of rigging boards per page Maintenance Operation 111 Data

114 Rigging boards INJURY HAZARD! Rigging boards under tension may shoot forward and injure face and body. Do not remove rigging boards when they are under tension. Remove any pressure exerted by the load beforehand. Do not remove rigging boards with force; they may strike back. Rigging boards at rear (S.PR) Moving the sideposts for S.CS Always position the rigging boards on S.CS vehicles starting from the front wall or tailboard. If the rigging boards are not the right length, release the sideposts and slide them to a different position (see also "Moving sliding sideposts" on page 113). 1 Folding rigging board holder at rear Remove the rigging boards and fold the rigging board holders (1) to the side to be able to use the complete width for loading and unloading. 1 Slots Make sure that the rigging boards are firmly seated in the slots (1). 112

115 Sideposts General Schmitz Cargobull curtainsider semitrailers have three sideposts on each side as standard equipment: Sliding sideposts on vehicles with sliding roof, Removable sideposts on vehicles with Hamburg top. The sliding sideposts can also be removed. The sideposts are opened and closed in the same way in all vehicle types. S.PR Do not remove side by side sideposts at the same time. This will affect the stability of the top and could damage it. Keywords Safety Chassis Tensioning superstructure When driving unloaded or partially loaded the superstructure can be tensioned with diagonal belts. (see also "Tensioning when travelling empty" on page 173). S.CS vehicle type Note the following: There are five pockets on each side for sideposts. The sideposts can also be installed in a staggered arrangement. When the sideposts are staggered, loads greater than 2480 mm wide can be transported. In the S.CS vehicle type all sideposts can be removed and slid aside for loading and unloading. S.PR vehicle type Observe the warning sticker "S.PR sideposts" on sideposts for S.PR vehicle type! Warning sticker "S.PR sideposts" Moving sliding sideposts Removing sliding sidepost INJURY HAZARD! Pressure from the load may cause the sidepost to shoot forward when unlocked and cause injury. Remove all rigging boards first. When unlocking the sideposts stand to one side and well away from the sidepost. Remove any pressure from the load before unlocking the sidepost. Driving Superstructure Transport solutions Operation Maintenance 113 Data

116 Sideposts CRUSHING HAZARD! Your fingers may be caught and crushed between the sidepost and bracket. Do not place fingers between sidepost and bracket. Wear safety gloves. Disconnected sliding sideposts Disconnected sliding sideposts may move by themselves. Secure sliding sideposts to prevent them moving. 2 Lever 3 Sidepost pocket When swinging the sidepost out it will move down slightly, but will be retained in the sidepost pocket (3) by its holder in the top rail above and the lever (2). 1 Lock Release lock (1) and press right down. Support the sidepost with one hand while doing this. Sliding sidepost Lift bracket (2) out of the sidepost pocket (3). 114

117 Close lock (1). Hold sidepost and bracket with both hands and slide to the side. Closing sliding sideposts Open lock (3). Press sidepost on the outside frame and hold with one hand. Close lock (3) with the other hand. Sideposts for S.PR with Hamburg top Observe the warning sticker "S.PR sideposts": Keywords Safety Superstructure Transport solutions Maintenance Operation Driving Chassis 1 Lever 2 Sidepost pocket Place bracket (1) in the sidepost pocket (2). Warning sticker "S.PR sideposts" The sideposts cannot be moved for loading and unloading from the side on vehicles with Hamburg top. The sideposts must be completely removed. 3 Lock 115 Data

118 Sideposts Removing a sidepost Installing sidepost 1 Retainer 2 Pin Open sidepost and close lock. Hold sidepost as shown and lift. Turn sidepost until the pin (2) comes out of the retainer (1). Carefully remove the sidepost from the holder (1). 1 Retainer 2 Pin Position pin (2) in the retainer (1) and turn sidepost. Close and lock sidepost. 116

119 Corner sideposts turning to the outside* Turning the corner sideposts to the outside/inside Keywords Corner sideposts turned to the outside* To load and unload bulky goods, corner sideposts can be turned to the outside about 450 mm on each side. ACCIDENT HAZARD! Due to overwidth, driving with corner sideposts turned to the outside* can cause accidents with personal injury. Never drive with corner sideposts turned to the outside*. Outside frame The outside frame can bend or twist. In this case, sliding roof and sideposts do not slide any longer. Slide the sliding sideposts before turning the corner sideposts forwards. Holdback stays For turning to the outside, do not block the rear doors with the holdback stays (see "Holdback stay" on page 103). Superstructure Driving Chassis Safety Procedure: Open sliding tarpaulins on both sides (see "Opening sliding tarpaulin" on page 89), Open both rear doors (see "Opening door wing" on page 100), Open the sliding roof and slide it forwards completely (see "Opening sliding roof" on page 123), Remove all rigging boards (see "Removing/replacing rigging boards" on page 111), Slide the sliding sideposts forwards (see "Moving sliding sideposts" on page 113), Turn the corner sideposts to the outside. Sliding sideposts moved forwards. The first sliding sidepost can stand still Slide the sliding sideposts forwards. The first sliding sidepost can stand still. Secure the rear doors to prevent them from swinging. E.g. With a rubber strap. Transport solutions Operation Maintenance 117 Data

120 Corner sideposts turning to the outside* Turning the corner sideposts with the crank 1 Pin 2 Crank Insert the crank (2) on the pin (1). The crank is supplied with the corner sideposts. Turn the crank (2) clockwise. The right corner sidepost extends until it reaches the stop, then the left corner sideposts extends. Turn the crank (2) anticlockwise. The corner sideposts retract. 118

121 S.PR "removable sideposts*" S.PR without top To transport goods that can be exposed to the elements, the S.PR can be supplied without top. Except the front wall and the front corner sideposts, all sideposts and side boards can be removed, thus creating a large surface for bulky goods. Side boards and sideposts can be mounted without tools, see: "Removing/attaching the side board" on page 108 "Removing/attaching the tailboard" on page 106 Removing/installing centre sideposts Release the lock on the sidepost and press it down. Hold the sidepost with one hand while doing this. Lift the sidepost from the sidepost pocket. Install in reverse order. Superstructure Driving Chassis Safety Keywords Removing/installing corner sideposts Removing/installing rear corner sideposts Pull up corner sideposts and remove them from the guide. Install in reverse order. Transport solutions Operation Removing/installing centre sideposts Maintenance 119 Data

122 Sliding roof (S.CS) Sliding roof (S.CS) Opening Open rear door and latch door wing with the revolving rod locks. (see "Door wing open slightly and secured" on page 100) To open the sliding roof use the roof opening tool fastened to the chassis frame (see also "Roof opening tool" on page 48). Hook roof opening tool (1) on the pull rope (3) below the end cross tube (2) and pull down strongly. The two locking pins (left and right on the top) must be open. Locking pin Opening the cross tube 1 Roof opening tool 2 Cross tube Press the cross tube (2) up with the roof opening tool (1). Opening sliding roof 1 Roof opening tool 2 Cross tube 3 Loop Hook roof opening tool (1) in the loop (3) and open the sliding roof. Cross tube opened, full load height 3 Pull rope 120

123 Closing Holdback stay Do not hold the doors open with the hold back stays. Use the revolving rod locks to hold the doors open (see page 100). Opening from the front Keywords Safety 1 Locking pin 2 Closing plate 3 Cross tube Close sliding roof fast; both locking pins (1) must lock into place. If necessary pull the cross tube (3) with the roof opening tool. Safety chain on the top at front 1 Cross tube 2 Snap-hook Unhook snap-hooks (2) from the cross tube (1) on both sides of the superstructure. Chassis Driving Superstructure Transport solutions Front tarpaulin on the front wall 3 Hooks (shown open) Operation Closing the cross tube 4 Cross tube 5 Loop Maintenance Pull cross tube (4) down at the loop (5). The sliding roof is closed. 121 Data

124 Sliding roof (S.CS) INJURY HAZARD! You may slip and fall if you climb up parts not designed for the purpose. Use a ladder with non-slip feet to loosen and fasten the tarpaulins. Closing ACCIDENT HAZARD! An unsecured top can tear and endanger traffic. Close the tarpaulin on the front wall carefully. Attach all hooks to the tarpaulin eyelets and secure by turning them 90. Always hook both snap-hooks in the first cross tube of the sliding roof. Opening sliding roof from the front Turn all hooks (3) 90 to open and fold tarpaulin up over its entire width. Up over the edge of the front wall. Hook roof opening tool inside at the centre of the cross tube and open sliding roof. Move sliding roof from the inside with the roof opening tool. It is not designed to be closed from the outside. Hook snap-hooks on left and right in the first cross tube of the sliding roof. Close tarpaulin on the front wall and secure with the hooks. Hooks locked 122

125 Sliding roof (S.PR) General To open the sliding roof use the roof opening tool that is fastened to the chassis frame on the left (see also "Roof opening tool" on page 48). Opening sliding roof Open tarpaulin at rear. Remove tarpaulin rope on both sides over the complete superstructure length and pull tarpaulin eyelets out of the hooks. (see "Opening tarpaulin" on page 97) Pull front rigging boards out of the tarpaulin strap. (see "Opening tarpaulin to the side" on page 98) Opening sliding roof 1 Roof opening tool 2 Loop Hook roof opening tool (1) in the loop (2) and open the sliding roof. The sliding roof locks when it is fully opened. Closing sliding roof Transport solutions Superstructure Driving Chassis Safety Keywords Sliding roof lock (open) 1 Cross tube 2 Lock Press end cross tube (1) upwards with the roof opening tool. Lock (2) is opened. Sliding roof locked 1 Cross tube 2 Lock Close sliding roof completely with the roof opening tool. Pull strongly in case the sliding roof is locked. Pull end cross tube (1) down with the roof opening tool until the lock (2) is closed. 123 Operation Maintenance Data

126 Sliding roof (S.PR) Removing outside frame The outside frames can be removed with a crane for loading from the side. INJURY HAZARD! The outside frame may fall and injure persons. Never remove the outside frame alone. Always have a helper available. 5 Frame division 6 Pin (on the outside) 7 Sliding sidepost Sliding roof The sliding roof may roll back and fall off if the outside frame is removed! Open the sliding roof completely and make sure that it is locked. Pull pin (6) out of the frame division (5) with the roof opening tool and place on the outside frame (1). The pin is fixed to the outside frame (1) so it cannot be lost. Dismantling connecting piece 1 Outside frame 2 Pin (on the inside) 3 Roof opening tool 4 Rear corner sidepost Open tarpaulins and sliding roof. Pull pin (2) out of the outside frame (1) with roof opening tool (3). The pin is fixed to the outside frame (1) so it cannot be lost. Dismantle the outside frame (1) from the division (5) with the roof opening tool (3). The frame division (5) must be taken apart completely. 124

127 Installing outside frame Keywords Chassis Driving Superstructure Transport solutions Safety Lift longitudinal rod with roof opening tool and lower to ground Insert roof opening tool (3) in the slot of the outside frame (1) and lift the outside frame (1) from the sliding section of the corner sidepost (4). 5 Frame division 6 Pin (on the outside) 8 Pin 9 Hole Lower outside frame (1) slowly until it hangs vertically. Lift the outside frame (1) manually enough so the pin (8) fits through the hole (9). Outside frame secured 1 Outside frame 2 Pin (on the inside) Suspend outside frame (1) on the pin (8) of the frame division (5). Insert roof opening tool (3) in the slot of the outside frame (1) and carefully lift outside frame (1). Position outside frame (1) on the sliding section of the corner sidepost (4). Slide frame division (5) to the outside frame (1) with the roof opening tool (3). Insert outside pin (6) in the frame division (5). Lock inside pin (2) in the outside frame (1). Operation Maintenance 125 Data

128 Hamburg top Hamburg top General The Hamburg top can be removed and the longitudinal rod removed for loading from above with a crane. Opening top Closing top Insert all cross members (1) in their retainers (5). Insert all tarpaulin rods (3) in their retainers (4). Close tarpaulin. Removing longitudinal member INJURY HAZARD! The outside frame may fall and injure persons. Never remove the outside frame alone. Always have a helper available. Hamburg top 1 Cross member (cross tube) 2 Longitudinal member 3 Tarpaulin rod 4 Tarpaulin rod retainer 5 Cross member retainer Open tarpaulin. (see "Opening tarpaulin" on page 97) Do not thread tarpaulin rope out of the first five hooks to prevent the tarpaulin from falling in front of the front wall! Open roof section by pulling tarpaulin back. From the loading area if the loading area is empty. From outside if it is loaded. Push tarpaulin rods (3) up out of their retainers (4) and remove. Do not remove the tarpaulin rods (3) in the front roof area but rotate them to the side only to prevent the tarpaulin from falling! Then push cross members (1) up out of their retainers (5) and remove. Release longitudinal member at the corner sidepost 1 Longitudinal member 2 Pin, shown open 3 Corner sidepost slider Open top. Pull pin (2) out and rotate

129 Installing longitudinal member Position longitudinal member (1) on the slider (3) of the corner sidepost and the connecting piece (5). Rotate pin. Make sure that it clicks completely in the longitudinal member. Close top. ("Closing top" on page 126) Keywords Safety Release longitudinal member at connecting piece 4 Pins on connecting piece 5 Connecting piece Pull both pins (4) out and rotate 45. Pull longitudinal member (1) up out of the connecting piece (5) and the slider (3). Chassis Driving Longitudinal member To remove another longitudinal member the supporting sidepost must be removed first. Superstructure Roof damage Do not remove side by side sideposts at the same time. This will affect the stability of the top and could damage it. Transport solutions Operation Maintenance 127 Data

130 Lifting roof Lifting roof Information on lifting roof The lifting roof can be lifted on one side or both sides. The roof is lifted hydraulically or mechanically. In the hydraulic version, the hydraulic pump is installed under the rear axle on the left or right side as desired. The roof hydraulics are operated manually or by compressed air*. The maximum lift height of the hydraulic or mechanical lifting roof is about 400 mm. Proceed as follows to lift the roof: Open sliding tarpaulin on one or both sides, open rear doors and latch with the revolving rod locks (see page 100), lift roof on one or both sides. ACCIDENT HAZARD! The superstructure may collide with obstacles while driving and cause accidents. Always drive with the lifting roof lowered and tarpaulins closed. Damage to lifting roof! Driving with the lifting roof raised may damage the superstructure. The roof is not designed for the loads encountered under such conditions. Do not drive with lifting roof raised. Do not use the lifting roof as a "press" for foam or similar material. Loss of strength! Careless handling may cause the roof rod to jump out and cause the roof to lose strength. Before starting to drive check that the sliding roof is not damaged by the loading procedure. Have any damage to the sliding roof repaired immediately. Note the instruction stickers on the rear doors. Preliminary operations, hydraulic and mechanical lifting roof INJURY HAZARD! The moving components may crush hands and fingers. Make sure that no person is in the loading area while the lifting roof is activated. INJURY HAZARD! If the load slides it can fall off the semitrailer and injure you or other persons. Before opening the superstructure make sure that no load can fall off the semitrailer. 128

131 Open sliding tarpaulin on one or both sides as required. Unhook the tarpaulin tension rods at front and rear to prevent them from catching while lifting the roof. Remove any tension straps used for reinforcing the superstructure while travelling empty from the sideposts. The sliders of the sideposts must be completely free to move. Open and latch both rear doors. ("Rear wall" on page 99) Manual hydraulic pump Remove handpump lever (2) from the holder and extend it. Move sliding section over the elbow of the handpump lever. Lifting left side Damage to lifting roof! Damage to the lifting roof during lifting. When lifting the roof make sure there is enough space above. Keywords Safety Chassis Driving Manual hydraulic pump 1 "Up/Down" valve ("Up" position shown) 2 Handpump lever (driving position) 3 "Left" valve (shown closed) 4 "Right" valve (shown closed) 1 "Up/Down" valve ("Up" position shown) 2 Handpump lever (pump position) 3 "Left" valve (shown open) 4 "Right" valve (shown closed) Move valve (1) to "Up" position. Open valve (3). Valve (4) must be closed. Pump. The lifting roof is raised on the left side of the vehicle. Superstructure Transport solutions Operation Inserting handpump lever Maintenance 129 Data

132 Lifting roof Lifting right side Pump. The lifting roof is raised on both sides of the vehicle. Lowering lifting roof 1 "Up/Down" valve ("Up" position shown) 2 Handpump lever (pump position) 3 "Left" valve (shown closed) 4 "Right" valve (shown open) Move valve (1) to "Up" position. Open valve (4). Valve (3) must be closed. Pump. The lifting roof is raised on the right side of the vehicle. Lifting both sides Lifting roof raised on both sides Turn valve (1) to "Down" position (note arrow on pump). Open valve on side that you want to lower. Valve (3) on left side, valve (4) on right side or both valves. Pump. The lifting roof lowers. Close superstructure. 1 "Up/Down" valve ("Up" position shown) 2 Handpump lever (pump position) 3 "Left" valve (shown open) 4 "Right" valve (shown open) Move valve (1) to "Up" position. Open valve (3) and (4). 130

133 Pneumatic hydraulic pump* Raise/Lower left side Keywords Safety Pneumatic hydraulic pump 1 "Select movement direction" valve 2 "Select roof side" valve 3 "Up/down" button 4 "Emergency Operation" hand pump Select the direction of movement of the lifting roof with valve (1): Lifting or lowering. The direction of movement is marked with an arrow. Select the roof side with valve (2): left, right or both sides. The roof side is marked with arrows. The lifting roof will move only while the actuation button (3) is pressed. If the compressed air supply fails the lifting roof can be opened and closed with the hand pump (4). The pneumatic hydraulic pump requires at least 5.2 bar pressure. 1 Valve in "Raise" position 2 Valve in "left" position 3 Actuation button Lift Move valve (1) to "Raise" position. Move valve (2) to "left" position. Press actuation button (3). The lifting roof is raised on the left side of the vehicle. Lower Move valve (1) to "Lower" position. Press actuation button (3). The lifting roof lowers. Raise/Lower right side Chassis Driving Superstructure Transport solutions Damage to lifting roof! Damage to the lifting roof during lifting. When lifting the roof make sure there is enough space above. 1 Valve in "Raise" position 2 Valve in "right" position 3 Actuation button Lift Move valve (1) to "Raise" position. Move valve (2) to "right" position. Press actuation button (3). The lifting roof is raised on the right side of the vehicle. Operation Maintenance 131 Data

134 Lifting roof Lower Move valve (1) to "Lower" position. Press actuation button (3). The lifting roof lowers. Raise/Lower both sides Mechanical lifting roof 1 Valve in "Raise" position 2 Valve in "both" position 3 Actuation button Lift Move valve (1) to "Raise" position. Move valve (2) to "both" position. Press actuation button (3). The lifting roof is raised on both sides of the vehicle. Lower Move valve (1) to "Lower" position. Press actuation button (3). The lifting roof lowers. Mechanical lifting roof, lifted on the right The roof can be lifted with several pump movements to a perceptible stop. Raising lifting roof Lifting device, rear right view 1 Hand lever of the lifting device The mechanical lifting roof has a lifting device on each corner sidepost. 132

135 For lifting preparation operations see "Preliminary operations, hydraulic and mechanical lifting roof" on page 128 Pull the hand lever (1) in the direction of the arrow. The roof lifts slightly. Lowering lifting roof Maintenance Keywords Safety Superstructure Operation Transport solutions Driving Chassis Roof lowering 2 Button Press the lever (1) against the sidepost. Press the button (2). The roof lowers. 133 Data

136 Height-adjustable superstructure Height-adjustable superstructure The height adjustment allows to change the superstructure height without tools. Thus the superstructure can be adapted to the permitted overall height (depending on the coupling height), or the superstructure height can be adapted to the necessary load height. The following heights can be adjusted in 50 mm steps (front in six steps and rear in three steps). Superstructure height Bottom position of superstructure Top position of superstructure front mm rear mm 2,750 2,900 3,050 3,050 The sliders of the sideposts must be completely free to move. Open and secure both rear door wings. (page 100) Lift roof on both sides. (page 128) Proceed as follows to change the superstructure height: Open sliding tarpaulins on both sides. Open and latch rear doors. Lift roof on both sides. Adjust lengths of sideposts. Lower roof. Fold tarpaulin. Preparation Overall height The superstructure may collide with obstacles and be damaged. Make sure that the permitted overall height is observed before driving away. Open sliding tarpaulins on both sides, (page 89) Remove any tension straps used for reinforcing the superstructure while travelling empty from the sideposts. Secure both rear door wings Adjusting sidepost length Tension The superstructure can be damaged by tension. Position opposite sideposts to the same height! The roof must be set to the same height both on the left and on the right. Position centre sideposts and front corner sideposts at the same height. Superstructure height Depending on coupling height, the front and rear superstructure heights can be set to different values. In this case, set the centre sidepost heights accordingly. 134

137 Safety Keywords Front corner sideposts Rear corner sideposts Place the rear corner sideposts in the same position. Then lower the roof completely. The roof lowers until the specified superstructure height. Folding tarpaulin Chassis Driving Centre sideposts 1 Plug 2 Scale Rotate and remove the plug (1). Insert the plug (1) in the desired position and rotate it. Read and note the position on the scale (2). Place all centre sideposts in the same position. Place the front corner sideposts in the same position. Folding the sliding tarpaulin with a lower superstructure height With lower superstructure heights, the tarpaulin must be folded. Superstructure Transport solutions Operation Maintenance 135 Data

138 Height-adjustable superstructure Fold lower section of tarpaulin inwards. Fold it until the shortened tarpaulin covers the frame/hook section. Rear door Variable roof end 1 Position for high superstructure height 2 Position for low superstructure height The revolving rod locks of the rear door engage in the corresponding position on the cross tube depending on superstructure height. Close the rear door as described in "Closing door wing" on page 101. Telescopic tarpaulin tension rods Tarpaulin tension rod, low superstructure height The tarpaulin tension rods are telescopic and adapt to the superstructure height. Tarpaulin tension rod, high superstructure height 136

139 Flexos General Keywords Transport solutions Operation Maintenance Superstructure Driving Chassis Safety Lateral heights to UK side rail depending on the fifth wheel heights Flexos is a Schmitz Cargobull system that allows the curtainsider semitrailer to be adapted to different fifth wheel heights so low towing vehicles can tow trailers with higher superstructure heights. Proceed as follows: Offset the front wall tarpaulin. Adjust the sideposts. Adjust the Multi Ride Height (MRH) air suspension for the new height. Note Have the superstructure height changed by a qualified workshop only. Schmitz Cargobull recommends a Schmitz Cargobull service centre. 137 Data

140 Flexos Offset front wall tarpaulin Tension Unequal sidepost adjustments can cause tension and damage. Always adjust both sides of the superstructure equally. Front wall tarpaulin 1 Strip for beading 2 Hollow rivet The front wall tarpaulin must be offset before lowering or lifting the superstructure height. Drill out and remove all hollow rivets (2). Set sideposts to the desired length. Drill new holes and rivet strip (1). Replace tarpaulin tension rods of the side sliding tarpaulins with shorter or longer ones as required. Adjusting middle and corner sideposts Adjust the superstructure height at the sideposts from front to rear as specified in the table: Corner sidepost front 1 Corner sidepost slider 2 Hole (every 25 mm) 3 Bolt Sidepost Corner sidepost front Sidepost 1 Sidepost 2 Sidepost 3 Corner sidepost rear Length 100 mm 75 mm 50 mm 25 mm 0 mm Centre sidepost Loosen bolt (3) and move slider (1) in or out 100 mm as required. The holes are at 25 mm intervals. Insert bolt (3) and tighten. 138

141 Setting driving height The MRH air suspension system (Multi Ride Height) was developed to allow all conventional driving heights to be set with the air suspension to match the fifth wheel heights of tractors. The required driving height is matched to the fifth wheel height by adjusting the air suspension valve at the axle. For a description see "Setting driving height" on page 38. Overall height After the height adjustment check the overall height of the semitrailer when it is hitched to the towing vehicle. The overall height must not exceed 4000 mm (EU). Keywords Safety Chassis Maintenance Operation Transport solutions Superstructure Driving 139 Data

142 Flexible corners (13.73 m)* Flexible corners (13.73 m)* The flexible corners are installed in Schmitz Cargobull semitrailers with an interior length of m. When unloaded the swivel radius is 2040 mm and when loaded 2150 mm. The flexible corner combined with an interior length of m allows 34 euro pallets to be loaded. Collision hazard When loaded the swivel radius is larger than with standard semitrailers and the trailer may collide with the tractor if space is restricted. Make sure that there is sufficient space available when you hitch a semitrailer with m interior length. See the instructions in "Swivel radius (turning circle)" on page 76! Flexible corner from the outside (unloaded) Flexible corners from the inside 1 Rubber corner 2 "Flexible corner" warning sign During loading the rubber corners are pressed out, making the front corner sections usable. 140

143 Additional sideposts* The additional sideposts are used to subdivide the load space into longitudinal or cross sections as required, and they can also be used for securing loads. Moveable bulkhead The additional sideposts can also be used to set up an additional partition to ensure that the load centre of gravity or the axle loads remain constant, such as when transporting rods. Use the additional sideposts only with closed tarpaulins and doors. Storage compartment for additional sideposts Keywords Safety Chassis 1 Supplementary sideposts 2 Pocket for additional sidepost in centre of floor 3 Pocket for additional sidepost in outside frame Insert the additional sideposts into the pockets in the floor and the outside frame. The maximum load on an additional sidepost at 1 m height is 400 dan (kg). The maximum load of the moveable bulkhead shown below is 12,000 dan (kg). Storage compartment on chassis 1 Snap closure 2 Supplementary sideposts When not in use, stow the additional sideposts in the storage compartment on the chassis or in the sidepost holder (page 50). Always make sure that the storage compartment is properly closed before driving to prevent any danger from additional sideposts falling out. Driving Superstructure Transport solutions Operation Moveable bulkhead of additional sideposts (example) Maintenance 141 Data

144 Load securing gear Load securing gear General This chapter gives you an overview of the various options for securing and handling loads in the vehicle. Instructions on load securing gear can be found in section "Load securing gear" on page 169. Anchors in the outside frame Maximum load of the lashing rings: 2,000 dan (kg). The lashing angle must be smaller than 60 degrees with respect to the vertical. Reinforced lashing eyelets* Maximum load: 4,000 dan (kg). The lashing angle must be smaller than 60 degrees with respect to the vertical. The reinforced lashing eyelets (heavy-duty eyelets) in the outside frame can be used with lashing from the inside. Lashing ring in the outside frame, tension strap attached from outside There are 13 pairs of retractable lashing rings in accordance with DIN EN in the outside frame. The lashing rings can be used with lashing from the outside and from the inside. Reinforced lashing eyelets: Max. resistance 4,000 dan (kg) Sticker "Load lashing rings/eyelets" Reinforced lashing eyelet folded out 142

145 Lashing holes* in outside frame The lashing holes* along the length of the outside frame allow lashing to be attached at any point on the superstructure. The design of the tarpaulin hook section (1) allows lashing to be used even when the tarpaulin is closed. Maximum load of the lashing rings: 2,000 dan (kg). The lashing angle must be smaller than 60 degrees with respect to the vertical. A maximum of three lashing points per linear metre may have the maximum load. Pallet stop strip* The pallet stop strip* prevents pallets or wiremesh boxes from slipping from the load area. At the same time, it is used as a stop during loading. Keywords Safety Chassis Straight pallet stop strip Driving Lashing holes in outside frame 1 Tarpaulin hook section Pallet stop strip combined with aluminium rigging board Superstructure Transport solutions Operation Using the lashing holes in the outside frame with the tarpaulin closed Maintenance Offset pallet stop strip 143 Data

146 Load securing gear Lashing winches* on outside frame Approval This type of lashing winch on the outside frame is not approved in all countries, because the backlash lock can be disabled without a tool. The lashing winches have a tension strap with a hook. The maximum load on the tension strap is 2,000 dan (kg). Lashing winch on outside frame 1 Ratchet gears 2 Locking pawl 3 Crank 4 Tension strap 5 Hook Label in accordance with DIN EN Note the directions on the tension strap label. Tensioning Swivel locking pawl (2) up and unroll tension strap (4). Throw tension strap (4) over the load and attach the hook (5) in the nearest lashing ring on the other side. After securing the load: swivel locking pawl (2) down. It must engage the ratchet gears (1). INJURY HAZARD! The crank may kick back and cause hand and arm injury. Only tighten the tension strap with the locking pawl engaged. Do not release the locking pawl under load. Pretensioning with the winch Pretension tension strap (4) with the crank (3). 144

147 Safety Keywords Tightening with a lever Insert lever in a hole of the crank (3) and tighten tension strap (4) with the lever. Releasing INJURY HAZARD! The tension strap can hit back and injure you or other persons. Before slackening off the tension strap, check whether the load has moved. If this is the case, do not slacken the tension straps. Keep the tension on the tension strap with a lever before releasing the locking pawl. Slowly slacken the tension strap and do not release the lever during this process. To release the locking pawl first tension the tie-down winch with a lever and release it cautiously! Pretension tension strap with a lever and release the locking pawl (2) with the other hand. Slowly release tension strap (4). Roll up tension strap (4) completely after use and secure lashing winch with the locking pawl (2). Tension straps on outside frame Operation Chassis Driving Superstructure Transport solutions Tension straps fixed on outside frame Maintenance 145 Data

148 Load securing gear The tension straps are bolted to the outside frame. The tension ratchets are bolted to one side of the superstructure, the tension straps are bolted to the other side. Combined with the Roof retain, tension straps on the outside frame are a convenient way to secure the load. Strap retainers in the roof Transport solutions For additional options for securing loads, particularly for specialised transport, see "Transport solutions" from page 147. Retainer for tension straps under the roof, tension straps run along the roof 1 Retainer With the "Roof retain" system, tension straps are placed on retainers (1) before loading and guided below the roof. After loading, tension straps are pulled from the retainers (1) and loop around the load. Retainer under the roof 146

149 Transport solutions Paper transport 148 Coil transport 154 Load securing gear in accordance with EN XL 157 Intermodal transport 159 Maintenance Safety Keywords Operation Transport solutions Superstructure Driving Chassis 147 Data

150 Paper transport Paper transport Equipment features The picture shows different options for securing paper rolls. The transport solution for paper transport offers many options for securing paper rolls. They include: short cross member distances and a reinforced floor, allowing a forklift axle load of up to 9,000 kg, the multifunction floor with four perforated rails, which can be covered, 13 pairs of lashing eyelets in the outside frame (see page 142), continuous lashing holes in the outside frame in combination with the tarpaulin hook section for securing loads with tarpaulin closed (see page 143), load securing wedges including varied storage options. 148

151 Multifunction floor Keywords Chassis Driving Superstructure Transport solutions Operation Maintenance Safety Multifunction floor with four system tracks Four longitudinal system tracks, each with a double row of holes, are installed in the multifunction floor. The rows of holes are used for fastening the load securing wedges. The safe floor load is 9,000 kg in accordance with EN 283. Perforated rails The perforated rails are available with system track to allow use of a pallet roller. INJURY HAZARD! Open system tracks can cause injury by tripping. Cover the system tracks with the aluminium sections when they are not being used. System track closed with fill strips for normal pallet transport Perforated rail without pallet roller function for securing wedges The maximum load of the multifunction floor without system tracks is 7,100 kg forklift axle load in accordance with DIN EN 283 and with the system tracks 9,000 kg forklift axle load in accordance with EN Data

152 Paper transport Load securing wedges FATALITY HAZARD! Loads that are secured with load securing wedges only may fall off the semitrailer and cause personal injury. Always secure the load with tension straps as well. Always use a minimum of two wedges in each direction to prevent the load from rotating. Always position the load securing wedge in the perforated rail with both flanged pins. The load securing wedges prevent the load from rolling and sliding across or along the trailer. However, load securing wedges are not suitable as the only load securing devices. The load may tip over the wedges or slide away from them. The load must always be secured with tension straps or chains in addition to the wedges. 1 Flanged pin 2 Bottom, fixed 3 Top, movable 4 Threaded rod The load securing wedge consists of two opposed sliding parts, the bottom and the top. The bottom is fixed immovably in the perforated rail by the two pins. The top is slid to adjust the pressure of the wedge on the load. Always slide the top of the wedge until it is hard against the load. Four different applications Positioning wedge against the load 1 Hexagon, spanner size 27 Insert load securing wedge into the perforated rail with both flanged pins. 150

153 Place the hexagon (1) with a ratchet (hexagon socket, spanner size 27) on the hexagon on the load securing wedge. Slide the top of the wedge by turning the ratchet until the top is tight against the load. Pallet roller You can move paper rolls up to 3,500 kg in weight or other heavy loads and move them and position them on the superstructure with two pallet rollers, also known as Joloda rollers. Keywords Safety Driving Chassis Two wedges each at the front and side, additionally secured with tension straps front and rear (only one wedge visible on the side) Wedge load The maximum load on a wedge in the load direction is 3,100 dan (kg). 2 pallet rollers required Notes Two pallet rollers are always required to lift and move loads (capacity per pair: 3,500 kg). Always use pallet rollers of the same length and the same carrying capacity. Always slide the pallet roller completely to the stop under the load before lifting the load. The load that you want to move should not be any longer than the pallet roller. Keep the system tracks clean so the pallet rollers move easily and are not damaged. Keep the top of the pallet roller clean so the paper rolls (or other loads) are not damaged. Superstructure Transport solutions Operation Two wedges each at front and left and right of paper roll. Additionally secured with tension straps and antislip mats Maintenance 151 Data

154 Paper transport Moving pallet rollers The pallet roller can be moved when lowered and also when raised. The pallet roller does not have a brake. The raised load is only braked by lowering it to the ground while the pallet roller continues to move. INJURY HAZARD! Loads lifted with the pallet roller may move unexpectedly and run over or crush persons. The semitrailer must be horizontal when using the pallet roller. Move the load slowly and brake the load as slowly as possible. Loads with a high centre of gravity may tip when braked suddenly (lowering pallet roller). Remove covers on system tracks. Place pallet rollers in the tracks. Insert handles. Move pallet rollers under the load. Pallet rollers must always be moved completely under the load to the stop. To lift the load press the two handles down strongly simultaneously. The pallet rollers remain in the lifted position. The load is lifted and can be moved. To lower, brake load and press handle up. The load is lowered. Emergency Stop A stopper is installed at the end of every system track (2). When crossing, the switch (1) on the pallet roller is actuated and the pallet roller is automatically lowered. This prevents lifted loads from rolling over the end of the superstructure and falling out. INJURY HAZARD! In an emergency stop the handle jumps up and may cause injury. Do not remain in the swivel range of the handle in case of an emergency stop. Pallet roller with handle inserted, lowered 152

155 Storage compartment in the front wall* Keywords Chassis Driving Transport solutions Superstructure Safety Pallet roller lifted 1 Switch 2 Stopper Storage compartment at rear* Storage compartment in the front wall, contents secured with tension straps Additional accessories can be stowed in the storage compartment on the front wall. Secure the contents of the storage compartment with tension straps to prevent anything falling out. Storage compartment at rear of vehicle 1 Closure, lockable Operation Maintenance A storage compartment is attached to the rear of the vehicle. Accessories for securing loads can be safely stored here. The storage compartment can be locked and is accessible from both sides of the vehicle. Make sure that the storage compartment is properly closed before driving. 153 Data

156 Coil transport Coil transport Equipment features The transport solution for coil transport offers many options for securing coils. They include: the stable chassis model for transporting coils to max. 30 t weight with a length of at least 1.5 m, the coil well, which can be covered, lined with wood in accordance with the VDI standard, for coil diameters from 900 to 2200 mm, coil safety supports in accordance with the SIDMAR standard, 4 pairs of reinforced lashing eyelets for belts* in the outside frame (see page 142). The semitrailer can be used as a standard platform trailer with the coil well covered. Stack well covers that are not required against the front wall. Open coil well with safety supports Stack well covers that are not required to prevent them from falling. Property damage Coil well The coil well may be damaged if you transport other goods in it. Transport only coils in the coil well. Property damage Placing the coils in the well too fast may damage the semitrailer. Always make sure that coils are placed slowly in the coil well when loading. Well covers of wood The forklift can drive on the well covers (max. axle load 5460 kg). The coil safety supports and tie-down chains etc. can be stored in the well starting from the front. 154

157 Coil safety supports Combination safety supports 70/80 are necessary to use both sidepost pockets: The end tapered to 70 mm fits in the sidepost pockets on the outside frame. The end with 80 mm cross-section is for the sidepost pockets in the coil well. Keywords Safety Safety supports The coil well has four pairs of sidepost pockets for coil safety supports. The coil safety supports comply with the SIDMAR standard. Combination safety supports 70/80 Sidepost pockets in the coil well with combination safety support, cross-section 80 mm 1 70 mm cross-section (tapered) 2 80 mm cross-section In addition to the sidepost pockets in the coil well, sidepost pockets are available in the outside frame. Sidepost pocket in the outside frame with combination safety support, cross-section 70 mm Load securing gear FATALITY HAZARD! Coils in the coil well that are not secured in any other way may move while the vehicle is moving and can then fall off the semitrailer and cause personal injury. Always use the coil safety supports. Load the coils so they fit flush to the safety supports. The coils must also be secured with chains or belts. You can secure the coils with the coil safety supports and also with the lashing eyelets in the outside frame applying 2,000 dan (kg) tensile force (see page 142) and the reinforced lashing eyelets in the outside frame applying 4,000 dan (kg) tensile force (see page 142). Chassis Driving Superstructure Transport solutions Operation Maintenance 155 Data

158 Coil transport Load distribution Identification of load centre of gravity 1 Load centre of gravity marker 2 Coil safety support (second position) Load distribution Incorrect load distribution will adversely affect the driving characteristics and may damage the semitrailer. Make sure that the load is properly distributed. Do not exceed or fall below the approved axle loads and support loads and the gross combination weight. When transporting heavy single coils it is important that you load the coil at the load centre of gravity (1) and fitted flush before the second safety support position (2) (viewed from the front wall). Load several light single coils flush with the first safety support position (3). This is the only way to ensure that the semitrailer is evenly loaded and that all axle and drawbar loads are within limits. 2 Coil safety support (second position) 3 Coil safety support (first position) 156

159 Load securing gear in accordance with EN XL Certified semitrailer in accordance with EN XL The following are also required in accordance with DCE Directive 9.5: Pallet stop on both sides or interior side boards as desired. Beverage transport: additionally reinforced centre sideposts, based on the load, the corresponding number of rigging boards, requirements in accordance with the load securing certificate. Keywords Safety Chassis Transport conditions Load securing certificate The Schmitz Cargobull curtainsider superstructure is TÜV-certified. Thanks to adequate equipment, the semitrailer S.CS and S.CS BS comply with the current requirements of the directives: VDI 2700 (securing of loads on road vehicles), EN (load restraint assemblies on road vehicles Safety), EN (Code XL) (securing of loads on road vehicles Securing of beverage products), and DCE Directive 9.5. Equipment features: reinforced centre sideposts, reinforced side tarpaulins with additional straps, "Schmitz Safety Roof" with reinforced roof tarpaulin, four rows of aluminium rigging boards (for S.CS BS only with short tarpaulin and zig-zag closure). Optional: flexible load securing gear* for partial loads. Load securing certificate The load is secured by the superstructure under the following conditions and additional securing is not required: The load is flush with the front wall, side walls and tailboard. The distances to the edges of the load area and in the spaces between parts of the load are no greater than 30 mm per linear load metre. The coefficient of friction between the load area and the load or parts of the load is min. = 0.3 Driving Superstructure Transport solutions Operation Maintenance 157 Data

160 Load securing gear in accordance with EN XL Load securing certificate Rigging boards are not required under these conditions. If the load is not at the rear opening, additional load securing gear in accordance with VDI 2700 is required. In this case Schmitz Cargobull recommends flexible load securing gear* (see page 171). ACCIDENT HAZARD! Unsuitable or incorrectly stowed load carriers may slip or fall from the superstructure and cause personal injury. Only transport approved load carriers. Transport only load carriers that have been loaded as specified by regulations. Before every trip stow all movable superstructure components (such as sideposts, tarpaulin closures, doors, sliding roof) as specified and secure them. Flexible load securing gear* Load is secured with the flexible load securing gear* to prevent it from slipping and falling backwards and forwards. For more detailed information see "Flexible load securing gear*" on page

161 Intermodal transport Schmitz Cargobull curtainsiders for intermodal transport have the following equipment: Grips for crane loading. Folding guard (depending on the vehicle type). Folding mudflaps on the last axle. Schmitz Cargobull semitrailers are suitable for the following wagons depending on equipment and height codes: Pocket wagon type 1A, DB 707 Variable loading gauge (e.g. Mega II, T4, pocket wagon 2000, DB 739, DB 744) Mega wagon (e.g. T5, pocket wagon 3000, AAE twin) Height coding Contact your operator for the approved height coding on the route you are using. The identification letters stand for: P for transport on non-heightoptimised pocket wagons of type 1A, DB 707. (P) for transport height-optimised pocket wagons of type 744 and type "Height coding" sticker shows the section information For transport on non-height-optimised pocket wagons the semitrailer must be fitted with a folding guard. The semitrailer can be loaded based on coding, P or (P), on the corresponding wagons only. DB tarpaulin tightener DB tarpaulin tighteners (Tyride tarpualin tighteners) have the following features: A locking mechanism prevents the tarpaulin tensioner from opening by pulling on the tension strap. A lock on the hook section prevents the claw hooks from detaching accidentally. Keywords Safety Chassis Driving Superstructure Transport solutions See the sticker on the side at the front left for the height coding of your semitrailer. This shows the section information. The number after the letters is the section number and shows the corner height in cm. Operation Maintenance 159 Data

162 Intermodal transport Folding guard Tyride tarpaulin tightener 1 Tarpaulin tightener 2 Lock 3 Strap 4 Claw hook Opening the tarpaulin tighteners Press locking mechanism (2). The tarpaulin tightener (1) springs open. Bumper, raised The bumper must be raised before loading the semitrailer on non-height-optimised wagons. Pull tension strap (3) down and release the claw hook (4). Tightening and closing the tarpaulin tightener Pull tarpaulin as far as possible under the outside frame. Attach claw hook (4). Pull tension strap (3) tight and hold with one hand. Press the tarpaulin tightener (1) down with the other hand. While doing that release the tension strap (3) slightly so the tension on the tarpaulin is not too high. Close tarpaulin tightener (1) completely. The locking mechanism (2) must engage visibly and audibly. Sticker "Folding guard" See also sticker "Folding guard" on page 213. Raise bumper 160

163 Raising (loading position) Pull bumper up strongly with both hands. The bumper clicks automatically into place. The drop lock (1) keeps the bumper in the raised position. Edges Keywords Safety Underrun guard drop lock 1 Drop lock 2 Cam The drop lock (1) slides along the cam (2) and keeps the underrun guard raised. While lifting, to lower the bumper, the drop lock (1) releases the cam (2) again. Edges for loading by crane 1 Edge 2 Tarpaulin reinforced The semitrailer can be lifted by the edges (1). The tarpaulin (2) is reinforced in the area of the edges (1). Preparing for loading Chassis Driving Superstructure Operation Transport solutions Bumper in driving position Lowering (driving position) Lift bumper slightly. The drop lock (1) releases the bumper. Slowly lower the bumper. Maintenance "Intermodal transport" warning sign 161 Data

164 Intermodal transport ACCIDENT HAZARD! The semitrailer may strike tunnel entrances and underpasses and cause injuries. Lower the semitrailer completely with the air suspension. Raise the bumper. Raise and lock the sideguards on both sides. Fold mudflaps up and hook them in place. Check tarpaulin to make sure that it is tight and well lashed down. Check tarpaulin tighteners to make sure that they are correctly hooked, tensioned and locked. Lower trailer completely with the air suspension. Check the following items after the semitrailer has been lowered from the wagon to the road: Air spring bellows lifted from the frame 1 Splitter Raise mud flaps Preparing for road travel While lifting, the semitrailer lifts the air spring bellows with the splitter (1) from the frame. The shock absorbers limit the maximum extension of the axle. Air spring bellows on the frame 1 Splitter Check all wheels to make sure that the splitter (1) are sitting properly on the frame. Bring air suspension to driving position. Follow directions in the chapter "Chassis" at "Up/down valve" on page 32 and "Auto-reset function" on page 34. Lower and lock bumper. Lower and lock the sideguards on both sides. Unfold mudflaps. 162

165 Operation Stability 164 Opening the semitrailer 165 Loading and unloading 166 Load securing gear 169 Tensioning when travelling empty 173 Attached forklift 174 Chassis Safety Keywords Maintenance Operation Transport solutions Superstructure Driving 163 Data

166 Stability Stability ACCIDENT HAZARD! The uncoupled semitrailer may tip if the load is not well distributed and cause personal injury. Make sure that the weight of the load and the forklift does not exceed the specified values. Never unhitch the semitrailer if the load exceeds the specified weights. In the case of doubt place supports under the semitrailer in the area of the skid plate while loading or unloading. If necessary lower the support legs of the rear landing leg* (see "Rear landing leg*" on page 43). Warning sticker "Stability with uncoupled semitrailer" The uncoupled semitrailer may tip during loading or unloading. The unloaded semitrailer may tip backwards if a forklift exceeding 3000 kg in weight (including load) drives on to it from the rear. The partially loaded semitrailer may tip forwards if the combined load on the semitrailer and the forklift (including load) exceeds 6000 kg. 164

167 Opening the semitrailer Opening the semitrailer may be hazardous for you or other persons. If the load has moved or fallen it may fall from the loading area when the semitrailer is opened. Open the semitrailer very cautiously and attentively. Take particular care if you did not load the semitrailer yourself or it can be seen from the outside that the load has moved. INJURY HAZARD! If the load has fallen or moved it may fall out when the tarpaulin or side boards of the semitrailer are opened and injure you or other persons. Before opening the semitrailer make sure that no load can fall. INJURY HAZARD! The side boards can open suddenly by pressure from the load, parts of the load can fall out of the superstructure and cause personal injury. When opening the side boards or the doors keep clear of their swing area by standing to the side. Close the lock again immediately if you see pressure from the load. Remove the pressure from the load before opening the side boards or doors. Driving Chassis Safety Keywords Note the following points before opening the semitrailer: Bulges in the tarpaulin indicate that the load has moved or fallen. In this is the case, do not slacken the tarpaulin. Open the semitrailer cautiously from the rear or the other side and see what has happened. Remove the out-ofplace load before opening that side. Direct other persons away from the danger area when opening the semitrailer. Weather-dependent: Remove snow and ice from the top of the superstructure before opening the tarpaulin or before unlocking the sideposts. Superstructure Transport solutions Operation Maintenance 165 Data

168 Loading and unloading Loading and unloading Load distribution plan (LVP) ACCIDENT HAZARD! If the semitrailer is loaded contrary to the specifications, the braking and steering characteristics of the semitrailer truck may be adversely affected and cause accidents with personal injury. Load the semitrailer in such a way that all axles and drawbars are not overloaded or underloaded and the approved overall weight is not exceeded. Commercial vehicles can only be loaded to their maximum approved payload when the overall centre of gravity of the load is a specific area. However, loads that are under the maximum payload must also be positioned only in specific sections of the loading area. Otherwise axles may be overloaded or underloaded. If the overall centre of gravity of the load is within this area, referred to as the load distribution curve (3), this guarantees that the axle loads will be within the approved range. The load distribution plan in conjunction with the load distribution curve (3) will show you what load can be loaded on the semitrailer at what distance from the front wall. Example of load distribution plan The load distribution plan shown below is intended as an example only. It cannot be transferred to your semitrailer because it depends on the actual dimensions and the weight of the equipment mounted on your semitrailer truck. The load distribution plan must be calculated separately for every semitrailer truck. Example: A 12 t machine component must be loaded. According to the load distribution plan the centre of gravity of the machine component must positioned be at least 3 m and a maximum of 9.90 m from the front wall. Two machines weighing a total of 24 t must be loaded. According to the load distribution plan the overall centre of gravity (resultant centre of gravity) of the two machines must be in the range of 6.10 m to 7.25 m behind the front wall. 166

169 Chassis Safety Keywords Load distribution plan (example) 1 Scale of distance from front wall in metres (m) 2 Scale of load in tonnes (t) 3 Load distribution curve Loading and unloading bulky goods Driving Operation Maintenance Transport solutions Superstructure Increasing side load height To increase the load height, lift the lifting roof*: see "Lifting roof" on page 128. Full rear load height To increase the load height, fold the cross tube upwards (see "Opening the cross tube" on page 120). 167 Data

170 Loading and unloading Increasing rear load width Type Max. axle load S.CS Light 5,460 kg S.CS Universal 7,100 kg S.CS BS 7,100 kg S.PR Mega 7,100 kg S.PR Universal 7,100 kg Maximum approved forklift axle load To increase the load width, turn the sideposts outwards, see "Corner sideposts turning to the outside*" on page 117. Safe floor load Breakage hazard! The floor of the semitrailer may break if it is overloaded. Do not exceed the maximum approved forklift axle load. Do not exceed the maximum approved load exerted by heavy single loads. Forklift axle load Note the maximum approved axle load of forklifts when driving on the floor of the semitrailer: Load bed Line load When loading heavy single loads observe the maximum approved line load of the load bed. Maximum approved line load: 2,000 kg per linear metre. Type S.CS Paper S.CS Coil Max. axle load 9,000 kg 5,460 kg 168

171 Load securing gear Legal requirements Be very careful with load safety. Take sufficient time to make sure that your load is loaded and secured safely for operation in traffic. Correctly secured loads prevent personal injury, property damage to the load, property damage to vehicles and the environment, and ensure security when checked by government inspectors and police. Load safety is a legal requirement. Detailed information on securing loads can be found in the German engineering association guidelines pp ff. For practical information on securing loads see the brochures issued by the professional association for vehicle operators. Factory-installed equipment You are responsible for securing loads properly and safely with appropriate equipment such as tension straps, antislip mats, locking rods etc. depending on the type of load. The factory-installed lashing points for securing loads will help you with this (see "Load securing gear" on page 142). Load securing certificate Schmitz Cargobull semitrailers are available with a load safety certificate for specific transport applications. If the conditions listed there are met, the factoryinstalled equipment for securing loads is sufficient. Additional action for securing loads are not required in such cases. Load securing certificates are available for the following types of transport: beverage transport, "Load securing gear in accordance with EN XL" on page 157. For information on securing loads flexibly see "Flexible load securing gear*" on page 171. Overwidth loads Never transport overwidth loads without apermit. Secure the parts of the load that extend over the front and back of the vehicle. Mark the parts of the load that extend over the sides so they can be clearly seen by other road users, even when it is dark. Keywords Safety Chassis Driving Superstructure Transport solutions Maintenance Operation 169 Data

172 Load securing gear Basic physical information While the semitrailer is being driven forces from acceleration and braking and also changes in direction all act on the load. These forces will affect the load as follows unless it is sufficiently secured, slippage, tipping, rolling and movement. You can calculate the forces for the individual directions of movement against which you must secure the load with the aid of the "maximum mass forces" specified in the VDI 2700 and EN standards. The load weight multiplied by the preceding number in the diagram will give the mass force with which the load can move: For example, in the forward direction with a 10 t load component this is 0.8 x 10 t = 8 t. Mass forces Note that the values in the diagram apply for road traffic. The values for intermodal transport, ferry travel etc. may vary. The securing forces actually required depend on the friction between the load and the vehicle floor and also the dimensions (ratio of width to height) and the stability of the load. Maximum mass forces in road traffic in the individual directions of movement in standard driving F g Weight of load 170

173 Flexible load securing gear* The flexible load securing gear* is used for securing loads on pallets to prevent them falling over or sliding to the rear or forward by placing cross beams. ACCIDENT HAZARD! If the load has fallen it may fall out when the body is opened and cause personal injury. Secure the last row of the load from the rear with two cross beams. Always secure the load at the front with three cross beams. Secure the load at the bottom and the top rigging board position. Strength data For strength data of the load securing gear see the separate load securing certificate. Always secure the load with flexible load securing gear* when the vehicle is partly loaded, if there is more than 15 cm of space between the load and the front wall or other parts of the load, if there is more than 15 cm of space between the load and the rear door or other parts of the load. Flexible load securing gear* is only required with a full load if there is a space greater than 15 cm between the last row of the load and the rear door. The system "flexible load securing gear*" consists of: two steel securing sideposts, a cross beam. Three cross beams are required for securing the load at the front and two at the rear. Example: Always secure the load at the front with three cross beams (differently distributed). Example: Load securing at rear with two cross beams Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 171 Data

174 Load securing gear Using the cross beam Property damage The superstructure can be damaged by excessive load. With partial load: Place continuous aluminium rigging boards at the same height as the securing rigging boards forward to the front wall and to the rear to the rear door. Example: Always secure the load at the front with three cross beams (evenly distributed). 1 Securing rigging board 2 Cross beam Position securing rigging boards (1) in the pockets of the sideposts horizontally and at the same height on left and right. Position cross beam (2) in the securing rigging boards (1) as close as possible to the load. Continuous support over the complete superstructure length at the height of the securing rigging boards 1 Securing rigging board 3 Aluminium rigging board 172

175 Tensioning when travelling empty Tensioning superstructure Frequent travel over poor roads will cause the superstructure to wear faster. If you tension the sideposts when travelling without load the superstructure will be stabilised and protected against damage. Tighten the tension strap. The superstructure is tight and stabilised. Operation Keywords Safety Superstructure Transport solutions Driving Chassis Tensioning sideposts 1 Sidepost 2 Eyelet 3 Tension strap Maintenance Place a tension strap (3) in every sidepost (1) in the eyelet (2) provided. Attaching to lashing rings or lashing holes* Attach the other end of the tension strap to an anchor (fastener holes*) on the floor on the other side of the superstructure. 173 Data

176 Attached forklift Attached forklift Lifting forklift Forklift in driving position For information on operating the forklift holder see "Forklift rack*" on page 61. Remove bumper. Unlock both forklift supports and pull out 5 cm. Drive the forklift with the forks into the pockets. Lift the forklift above the forklift supports with the vehicle hydraulics. FATALITY HAZARD! The raised forklift may fall on persons kneeling under it. Do not go underneath the raised forklift. Unlock the forklift supports before driving the forklift into place. Use a rod to pull the forklift supports out. Pull forklift supports out with a rod. Lower the attached forklift on the forklift supports. 174

177 Safety Keywords 1. Drive into the forklift holder 3. Pull out forklift supports Chassis Superstructure Driving 2. Lift with vehicle hydraulics 4. Lower forklift on to supports Connect electrical cable. Check that forklift lights operate. Lowering attached forklift Follow the above procedure in reverse order to remove the forklift. Disconnect electrical cable before driving the forklift out of the forklift holder. Install bumper. Only if you will be driving the semi-trailer truck without the forklift. Transport solutions Operation Maintenance 175 Data

178 176

179 Maintenance, care Requirements 178 Service schedules 179 Services 182 Wheels and tyres 195 Electrical system 197 Care of the commercial vehicle 203 Chassis Safety Keywords Maintenance Operation Transport solutions Superstructure Driving 177 Data

180 Requirements Requirements Operate the semitrailer only in perfect condition and with due regard to safety and hazards. This requires the semitrailer to be serviced and repaired as specified. Have any changes that occur with the semitrailer corrected immediately by a qualified workshop. This is particularly important with changes that affect the safety of persons and property. The semitrailer with all its components must be serviced regularly and repaired when necessary to ensure safe and economical operation. If inspections, services and repairs are not carried out at the correct time components may fail and cause accidents. Carry out functional inspections and services at the specified intervals and follow the directions. Note the intervals and instructions for inspection and service of OEM parts, such as axles, king-pins, landing legs. Safety inspection Have all inspections and services done at the specified intervals. National legislation regulates the inspection intervals for safety-relevant components of the semitrailer. If there is no relevant legislation, you are responsible for ensuring that the semitrailer is inspected at least once a year by a government accredited expert for operational and traffic safety. Technical qualifications Have services and repairs carried out by qualified specialist workshops only, who have all the tools and knowledge required to carry out this type of work. Schmitz Cargobull recommends the Schmitz Cargobull service centres for this work. Appropriately qualified technicians are required for maintenance and repairs to the semitrailer. Maintenance and repairs done by insufficiently qualified persons involves unforeseeable risks with negative consequences for people, the semitrailer and the environment. Maintenance and repair of the chassis requires training as a motor vehicle mechanic and experience in maintaining and repairing commercial vehicles, trailers and superstructures. Maintenance and repair of the electrical components of the superstructure requires training as a motor vehicle electrical technician. Maintenance and repair of the brakes requires training as a brake technician. Service and maintenance guide Documentation Register services in the service and maintenance guide. 178

181 Service schedules One-time services Keywords Have the following service items carried out once after delivery of the semitrailer. Service item after 50 km after 2,000 km after 5,000 km after 6 months Information on page Safety Wheel nuts: tighten 1 Brake system: adjust all brakes Chassis Driving 1 This applies for every wheel change Superstructure Maintenance Operation Transport solutions Threaded connections of control arms, shock absorber fastenings and axle connections: visual inspection 191 King-pin: lubricate 186 King-pin: check bolts for tightness Data

182 Service schedules Services Have the following service items carried out at the specified intervals. Service item every 5,000 km or two weeks every 10,000 km or every month Daily checks Carry out the required checks daily as listed in "Departure inspection" on page 18. every 30,000 km or every 3 months every 60,000 km or every 6 months every 120,000 km or every 12 months Information on page Axle and wheel brakes: check state and wear Wheel nuts: check tightness. Note the torque. Follow directions of axle and brake manufacturer. 195 King-pin: lubricate 186 Lighting system: check components for damage Tyres: check pressure 195 Compressed air system: check for leaks, drain compressed air reservoir Shock absorbers: visual check for oil leakage Hydraulic lifting roof*: Check oil level King-pin: check bolts for tightness King-pin: check for wear 186 Skid plate: check that knurled pin is tight Line filter in compressed air system: clean Guide links and rollers of sideposts, tarpaulin and sliding roof: clean 180

183 Service item every 5,000 km or two weeks every 10,000 km or every month every 30,000 km or every 3 months every 60,000 km or every 6 months Keywords Front landing leg: lubricate and check that it is properly fastened Safety Rear landing leg*: lubricate and check that it is properly fastened Legally required safety inspection Chassis Renewal of load safety certificate All mounted parts: check bolts for tightness 182 Driving Threaded connections of control arms, shock absorber fastenings and axle connections: visual inspection 191 Superstructure Maintenance Operation Transport solutions every 120,000 km or every 12 months Information on page 181 Data

184 Services Services Load safety certificate* Load securing certificate Check the following items on semitrailers with load safety certificate annually. Check that all equipment is present and in good technical condition. The equipment features of the transport solutions are described in section "Equipment features" (Paper transport page 148, Coil transport page 154). Carry out services as specified below. Front corner sidepost bolts (outside) Threaded fasteners Check that all threaded fasteners and rivet are tight. If necessary, tighten or replace bolts and rivets. Rear corner sidepost bolts (outside) Bolts and rivet on the front wall 1 Bolt 2 Rivet Door lock bolts 182

185 Front wall Transport solutions Keywords Chassis Driving Safety Front corner sidepost bolts (inside) Front wall sections Rear corner sidepost bolts (inside) Check that front wall sections are sealed. The material of the front wall corner section must not be overstretched. Replace if necessary. Sliding tarpaulin Superstructure Sidepost reinforcements Sliding tarpaulins Check sliding tarpaulin for tears. Repair if necessary. Check that the tarpaulin tension rods are properly seated in the sideposts. Check tarpaulin welting for tears. Replace if necessary. Operation Maintenance 183 Data

186 Services Tarpaulin locking gearbox Check straps for cracks. Replace straps if cracked. Open and close tarpaulin tighteners. The tarpaulin tighteners must close reliably and remain closed. Replace tarpaulin tightener if necessary. Visual inspection of flat hooks. The flat hooks must not be extended. Replace straps if necessary. Tarpaulin roller Tarpaulin locking gearbox Check that tarpaulin locking gearbox functions properly. The crankshaft must turn smoothly and must not be misaligned. The square pin for the tarpaulin tension rod must not be worn. The shaft of the square pin must not be misaligned. Replace if necessary. Tarpaulin tightener Tarpaulin tightener Check that the tarpaulin tightener rivets are tight. Replace rivet if necessary. Check for holes becoming longitudinal in the tarpaulin tighteners and tarpaulin and tarpaulin rivet areas. Longitudinal holes are not permitted; the tarpaulin tighteners may be torn off. 184 Tarpaulin roller riveted or sewn Check riveted tarpaulin rollers Check that rollers are tight, run easily and have an undamaged surface. Replace if necessary. Check that the tarpaulin roller rivets are tight. Replace rivet if necessary. Check for holes becoming longitudinal in the roller and tarpaulin rivet areas. Longitudinal holes are not permitted; the tarpaulin roller may be torn off. Check sewn tarpaulin rollers Visual inspection of seams. Seams must not be torn or have gaps. Repair if necessary.

187 Door hinges Sidepost pockets Keywords Chassis Transport solutions Driving Safety Rear door hinges Visual inspection of hinges: The hinges must not be broken or stretched and all hinge rods must be present. Replace hinges if necessary. Sidepost pockets Check bolted connections on all sidepost pockets and the supporting members. The bolts must not be loose or missing. If necessary, tighten or replace bolts. Pallet stop strips Superstructure Sidepost locks Straight pallet stop strip Operation Sidepost locks Maintenance Check all sidepost locks for function. The lock must move easily and close reliably. 185 Data

188 Services Check that pallet stop strips are properly fastened and in good condition. The strips must be tightly connected to the superstructure over their entire length. They must not be bent or detached. Repair if necessary. Lifting roof hydraulic pump Oil level of hydraulic pump Check oil level Make sure that a height-adjustable superstructure is in its bottom position of 2900/2950 mm when checking the oil level. Care of the hydraulic pump Wipe the hydraulic pump with a damp cloth. Do not use a pressure washer or steam cleaner to clean the hydraulic pump. Do not use chemical cleaning agents. Skid plate Frequent oil adding If you have to add oil: find the reason for the oil loss and have it repaired. Pneumatic hydraulic pump 1 Bleed screw Check and add oil when the lifting roof is closed: Open bleed screw. The oil level must reach the MAX mark. If the oil level does not reach the MAX mark: add oil. Approved hydraulic oil, see "Hydraulic oil" on page 211. Close bleed screw. The oil level must not be below the MIN mark with the lifting roof open at both sides. Otherwise add oil with lifting roof closed. Knurled pins on skid plate 1 Knurled pins Check that all knurled pins are tight Note the torque: knurled pins on skid plate on chassis: 280 Nm. King-pin King-pin Contact the manufacturer or a qualified workshop if you have any questions or doubts about the king-pin. Follow the manufacturer's directions for service and replacement. 186

189 ACCIDENT HAZARD! The use of a king-pin under the limit diameter (wear limit) can cause the semitrailer to become uncoupled while driving. Check the diameter regularly and have a worn king-pin replaced when required. Wear limits of king-pin Keywords Safety Service instructions Replace the king-pin when worn and when corrugations are detectable. Note the limit dimensions in the table on page 187. The type of king-pin specified in the operating permit and installed when the vehicle was first registered must be used as a replacement. Always replace the fastening bolts. When replacing king-pins with threaded fasteners use only approved components with an inspection stamp. Tighten the fastening bolts with a torque spanner and check the torque regularly. Note the specified torques on page 209. Follow the installation directions of the manufacturer. Lubricate the king-pin at the intervals specified in the service tables. Regular lubrication is the most important factor for long life of the king-pin and fifth wheel. For recommended lubricants see page 211. King-pin dimensions King-pin Size: 50 (2") 90 (3.5") A New 73 mm 114 mm Wear limit 71 mm 112 mm B New 50.8mm 89mm Wear limit 49 mm 86 mm C Minimum 82.5 mm 72 mm Maximum 84 mm 74 mm New and wear dimensions of king-pin Compressed air system Check all coupling heads, valves and lines for seals and air leaks. Seal leaks. Drain compressed air reservoir. Landing legs Maintenance Follow the directions of the landing leg manufacturer. Chassis Driving Superstructure Transport solutions Operation Maintenance 187 Data

190 Services Shock absorbers Follow the instructions below for inspecting the shock absorbers: Check the shock absorbers in dry weather, not during rain. Have leaking shock absorbers replaced. Leaking shock absorber no longer function correctly and driving characteristics will deteriorate. Tyre wear may also increase. You can assess the wear of the rubber sockets by rotating the shock absorber. Have the shock absorbers replaced if the rubber sockets are worn. The shock absorber is leaking. Moisture from leaking oil is visible: replace shock absorber Oil will drip out if the shock absorber leaks. In case of doubt wipe the shock absorber clean. Drive the semitrailer for two days and check again. Oil spray makes the shock absorber dirty, but shock absorbers do not absorb moisture and remain dry: Not a fault! Visually inspect the shock absorbers: The shock absorber can "sweat slightly" and this is actually desirable for lubrication. The shock absorber is leaking copiously. Moisture from leaking oil is visible: replace shock absorber Brake pad wear check Wear check Always check both sides of an axle. 188

191 Transport solutions Chassis Driving Superstructure Operation Maintenance Safety Keywords New 1 Brake calliper marker 2 Brake calliper mounting bracket marker The thickness of the brake pad can be checked with the wheels installed by the position of the brake calliper mark (1) compared to the fixed mark (2) on the brake calliper mounting bracket. The new status of the brake pads is shown in Figure A. The brake pads and brake discs must also be checked with the wheels installed If the status shown in Figure B is reached, the wheels must be removed to check the brake pad thickness and the brake disc. 189 Data

192 Services Brake pad wear indicator Depending on the installed system, the ABS warning light in the tractor will flash to indicate that the wear limit of 2 mm has been reached when the ignition is on and when stopped. Depending on the system the ABS warning light flashes 4 times, pauses briefly and flashed 4 times again or the ABS warning light flashes continuously. Operating console 1 Brake pad wear indicator The brake pad wear indicator (1) provides a convenient and safe option for detecting the wear limit of the brake pads on axles with disc brakes at an early stage. The wear indicator is on the operating console. Check whether the disc brake pads have reached the wear limit every day. The ABS warning light stops flashing as soon as you drive off. After replacing the brake pads check that all wear sensor system wires, because at least one wire is worn and must be replaced. Insert the cable for the wear indicator into the new brake pads. Then the wear indicator will revert to black after turning on the ignition. Combined with Trailer-Information-System (TIS), the brake pad wear is shown on the display near the operating console. For further information on the operation please contact the manufacturer. Brake pad wear indicator 1 View window with wear indicator The brake pad wear indicator also functions when the semitrailer is uncoupled, i.e. without power from the tractor. If you see the red wear indicator in the view window (1) of the brake pad wear indicator, at least one brake pad has reached the wear limit of 2 mm; the pads must be replaced. 190

193 Air suspension system MRH2/MRH3 The following service instructions refer to the following Schmitz Cargobull air suspension systems: MRH3, make Weweler from 2007, MRH2, make Weweler from The inspections must be carried out at the specified intervals in accordance with the relevant service instructions to ensure operating and road safety of the vehicle. A Schmitz Cargobull or Weweler customer service workshop should be used to repair faults or replace worn parts, unless the vehicle operator has sufficient qualified technicians and technical equipment in house or an official permit. Connecting rods must always be replaced in pairs. When installing spare parts we recommend using exclusively parts tested and approved by Schmitz Cargobull to ensure that the operating permit and the warranty remain valid under national and international regulations. These service instructions are only applicable for the air suspension system. Please follow the separate service requirements of the axle manufacturer. All Schmitz Cargobull air suspension systems are designed as low-maintenance systems. Therefore, all movable connections are rubber-steel sockets that do not require lubrication. Visual inspection and test Check before every trip: Apply operating pressure to air reservoirs of brake and air suspension systems. Drain condensation. Check air spring bellows for folds or damage. Check after the first two weeks, six months and then at least once a year: Check threaded connections of control arms, shock absorber fastening and axle ties for rust and signs of settling. If traces of rust or settling are found in the area of the threaded connections, this indicates internal movement in the connections. The threaded connections should be unscrewed and then retightened in accordance with the following tables (see also relevant diagram). When tightening the shock absorber threaded connection the bolts must be secured to prevent them loosening. Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 191 Data

194 Services MRH2/MRH3 threaded connections Item Threaded connections Rotation angle process Torque Pretighten to torque +10 % / 0 % Retighten to angle +10 % / 0 % Tighten Connecting rod: 1 Spring pin M27x2 250 Nm Shock absorbers: 2, 3 Shock absorber bolt M16x2 170 Nm Axle ties: 4 Spring U-bolts MRH2 M /-0 Nm Spring U-bolts MRH3 M20x /-0 Nm 5 Bolt underneath bellows M12x /-16 Nm 6 Bolt on top of bellows M8x ±3 Nm 7 Nut on top of bellows M12x /-16 Nm 8 Bellows stop bolt M /-16 Nm Axle lift: 9 Rubber buffer bolt M10 50 ±10 Nm 10 Bellows fastener bolt M10 30 ±10 Nm Torque values for MRH2/MRH3 threaded connections 1 The air suspension system must be at driving height. 192

195 Driving Superstructure Transport solutions Operation Maintenance Chassis Safety Keywords MRH2/MRH3 threaded connections A Axle lift B Torsion angle process M, X, O Connecting rod types Rubber sockets of link points The articulated connections are designed as rubber-steel sockets. The corresponding torsion angle or the corresponding tightening torque guarantees that the inner steel socket cannot rotate and the torsion movement is taken by the rubber alone. Check rubber spring bushings: Move the vehicle slightly forward and backwards with the brakes set or move the spring eye between the spring hanger and connecting rod. There must be no significant play (max. 1 mm). Replace damaged parts immediately. If the track plate (3) is bent or damaged near the clamp connection, the complete spring pin and the track plates must be replaced. The rubber socket and the spring bracket must also be checked. Check the specified torsion angle and tightening torque. 193 Data

196 Services Tracking (MRH2/MRH3) If necessary (e. g. after repairs), the axle can be tracked on all MRH2/MRH3 suspension systems. See diagram (A). The marked positions, diagram (B), item (1) and (2), must be primed, galvanised or KTL-coated only. Tracking axle A Track adjustment B Specified surfaces 1 4 surfaces, primed or galvanised on both sides only, no paint 2 on both sides, primed or galvanised inside and outside only, no paint 194

197 Wheels and tyres Checking condition The condition of the wheels and tyres is very important for the operating safety of the semitrailer. Inspect the wheels regularly for deformation, rust, cracks and breaks: Replace cracked, deformed or otherwise damaged wheels immediately. Replace wheels with cracked or deformed wheel stud seats immediately. Never weld cracked rims or wheel discs. The weld would crack after a very short time because of the dynamic stresses occurring while driving. Rust can cause stress cracks in wheels and tyre damage. Check the contact surfaces to the tyres and the hub and remove any rust. Replace the surface protection of the contact areas as necessary. Check the tyres regularly for wear, damage and foreign objects embedded in them: Replace damaged tyres immediately. Check the tyre pressure with cold tyres as specified by the manufacturer every two weeks. In general, the tyre pressure should be 9 bar for tyres of 4.5 t carrying capacity. Attaching wheels Because of settling processes the wheel nuts will loosen during the first few kilometres of driving the new semitrailer. For this reason the wheel nuts must be tightened to the specified torque after 50 km of driving (see Torque values "Wheel nuts" on page 209). The wheel nuts of the changed wheel must also be tightened to the specified torque after every wheel change. Follow the directions below when attaching tyres: Clean the contact area of the wheel on the hub before installation. Replace damaged, tight or rusted wheel nuts and wheel studs. Always use a torque spanner to tighten and retighten wheel nuts. Tighten wheel nuts in stages and crosswise. Follow the directions and torques specified by the axle manufacturer when attaching wheels. Keywords Safety Chassis Driving Superstructure Transport solutions Maintenance Operation 195 Data

198 Wheels and tyres Tyre pressure monitoring system* (TPMS) TIS TPMS sensor on each wheel The tyre pressure monitoring system continuously monitors tyre pressure on all wheels. During the semitrailer inspection tours, check the TPMS indicator. Combined with Trailer-Information-System (TIS), the exact tyre pressure values are shown on the display near the operating console (up/down valve). TPMS indicator 1 View window If a tyre pressure falls over 20 % compared to the specified tyre pressure (corresponding to 1.8 bar with a specified tyre pressure of 9 bar), a red mark is displayed in the view window (1). In this case, check tyre pressure on all wheels and adjust it. 196

199 Electrical system Rear lights Keywords Chassis Safety Rear light assignment (shown: right tail light) A Flashing light (yellow globe) B Brake light C Tail fog light D Reversing light E Reflector G Tail light LED H Tail light Connection Function / light Item 1/4 green Indicator / 21 W A 6 red Brake light / 21 W B 2 blue Tail fog light / 21 W C 8 grey Reversing light / 21 W D 4 brown Rear light / LED, 1 W G 7 black Rear light / 21 W H 3 white GND not shown Driving Superstructure Transport solutions Operation Maintenance The rear lights are connected by a 7-pin ASS2 connection. 24 volt power supply. 197 Data

200 Electrical system Light system circuit diagram FG

201 Socket assignment charts Pin Colour Consumers on 15-pin outlet (ISO 12098) 1 Yellow Left indicator 2 Green Right indicator 3 Blue Tail fog light Keywords Safety 4 White GND 5 Black Left tail light 6 Brown Right tail light Chassis 7 Red Brake light 8 Grey Reversing light 9 Brown/Blue Permanent positive 10 Brown/Red Optional interior lighting 11 Yellow/Black Free 12 Pink Optional steering axle 13 White/Black Free 14 Violet Optional axle lift / starting aid 15 Orange Free 15-pin socket (ISO 12098) 15-pin socket (ISO 12098) Driving Superstructure Transport solutions Maintenance Operation 199 Data

202 Electrical system Pin Colour Consumers on 7-pin outlet (ISO 1185) 1 White GND 2 Black Left tail light 3 Yellow Left indicator 4 Red Brake light 5 Green Right indicator 6 Brown Right tail light 7 Yellow/Black Free 7-pin socket (ISO 1185) 7-pin socket (ISO 1185) 200

203 Pin Colour Consumers on 7-pin outlet (ISO 3731) Keywords 1 White/Black GND 2 Violet Optional axle lift / starting aid 3 Grey Reversing lights 4 Brown/Blue Permanent positive 5 Orange Free 6 Pink Optional steering axle 7 Blue Tail fog light 7-pin socket (ISO 3731) Maintenance Safety Chassis Driving Transport solutions Operation Superstructure 7-pin socket (ISO 3731) 201 Data

204 Electrical system Tail lift batteries EXPLOSION HAZARD! Gases emitted by batteries may explode. Switch off the tractor engine while servicing batteries. Do not smoke, use open flames or cause sparks near batteries. Tail lift batteries The tail lift batteries have a rated voltage of 24 Volt (2 x 12 Volt connected in series). The capacity is impressed on the housing. Note the capacity when replacing the batteries. The capacity must be compatible to the generator output of the tractor. Check the acid level in the batteries by the acid level indicators. Add distilled water as required to the maximum level indicator. ACID HAZARD! Battery acid causes burns to hands and eyes. Wear safety gloves and safety glasses when working on batteries. Clean battery acid immediately with clean water. 202

205 Care of the commercial vehicle General The standard hot-galvanised surfaces of the chassis on Schmitz Cargobull semitrailers offer good protection against mechanical operating stresses and rust. The semitrailer is subject to many external influences during operation. Special care is therefore required to maintain the value of the semitrailer. Patches White patches on the hot-galvanised surface of new vehicles during winter are normal and do not affect the quality and longevity of the surface. You can remove these patches as described below: Surface damage! Surface damage caused by incorrect cleaning. Wash the hot-galvanised surface during the first three months with a cold-water spray only under 50 C. Do not use any additives. Clean chassis thoroughly with clean water. Use a pressure washer for better cleaning. Allow chassis to dry. The hot-galvanised surface can be cleaned with special cleaning agents after the first three months. Schmitz Cargobull recommends ph-neutral cleaning agents. POISON HAZARD! Cleaning agents can be poisonous and may cause injury on skin contact or when ingested. Follow the directions for use of the cleaning agent. Keep cleaning agents closed and out of reach of children at all times. Never use drink containers for storing cleaning agents. During the first 3 months Surface damage! Newly painted surfaces are not yet fully hardened and may be damaged if pressure washers are used too early. Wash painted surfaces with cold water spray only without additives during the first three months. Do not use pressure washers or steam cleaners or hard brushes. Spray the painted surfaces with water when you have the vehicle washed in truck washes with rotating brushes. Keywords Safety Chassis Driving Superstructure Transport solutions Operation Maintenance 203 Data

206 Care of the commercial vehicle After 3 months Paint damage Paint damage caused by incorrect cleaning. Wash painted surfaces with water at temperatures below 60 C only. Do not use aggressive cleaning agents; use standard commercial products labelled "ph-neutral". Keep the cleaning nozzle at the specified distance when using a pressure washer or steam cleaner. When using a pressure washer note the following points: Distance between round jet nozzle and the surface to be cleaned: minimum 70 cm. Distance between flat spray nozzle or rotating nozzle and the surface to be cleaned: minimum 30 cm. Do not direct the water spray on electrical components, plug connectors, seals or hoses. Care of the vehicle surface Painted surfaces can be cleaned and cared for with suitable paint care agents, paint cleaners, tar removers, paint preservation agents etc. Do not use these products under direct sunlight. Damage to small areas of paint can be temporarily repaired with the appropriate shade of spray paint. POISON HAZARD! Cleaning agents can be poisonous and may cause injury on skin contact or when ingested. Always follow the directions for use. Keep cleaning agents closed and out of reach of children at all times. Do not store disinfectants and cleaning agents in drink containers. Environmental protection Dispose of empty containers properly. Damage to the hot-galvanised surface is not serious when less than 2 mm wide. Larger damaged areas up to 5 cm 2 can be repaired with suitable zinc-dust paint. If a transport container is accidentally damaged during transport of aggressive substances and some of the load escapes, the contaminated areas of the vehicle must be rinsed immediately with a large amount of water. If all of these directions are followed the paintwork and hot-galvanised surfaces of the vehicle can be prevented from losing value prematurely. 204

207 Specifications Dimensions 206 Safe floor load 208 Torque values 209 Grease and oil 211 Warning sticker overview 212 Safety Keywords Maintenance Operation Transport solutions Superstructure Driving Chassis 205 Data

208 Dimensions Dimensions Dimensions S.CS / S.CS BS S.CS 24/L or E (BS) S.CS 24/L L S.CS 24/L MB Varios (BS) Chassis model E (Euro) L (Light) M (Mega) Chassis front G 125 mm 150 mm 90 mm Track/spring 2,040/1,300 mm 2,040/1,300 mm 2,040/1,300 mm centre Overall vehicle A 13,720 mm or 13,720 mm 13,720 mm length 13,830 mm Overall vehicle C 2,550 mm 2,550 mm 2,550 mm width Width between D 2,480 mm 2,480 mm 2,480 mm rigging boards Rear door width in interior (except for beverage equipment) D 2,480 mm 2,480 mm 2,480 mm Superstructure length in interior B 13,620 or 13,730 mm 13,620 mm 13,620 mm Side load length I 13,090 mm 13,090 mm 13,090 mm Side board M height Interior superstructure height E 2,780 mm 2,780 mm front 2,750/3,050 mm rear 2,900/3,050 mm 206

209 Side load height F 2,700 mm 2,700 mm front 2,600/2,900 mm rear 2,750/2,900 mm Rear load height 1 E 2,740 mm 2,740 mm 2,695 mm Fifth wheel L 1,050 mm 1,050 mm 925-1,150 mm height loaded 2 Rear load height K 1,178 mm 1,200 mm 990 mm loaded Overall loaded height approx. H 4,000 mm 4,000 mm 4,000 mm 1 2 S.CS / S.CS BS S.CS 24/L or E (BS) S.CS 24/L L Load height = interior height, when the cross tube is raised S.CS 24/L MB Varios (BS) With different fifth wheel heights different superstructure heights are possible S.PR S.PR 24/L or E S.PR 24/L MB Varios Chassis model E (Euro) M (Mega) Chassis front G 125 mm 90 mm Track/spring centre 2,040/1,300 mm 2,040/1,300 mm Overall vehicle length A 13,720 mm or 13,830 mm 13,720 mm Overall vehicle width C 2,550 mm 2,550 mm Width between rigging boards D 2,480 mm 2,480 mm Rear door opening width D 2,480 mm 2,480 mm Superstructure length in interior B mm or mm 13,620 mm Superstructure width in interior D 2,480 mm 2,480 mm Interior superstructure height E 2,790 mm 3,000 mm Superstructure height under top F 2,750 mm 2,850 mm Side board height M Fifth wheel height loaded 1 L 1,050 mm 925-1,150 mm Rear load height loaded K 1,178 mm 990 mm Overall loaded height approx. H 4,000 mm 4,000 mm Keywords Safety Chassis Driving Superstructure Transport solutions Operation 1 With different fifth wheel heights different superstructure heights are possible Maintenance 207 Data

210 Safe floor load Safe floor load Breakage hazard! The floor of the semitrailer may break if it is overloaded. Do not exceed the maximum approved forklift axle load. Do not exceed the maximum approved load exerted by heavy single loads. Line load When loading heavy single loads observe the maximum approved line load of the load bed. Maximum approved line load: 2,000 kg per linear metre. Forklift axle load Observe the maximum approved axle load of loading vehicles when driving on the semitrailer platform: Type S.CS Paper S.CS Coil S.CS Light S.CS Universal S.CS BS S.PR Mega S.PR Universal Max. axle load 9,000 kg 5,460 kg 5,460 kg 7,100 kg 7,100 kg 7,100 kg 7,100 kg Maximum approved forklift axle load Load bed 208

211 Torque values Wheel nuts Keywords Thread size Torque M22x1.5 Chassis bolts 630 Nm Safety Thread size Strength class Torque M10 x Nm M10 x Nm M10 x Nm Chassis M14 x Nm M18 x Nm King-pin Driving Thread size M14 Torque 190 Nm ±10 Nm Superstructure Maintenance Operation Transport solutions 209 Data

212 Torque values Mounted parts Bolts for Strength class Torque Large tension claw for pallet boxes Large tension claw for rigging board holder and pallet roller box M16 M Nm 90 Nm Retainer for toolbox and wing M10 40 Nm Toolbox on retainer M8 6Nm Wing on retainer M8 15 Nm SSE rigging boards M8 15 Nm Small new tension claw with flanged nut Small tension claw with hemisphere M10 M10 30 Nm 30 Nm Retainer for brake shoe M Nm Retainer for single ladder M Nm Threaded support fastener M Nm 210

213 Grease and oil Lubricants High-pressure grease with MoS 2 or graphite additive for fifth wheel king-pins and friction plates, e.g.: BP L21 M BP HTEP 1 Esso multipurpose grease M Shell Retinax AM Hydraulic oil Hydraulic oil for hydraulic lifting roof (manual hydraulic pump) e.g: Vitam GF 46 Aero Shell Fluid 4 (recommended by manufacturer) hydraulic oil for hydraulic lifting roof (pneumatic hydraulic pump) e.g: Pentosin CHF 11S Shell Arctic Tellus 32 Quantity for hydraulic lifting roof: Pump approx. 425 ml System approx ml Cleaning agents Keywords Safety Chassis Driving Superstructure Transport solutions Cleaner for painted surfaces, e.g.: Standard cleaners labelled "ph-neutral" Operation Maintenance 211 Data

214 Warning sticker overview Warning sticker overview The warning stickers on the semitrailer are part of the operating manual. Observe the stickers in the same way as the operating manual. Keep the stickers readable and replace illegible or lost stickers immediately. The various stickers can be ordered under the following part numbers. Warning sticker "EBS" part no "Turning circle" warning sign part no Warning sticker "S.PR sideposts" part no "Intermodal Transport" warning sticker part no

215 Safety Keywords Warning sticker "Load lashing rings/eyelets" part no Sticker "Folding guard" part no Chassis Superstructure Operation Maintenance Transport solutions Driving Warning sticker "Stability with uncoupled semitrailer", part no Warning sticker "Reduced rotation radius" part no Data