PLUS 11 MK 2 CAR TRANSPORTER DRIVERS MANUAL FOR THE ULTIMATE IN QUALITY AND SERVICE PLEASE CONTACT US AT:- The Old Airfield, Gosfield, Halstead, Essex C09 1SA (01787) 478490 Fax :( 01787) 476047 www.transporter-engineering.com E-mail: enquiries@transporter-engineering.com Issue : - Man/P11,02 1 Last rev: 26.08.2010
CONTENTS DECK MAXIMUM LOADS AND LOAD SECURITY..3 OPERATION AND SAFETY SIGNS...4 CARE OF BODY PAINT WORK...4 GENERAL SAFETY...4 GENERAL VEHICLE LAYOUT...5 TYRE PRESSURES AND TORGUE SETTINGS...6 MAXIMUM DECK LIFTING CAPACITIES...7 DAILY SAFETY CHECKS...8 OPERATION OF THE POWER TAKE OFF UNIT (PTO)...8 LOADING RAMPS...8 OPERATING DECKS...9 HAND RAILS...10 TRAILER SUSPENSION VALVE OPERATION...10 LOADING LIGHTS...10 COUPLING AND UNCOUPLING THE RIGID...11 UNLOADING IN THE EVENT OF A MECHANICAL FAILURE...12 VEHICLE SECURING SYSTEMS...13 VEHICLES ON THE TRANSPORTER...14 LOADING SEQUENCE DIAGRAMS...15 TYPICAL LOADING DIAGRAMS...31 SERVICE FACILITIES (Listings) SUPPLIMENT SHEET SERVICE FACILITIES (Locations) SUPPLIMENT SHEET This manual is an important document and as such should remain with the vehicle. It is a Health and Safety requirement that the driver can refer to the document to establish SWL. Before operating this transporter you must be trained in its operation and be fully conversant with the controls. Misuse could cause injury to operator and serious damage to the vehicle. Issue : - Man/P11,02 2 Last rev: 26.08.2010
DECK MAXIMUM LOADS AND LOAD SECURITY The following sets out the maximum applied load for each deck and loading angles, subject to the following criteria being established at all times. Each vehicle deck maximum imposed load limit of 2,500 kgs which must not be exceeded. The trailer top deck and the rigid top deck each have a combined maximum imposed load limit of 7,500 kgs and 5,000 kgs respectively which must not be exceeded. The trailer front scissor arm mechanism maximum imposed load limit of 2,500 kgs which must not be exceeded, although the hydraulic pressure relief system is not designed to lift an imposed load in excess of 750 kgs. All imposed loads should be uniformly distributed. All loads carried must be fully and properly secured prior to moving decks or the vehicles carried, in accordance with your company loading instructions. Never move the transporter unless every vehicle loaded on it is fully and properly secured. The above criteria apply subject to the transporter and all its equipment being properly maintained. If you are in any doubt never operate a deck or move a transporter without contacting your manager. OPERATION AND SAFETY SIGNS 1. Operation signs are located next to all controls. 2. Warning signs are a reminder to be alert to potential dangers in the area shown with a risk of injury or death. 3. Caution signs are a reminder to be alert to potential dangers in the area shown which may cause product or surrounding damage. 4. Always replace signs that have been lost or defaced. Issue : - Man/P11,02 3 Last rev: 26.08.2010
CARE OF BODY AND PAINTWORK The use of cold water at normal tap pressure is recommended for the first three months, after which steam cleaning at temperatures below 60 degrees centigrade and spraying no closer than 300 mm from the surface is permissible, with care. Any damage to the painted surfaces, eg dents, scratches, should be treated and repainted as soon as possible to prevent any further degradation of the bodywork. ALWAYS ensure lubrication points, slides etc are adequately greased after the use of high pressure or steam cleaners. Never pressure wash lifting chains. GENERAL SAFETY WARNING: These safety precautions are important. You must also refer to the chassis/cab manufacturers operating and maintenance instructions together with the Transporter recommendations. You must always abide by the laws and regulations of the country in which you operate. You must fully understand all controls for operating this vehicle before use. You must obey all warning/cautionary and safety labels on this vehicle and replace any that are missing or damaged. Carry out routine servicing as specified by Transporter and the manufacturer of the chassis/cab. Always know the height of your transporter by measuring the load before departure; adjust the height indicator accordingly. Transporter recommends four straps per vehicle: 2 forwards and 2 rearwards. Beware of overhead obstructions: bridges, trees, cables etc. Make sure all loose equipment is secured safely. Stand the vehicle on firm level ground when operating, lifting or jacking. Apply the parking brake and chock the wheels. Do not exceed the lifting capacities of the decks. It is important that the vehicle is operated within the C & U regulations and axle, GVW and GTW are not exceeded. Do not make adjustments that you do not understand. Do not move the decks whilst on the transporter. Never go under an unsupported deck. Other persons must be kept at a safe distance while the vehicle or its equipment is in operation. Check that the decks are not contaminated with oil or grease and that the straps are stored in a manner that will not interfere with the safety of personnel working on the deck. All movements on the Plus 11 MK 2 are hydraulic with the exception of the manual loading ramps. Loosen the lock and slide the ramp out fully using the strap; always lock the ramp in the out position by straddling it, keeping your back straight then lift the ramp into the locked position. It is recommended that the ramp is lifted off the lock by straddling the ramp and lifting it out of the locked position before driving on the last car. After positioning the car, slide the ramp in with the strap and lock in place. Issue : - Man/P11,02 4 Last rev: 26.08.2010
GENERAL VEHICLE LAYOUT 1 2 3 4 5 6 4 7 15 16 14 17 18 19 14 20 21 22 23 8 9 10 11 12 13 24 25 26 27 28 29 30 31 RIGID DRAWBAR 1. Over cab platform. 13. Towing eye 2. Peak ramp. 14. Drawbar lifting pillars 3. Peak ramp flap support pin. 15. Van loading bridging plate. 4. Rigid lifting pillars. 16. Top deck front sliding ramp. 5. Main top deck. 17. Top deck rear sliding ramp. 6. Top deck kick up ramp. 18. Main top deck 7. Top deck rear extension ramp. 19. Rear pillar ladder 8. Front bumper ladder. 20. Scissor ramp inner section. 9. Hand pump valve. 21. Scissor ramp outer frame. 10. PTO/hand pump control valve. 22. Front section of kickup ramp. 11. Hydraulic/air control valves. 23. Kick up ramp 12. Towing coupling. 24. Well deck ramps 25. Hydraulic/air control valves. 26. Park and Shunt valve (offside). 27. EBS diagnostics socket. 28. Bogie decking 29. Fold down step for rear ladder. 30. Rear end section. 31. Manual loading ramps and stowage. Issue : - Man/P11,02 5 Last rev: 26.08.2010
TYRE PRESSURES AND TORQUE SETTINGS 130 PS1 90 PSI Trailer tyres all 124 PSI 315/70 R22.5 315/60 R22.5 295/60 R22.5 (150/147 L Rated) TORQUE SETTINGS Wheels Torque M22x1.5 Tow Hitch Bolt Torque M20 (8.8) Tow Hitch Castellated Nut Tow Eye Bolts Torque M20 (10.9) @ 570-630 Nm (445 lb ft) @ 410 Nm (330 lb ft) @ 500 Nm (360 lb ft) @ 610 Nm (450 lb ft) Issue : - Man/P11,02 6 Last rev: 26.08.2010
MAXIMUM DECK LIFTING CAPACITIES PEAK RAMP 2500 KG KICKUP RAMP 2500 KG TOP DECK (total) 5000 KG FRONT RAMP 2500 KG SLIDING RAMP 2500 KG TOP DECK (total) 7500 KG MAXIMUM DOWN FORCE ON COUPLING 1000 KG SCISSOR RAMP FRONT USE AS LOADING AID (LIFTING CAPACITY 750 KG) SCISSOR RAMP REAR 1750 KG KICKUP FRONT RAMP 2500 KG KICK UP REAR 5000 KG The weights indicated are the maximum amounts that can be lifted by individual decks and are not a guide to the legal capacity of the transporter. Gross vehicle weights vary depending upon the axle configuration of the rigid. Five axle road trains gross train weight Six axle road trains gross train weight Trailer gross 38000KG 41000KG 22100KG Issue : - Man/P11,02 7 Last rev: 26.08.2010
DAILY SAFETY CHECKS A visual inspection should be conducted daily on the following items: 1. All routine driver checks as set out in the Guide to Maintaining Roadworthiness should be performed to the rigid unit and trailer. In addition the following items must be checked. 2. Security of the front ladder. 3. Safety hand rails are all secure and complete with no visual damage (see the hand rails section). 4. Securing straps and bollards are working correctly, with no cuts to straps or defects to bollards. 5. Make sure that all straps are stowed securely, clear of all moving parts. 6. Visually inspect the rigid coupling, connecting pipes and suzie cables for defects. ENGAGING OPERATING AND DISENGAGING THE POWER TAKE OFF (PTO) Both trailer hydraulic pipes must be coupled before attempting to perform the following procedure. A link pipe must be used if not trailer is coupled. 1. Make sure that the air is at full pressure. 2. Press the clutch pedal down keeping it disengaged. 3. Engage the PTO using the switch in the cab. 4. Slowly re-engage the clutch. 5. It may be necessary to increase the engine RPM to a maximum of 800 RPM. This will be achieved by either a hand throttle or the cruise control. 6. To disengage the PTO, press down the clutch pedal keeping it disengaged. 7. Switch off the PTO. 8. Re-engage the clutch gently. REMOVING LOADING RAMPS Always bend your knees and not your back when moving ramps. When tipping a loaded vehicle with a car in position 11, slide the ramps out to maximum and lift into locating lugs after this first car has been removed. 1. Make sure the transporter is on level ground. 2. Release the loading ramp s stowage pin. 3. Use the straps to draw out the loading ramp lifting initially. 4. Stand with a leg either side of the ramp and pull out to full extent. 5. Lift ramp onto the locating lugs. The ramps are now secure and ready for loading. REPLACING LOADING RAMPS Always bend your knees and not your back when moving ramps. It is good practice to lift the ramps off the locating lugs before driving the last car into position 11. 1. Stand with a leg either side of the loading ramp and lift it off the locating lugs. 2. Using the webbing strap to draw the ramp back to its stowed location. 3. Use the locking pin to secure the ramp in place, making sure the ramp straps are retained behind the catch. Issue : - Man/P11,02 8 Last rev: 26.08.2010
Control handles Lock release air buttons OPERATING DECKS Important! All personnel must be clear of the vehicle before operating any controls. LIFTING DECKS 1. Pull the relevant control handle towards you from its neutral position. The deck should now raise as the handle is held in this position. 2. When the deck is at the required height, return the lever to the neutral position then lower the deck onto the locking rack. The deck must be supported by the locking rack, not by the chain or hydraulic cylinders. LOWERING DECKS 1. Pull the relevant control handle towards you from its neutral position, so that the deck lifts enough to release the locking pawls on both sides. 2. Press in and hold the relevant locking release air button. 3. Push the control handle away from you whilst keeping the air button depressed, the deck should now lower. Always check the deck is lowering evenly. 4. When the deck has reached its required level, return the lever to the neutral position. 5. Release the air button to re-engage the deck locks. 6. Further lower the deck so that the pawl is supported by the locking rack. The locking rack blocks are spaced at 50mm intervals. Issue : - Man/P11,02 9 Last rev: 26.08.2010
Most decks and ramps are operated using the above method, but some slide ramps have a double pilot check valve as a locking mechanism instead of a locking pawl. Always check that the control levers return to neutral when released. HAND RAILS The transporter has been fitted with a hand rail system that meets Health and Safety regulations at time of manufacture. Any retrospective change in the legislation after the vehicle has entered service is the responsibility of the operator. The system must be maintained and defected if: Posts are missing. Posts have been damaged, distorted or corroded. Ropes are not tensioned or defective. TRAILER SUSPENSION RAISE/LOWERVALVE (Optional fitting) The suspension valve can be used to raise or lower the trailer suspension height, to aid ground clearance when loading and unloading certain vehicles. This valve must be returned to the main ride height position as shown before setting off. The vehicle may be driven with the valve in the high position to aid loading the transporter on and off ferries. LOADING LIGHTS Loading lights are a standard fitting on the Transporter car transporters. These are operated from inside the cab using the trailer coupling light switch. Extra care should be taken when working in the dark if possible position the vehicle in a well lit area. Issue : - Man/P11,02 10 Last rev: 26.08.2010
Coupling in open position Coupling in locked position UNCOUPLING THE RIGID UNIT Before carrying out the following procedure, ensure that the transporter is on firm level ground, with a suitable block to support the trailer front cross member, ideally in the centre. 1. Apply the trailer parking brake. 2. Raise the rigid suspension. 3. Put the suitable supporting block under the trailer front cross member in the centre. 4. Lower the suspension on to the supporting block, so that the towing eye is in the centre of the coupling (ie there should be a gap at the top and bottom). 5. Disconnect all suzies and hydraulic pipe connections. 6. Lift the coupling pin release lever (you may have to rock the truck to get the pin to release). 7. Carefully drive the rigid away from the drawbar slowly. 8. Caution Do not put you hand in the open coupling jaws, it may snap shut. To close the coupling, push the lever with your hand in the opening direction. The pin will locate in the locked position. RE-COUPLING THE RIGID UNIT 1. Make sure that the coupling pin release handle is in the raised position. 2. Reverse the rigid unit to the trailer checking that the coupling is central to the towing eye; if so reverse onto the eye (you may have to rock the unit backwards and forwards to fully engage). Make sure that the coupling has fully locked shut and the lock control pin is home. Apply the truck parking brake. 3. Raise the rigid unit suspension and connect all the suzies and hydraulic pipes. 4. Remove the block from under the trailer and reset the suspension of the rigid unit to its normal ride height position. Issue : - Man/P11,02 11 Last rev: 26.08.2010
5. Release the trailer parking brake. UNLOADING IN THE EVENT OF A MECHANICAL FAILURE You will require adequate air pressure to enable the locking pawl air valves to operate. Should power be lost to the PTO pump, follow the procedure listed below. 1. Switch the change over control valve (located behind the main rigid control handles) from the PTO pump to the hand pump position, turning the lever 90 degrees. (See photos above). 2. Place the supplied handle into the hand pump valve. This valve is situated next to the main rigid control levers. 3. The control handle for the deck you want to move will have to be pulled towards you and held open, whilst at the same time the hand pump is manually pumped up and down, lifting the deck so that the locking pawls can be released. 4. When the locking pawl has been released, de-press the air button whilst lowering the deck with the control handle. (This operation may be slower than usual). Issue : - Man/P11,02 12 Last rev: 26.08.2010
VEHICLE SECURING SYSTEMS The load restraint system used on the transporter can either be bollards and straps, mobile straps, or wheel chocks, or you may have a mixture of all three systems. Pulling directions must be considered when securing vehicles on the transporter, as a guideline two straps pulling in either direction (ie forwards and backwards), with chocks on each wheel should be adequate. Your company should be able to advise you on the system and number of restraints required for particular loads being carried. Bollard Swivel T hook and strap A typical wheel chock Over wheel Strap Assembly Tommy Bar Hand Ratchet Issue : - Man/P11,02 13 Last rev: 26.08.2010
CAUTION BEFORE TILTING CAB 1. Remove or hinge the front ladder forward. Failure to carry out this procedure will damage the cab. 2. You must ensure the peak ramp is DOWN to the stops before raising it over the cab platform. 3. Failure to carry out this procedure will severely damage the lifting mechanism. LOADING VEHICLES ONTO THE TRANSPORTER 1. Before loading ensure that all the decks are set in their correct position for loading, with all the straps and wheel chocks stowed safely out of the way. 2. Check that visibility is good, with frost etc cleared from vehicle windows. 3. Check that the ground clearance is adequate. 4. When the vehicle is loaded into position, apply the hand brake fully and leave the vehicle in first gear (or in park position on automatics). LOADING THE TRANSPORTER PLUS 11 Before carrying out the following procedure, make sure you have had sufficient training and are fully conversant with all the controls and operation of the transporter. You should also be wearing suitable safety equipment, eg high visibility jacket, boots and gloves. Remove all sharp objects such as rings and watches that could damage the vehicles during loading. The following pages will guide you through the method of loading the Plus 11 Transporter. (The procedure for unloading the transporter is generally as for loading it, but in reverse). Issue : - Man/P11,02 14 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Remove loading ramp stowage pins, pull out loading ramps and lift into locked position. Set trailer top deck front to align arrows and fully lower rear to loading angle. Issue : - Man/P11,02 15 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Car 1: Reverse car onto front drop ramp. Secure car to ramp, fully extend ramp and lower to desired height. Issue : - Man/P11,02 16 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Car 2: Fold over front wheel stops, drive car onto ramp up to stops. Secure car to ramp, extend and lower to desired position. Issue : - Man/P11,02 17 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Car 3: Drive car onto rear of deck, lift up wheel stop and secure. Adjust clearance between cars and raise top deck to maximum height. Issue : - Man/P11,02 18 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Adjust well deck rear to align with upper arrows on pillar and lower onto locks. Raise front of well deck scissor and front of kickup ramp to maximum, lowering ramps onto their locks. Issue : - Man/P11,02 19 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Raise over cab platform slightly, and adjust top deck to bridge between peak ramp and trailer. Car 4: Reverse car onto peak ramp. Issue : - Man/P11,02 20 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Lower over cab platform and secure car to peak ramp. Raise car to maximum height Issue : - Man/P11,02 21 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Car 5: Drive car onto top deck kickup ramp, lift slightly and secure car to ramp. Raise car 5 to maximum. Note - check clearances between car and cab. Issue : - Man/P11,02 22 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Car 6: Drive car onto top deck rear and secure. Adjust top deck kickup ramp and lock the supports. Issue : - Man/P11,02 23 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Raise top deck. Caution Check clearance between car and trailer top deck. Lower well deck rear to align with lower arrows on pillar and lower onto locks. Issue : - Man/P11,02 24 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Extend well deck extension and adjust deck scissor to align with rigid deck and lock position. Car 7: Reverse car behind cab, as close to cab as possible. Issue : - Man/P11,02 25 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE 8: Retract well deck extension and drive car on to ramp Secure car to ramp and raise the well deck rear. Issue : - Man/P11,02 26 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Car 9: Drive car onto front of kick-up ramp and secure to ramp. Over wheel hoops on rear of kickup ramp. Issue : - Man/P11,02 27 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Car 10: Reverse car onto rear of kickup ramp and secure. Lower kickup ramp front and raise kickup rear. Issue : - Man/P11,02 28 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Car 11: Drive car onto rear of trailer and secure to deck. Adjust slide ramps and deck to running positions. Store loading ramps and lock into stowage. Issue : - Man/P11,02 29 Last rev: 26.08.2010
PLUS 11 MK 2 RIGID AND DRAWBAR LOADING SEQUENCE Adjust top deck and peak ramp to running positions. Remember: Check every vehicle carried is fully secured and that the running height is known and marked in the cab accordingly. Ensure all unused chocks and straps are safely secured. Issue : - Man/P11,02 30 Last rev: 26.08.2010
SAMPLE SCHEMATICS Issue : - Man/P11,02 31 Last rev: 26.08.2010
5 FORD TRANSITS AND 3 MONDEOS 5 FORD TRANSIT CHASSIS CABS, 1 TRANSIT VAN AND 1 FOCUS SALOON 3 FORD KAS AND 9 FOCUS Issue : - Man/P11,02 32 Last rev: 26.08.2010
Issue : - Man/P11,02 33 Last rev: 26.08.2010
8 LAND ROVER (MIX) 6 FORD TRANSITS AND 1 FOCUS Issue : - Man/P11,02 34 Last rev: 26.08.2010
11 HONDA CIVICS 11 FORD MONDEOS 8 FORD RANGERS Issue : - Man/P11,02 35 Last rev: 26.08.2010
Issue : - Man/P11,02 36 Last rev: 26.08.2010
11 PEUGEOT 307S 7 VAUXHALL VIVARO VANS 11 VOLKSWAGEN PASSATS Issue : - Man/P11,02 37 Last rev: 26.08.2010
Issue : - Man/P11,02 38 Last rev: 26.08.2010
TYPICAL LOAD DIAGRAMS 12 CAR LOAD (MINIS) 11 CAR LOAD (AVENSIS) 11 CAR LOAD (COROLLAS) 11 CAR LOAD (TOYOTA MIX) Issue : - Man/P11,02 39 Last rev: 26.08.2010
9 CAR LOAD (FREELANDERS) For any assistance required, please contact Transporter on 01787 478490 Issue : - Man/P11,02 40 Last rev: 26.08.2010