STAS STAS Bs User manual

INSTRUCTIONS FOR USE

CONTENTS

AINTRODUCTION .............................................................................................................. 1

1. General................................................................................................................................................. 1

2. Safety at work...................................................................................................................................... 1

3. Observations .......................................................................................................................................1

BSAFETY REGULATIONS ................................................................................................ 2

1. Prevention of accidents and overview of warnings and safety measures ...................................2

1.1 General ................................................................................................................................................................ 2

2. Personal protective measures...........................................................................................................2

2.1. Footwear ............................................................................................................................................................. 2

2.2. Clothing ............................................................................................................................................................... 2

2.3. Gloves .................................................................................................................................................................. 2

3. Pictograms ..........................................................................................................................................2

CGENERAL DESCRIPTION OF THE TIPPER................................................................... 5

1. Chassis part ........................................................................................................................................ 5

2. Tipper part ...........................................................................................................................................5

3. Different types of tipper depending on intended use .....................................................................5

4. Tipping system....................................................................................................................................6

4.1. Description of the system.................................................................................................................................... 6

4.2. Speed and maximum load ................................................................................................................................... 7

5. Trailer identification ...........................................................................................................................7

5.1. Position of identification plate and trailer identification number....................................................................... 7

5.2. Identification plate .............................................................................................................................................. 7

5.3. Trailer identification number .............................................................................................................................. 8

DSYSTEM DESCRIPTIONS ............................................................................................... 8

1. Kingpin, fifth wheel rubbing plate and fifth wheel ..........................................................................8

2. Landing legs........................................................................................................................................9

2.1. Description .......................................................................................................................................................... 9

2.2. Operation steel type landing leg ......................................................................................................................... 9

2.3. Operation aluminium type landing leg (with one and with two supporting legs)............................................. 10

3. Brakes ................................................................................................................................................11

3.1. General .............................................................................................................................................................. 11

3.2. EBS..................................................................................................................................................................... 12

3.3. Brake connection............................................................................................................................................... 18

3.4. Prevention of premature brake wear................................................................................................................ 19

3.5. Brake synchronisation ....................................................................................................................................... 19

3.6. Brake plate ........................................................................................................................................................ 19

3.7. Drum brake........................................................................................................................................................ 20

3.8. Disc brake .......................................................................................................................................................... 20

3.9. Parking brake –spring brake cylinders.............................................................................................................. 20

3.10. Emergency brake ............................................................................................................................................... 21

4. Suspension ....................................................................................................................................... 21

4.1. General .............................................................................................................................................................. 21

4.2. Raising and lowering valve ................................................................................................................................ 22

4.3. SmartBoard........................................................................................................................................................ 23

4.4. Load indication through SmartBoard and any possibly calibration................................................................... 24

5. Wheel accessories ........................................................................................................................... 25

5.1. Tyres and rims ................................................................................................................................................... 25

5.2. Spare wheel and spare wheel carrier ................................................................................................................ 25

5.3. Wheel chock ...................................................................................................................................................... 25

5.4. Mud guards and mud flaps................................................................................................................................ 25

6. Doors ................................................................................................................................................. 26

6.1. Barn door........................................................................................................................................................... 26

6.2. Top hinged door ................................................................................................................................................ 27

6.3. Universal door ................................................................................................................................................... 28

6.4. Leakproof rear door........................................................................................................................................... 28

6.5. Hydraulic top hinged door................................................................................................................................. 30

7. Roof covering ................................................................................................................................... 32

7.1. Catwalk with ladders ......................................................................................................................................... 32

7.2. Roll-over roof sheeting system.......................................................................................................................... 33

7.3. Roof sheeting system, type “Dawnbarn” .......................................................................................................... 34

7.4. Roof sheeting system, type “Cramaro”............................................................................................................. 35

8. Tipper accessories ........................................................................................................................... 36

8.1. Towing hook ...................................................................................................................................................... 36

8.2. Grain hatch ........................................................................................................................................................ 37

8.3. Bodyguard ......................................................................................................................................................... 38

8.4. Hinged rear under-run bar ................................................................................................................................ 38

8.5. Weighing equipment ......................................................................................................................................... 40

8.6. Landing legs at the back .................................................................................................................................... 40

8.7. Fire extinguisher ................................................................................................................................................ 41

8.8. Floor heating...................................................................................................................................................... 41

9. Lighting and signalisation ............................................................................................................... 41

10. Various accessories......................................................................................................................... 42

10.1. Tool box ............................................................................................................................................................. 42

10.2. Retractable ladder for accessing load space ..................................................................................................... 42

10.3. Side guards ........................................................................................................................................................ 43

10.4. Ladder................................................................................................................................................................ 43

11. Options .............................................................................................................................................. 44

11.1. Alloy rims ........................................................................................................................................................... 44

ESPECIFIC PROCEDURES............................................................................................. 44

1. Trailer coupling and uncoupling .................................................................................................... 44

1.1. Coupling .............................................................................................................................................................44

1.2 Uncoupling .........................................................................................................................................................45

2. Trailer loading and unloading......................................................................................................... 45

2.1. General safety instructions concerning loading and unloading .........................................................................45

2.2. Loading the trailer ..............................................................................................................................................46

2.3. Unloading the trailer ..........................................................................................................................................47

2.4. Weights and tipping angles for various products...............................................................................................50

3. Venting the hydraulic cylinder........................................................................................................ 51

3.1. Hydraulic cylinder of the make HYVA.................................................................................................................51

3.2. Hydraulic cylinder of the make EDBRO ..............................................................................................................51

FPREVENTIVE MAINTENANCE ..................................................................................... 51

1. Mechanical maintenance ................................................................................................................. 51

1.1. Visual checks ......................................................................................................................................................51

1.2. Tyres ...................................................................................................................................................................51

1.3. Tightening torques for bolts...............................................................................................................................52

2. Maintenance schedule trailer bodywork........................................................................................ 52

3. Maintenance schedule tipping mechanism................................................................................... 52

4. Maintenance schedule roof sheet, type “Cramaro” ..................................................................... 53

5. Maintenance schedule hinged rear under-run bar (option)......................................................... 53

6. Lubrication points ............................................................................................................................ 53

7. Wheels............................................................................................................................................... 54

GTROUBLESHOOTING................................................................................................... 55

1. Most common causes of problems with the tipping cylinder ..................................................... 55

2. Most common causes of problem with the roof sheet, type “Cramaro” .................................... 55

3. Most common causes of problems with the “bodyguard” .......................................................... 55

4. Wabco diagnoses............................................................................................................................. 56

4.1. Through SmartBoard ..........................................................................................................................................56

4.2. Via Interface and PC with voltage supply ISO7638 ............................................................................................57

HTECHNICAL SPECIFICATIONS.................................................................................... 57

1. Trailer - mechanical ......................................................................................................................... 57

1.1. Kingpin and fifth wheel rubbing plate................................................................................................................57

1.2. Aluminium landing legs ......................................................................................................................................57

1.3. Landing legs “steel type” (at the front and at the back) ....................................................................................57

2. Tipping system ................................................................................................................................. 57

STAS nv –Flanders Fieldweg 45 –8790 WAREGEM (BELGIUM) Instructions for use, tipper trailer –Version 3.1

Tel. +32 (56) / 60 01 91 –Fax +32 (56) / 60 01 95 –e-mail : [email protected] web –- http://www.stas.be Page 1

A INTRODUCTION

1. Ge n eral

We would like to congratulate you on the purchase of your new STAS trailer.

STAS trailers have been built to serve the user for many years. If the trailer is used and maintained in

accordance with the legal provisions and professional regulations, we can guarantee you many years of

reliable operation.

We recommend you study the instructions and accompanying documentation carefully prior to using

the trailer in order to familiarise yourself with all functions of the trailer and to enable you to use it in the

best possible manner.

Your trailer has been designed in accordance with current safety standards.

We wish you every enjoyment in the use of your new trailer.

The STAS team.

An up-to-date list of STAS sales points and recognised service points can be found on our

website: www.stas.be.

2. Saf ety at work

This manual and accompanying documentation have been drawn up with the following in mind:

prevention is better than cure. We would therefore ask you to take note of the following.

You will have been made aware of the main operational and safety instructions

for your trailer at the time of delivery. Please apply them correctly.

Please study these instructions and accompanying documentation carefully

prior to including the trailer in your trailer fleet.

Please ensure the driver of this trailer is also familiar with these instructions.

3. Ob s erva tion s

Although every care has been taken during the compilation and verification of this manual, it may be

possible that, as a result of technical progress, certain components vary slightly from the illustrations in

the text. STAS nv reserves the right to apply modifications without prior notice and cannot be held liable

for any possible errors.

These instructions apply to trailers with a number of different options. It is possible that certain options

have not been fitted to your trailer, or are not available for your type of trailer.

This manual should always be kept with the trailer and the operator must be able to refer to it at any

time.

This manual was originally written in Dutch. It is therefore possible that you are in possession of a

translation. The original Dutch manual is also available on request.

Please do not throw this document on the public road.

The following information is important and should be taken into account when

referring to the manual:

The “front” is the front side of the trailer closest to the lorry.

The “back” is the rear of the trailer furthest from the lorry.

In order to determine the left and right hand side, the operator should be

looking from the rear to the front of the trailer.

STAS nv –Flanders Fieldweg 45 –8790 WAREGEM (BELGIUM) Instructions for use, tipper trailer –Version 3.1

Tel. +32 (56) / 60 01 91 –Fax +32 (56) / 60 01 95 –e-mail : [email protected] web –- http://www.stas.be Page 2

B SAFETY REGULATIONS

1. Pre vention of ac c i dent s and ove r vie w of w a rnings an d safe t y

me a sure s

1.1 G e n e r a l

As STAS nv is not aware of the conditions in which the trailer will be used, the company cannot assess

risks caused by external factors. The owner of the trailer must himself have a risk analysis carried out of

such external risks in the interests of his employees and all third parties involved. On the basis of this

risk analysis the owner of the trailer is advised to himself provide training for all users of the trailer.

It is strongly recommended that operators who are new to the trailer and tipping system learn to use it

with the trailer in an unloaded state.

Any possible information regarding regulations relating to unloading yards, safety procedures, etc.

required by drivers who are not employed by the company where the unloading is taking place should

always be obtained.

Always inform the person in charge of your arrival and your departure, and comply with the driving and

unloading procedures in the unloading yard and the general instructions on site.

Never reverse your trailer without first ensuring it is safe to do so. Ensure there is no one in the danger

zone around the trailer. If there is a signalling person present in the unloading yard, ensure that both

parties are familiar with the sign being used. Cease any movement if you can no longer see the

signalling person.

2. Per sona l pro tecti ve measu res

2 . 1 . F o o t w e a r

When operating the tipper protective footwear should be worn at all times. Footwear may include fixed,

high fitting shoes with steel toe caps and insulating soles. Slippers, loose fitting shoes, or shoes which

could endanger the operator or which do not offer sufficient protection should never been worn.

2 . 2 . C l o t h in g

Suitable clothing should ensure the operator is visible whilst carrying out his work and this will

contribute to general safety. Clothing should never be left loose and must always be done up. It should

preferably be of an eye-catching colour and be fluorescent which will also offer additional visual safety.

2 . 3 . G l o v e s

The operator of the trailer should always wear safety gloves in order to avoid injuries caused by sharp

or protruding components. Gloves may also offer protection against injuries caused by the nature and

characteristics of the load.

This manual contains some photographs in which the operator is not wearing

safety gloves. These photographs were taken deliberately that way, and only

for the clarity of the photograph.

3. Pic togr ams

Some of the pictograms listed below can be found on the trailer and/or on the following pages of this

user manual. The following is an overview of the warnings and safety measures applicable to your

trailer.

This pictogram appears on the trailer to emphasise the fact that the operator should have

studied or referred to the user manual.

This pictogram appears in various places in this manual and indicates measures which

should be observed in order to guarantee safety.

This manual should therefore be studied carefully prior to attempting to use the trailer. If

particular chapters or paragraphs are unclear, please do not hesitate to contact STAS nv!

You should also ensure that everyone who is authorised by you to use the trailer is familiar

with and understands these instructions.

The tipping mechanism satisfies the fundamental health and safety requirements as

determined in machinery directive 2006/42/EEC.

The tipping mechanism may only be used when the trailer is coupled to the lorry.

This CE marking confirms conformity with the machinery directive.

This pictogram indicates areas which could present a hazard for fingers and/or other parts

of the body. The hazardous areas themselves are indicated by shaded lines.

This pictogram indicates areas where fingers and/or other parts of the body are at risk of

being cut. The hazardous areas themselves are indicated by shaded lines.

This pictogram indicates the boundary of an area which is not accessible during normal

operation.

This pictogram indicates the outermost moving part of the trailer, and is also used to

indicate the hazardous areas where trapping of hands and/or other parts of the body could

occur.

STAS nv –Flanders Fieldweg 45 –8790 WAREGEM (BELGIUM) Instructions for use, tipper trailer –Version 3.1

Tel. +32 (56) / 60 01 91 –Fax +32 (56) / 60 01 95 –e-mail : [email protected] web –- http://www.stas.be Page 3

This pictogram indicates the presence of electrical voltage. The trailer receives 24V DC

from the towing vehicle.

Damaged electrical conductors should be replaced or repaired immediately as they could

cause short-circuiting, physical injuries or fire.

The components of the electrical system have been carefully balanced. The electrical

system for your trailer therefore conforms to the EMC directive.

This pictogram can be found near electrical connections. It serves to remind the operator

that it is not allowed to disconnect the electrical connections by pulling the cable.

This pictogram can be found near the trailer doors. It serves to remind the operator to

ensure there is no one in the immediate vicinity when the doors are opened or closed. In

this way, any trapping hazards can be avoided.

Danger of trapping also occurs if activities take place between the tipping body and

chassis. The tipping body must first be supported by a support suitable for this purpose.

This pictogram indicates that wearing gloves is strongly recommended.

This pictogram indicates that wearing safety goggles is strongly recommended.

This pictogram indicates that wearing safety boots is strongly recommended.

This pictogram indicates that wearing a safety helmet is strongly recommended.

This pictogram indicates that the person on the catwalk should protect himself by wearing a

safety harness.

This pictogram indicates the danger of falling objects when opening the roof sheet.

Make sure there are no loose parts on the catwalk. These parts can fall downwards during

tipping.

This pictogram indicates the date on which the trailer was painted. This date is important

as the trailer should not be cleaned with a high-pressure hose until 4 weeks after it was first

painted.

During cleaning:

the maximum water temperature should be no more than 65°C,

only neutral cleaning substances should be used.

This pictogram indicates a slippery surface as a result of spilt oil.

The hydraulic cylinder is moved by forcing oil into the cylinder body. When coupling or

uncoupling these systems, oil may be spilt. Spilt oil should be removed immediately as it is

harmful to the environment and can cause a slipping hazard.

This pictogram warns of the dangers of obstacles (branches, building constructions, piping,

etc.) in the working area of the tipper.

Take care when unloading in the vicinity of electrical wires and cables so these are not

touched when unloading or driving past.

High-voltage lines in the open air can already cause a voltage flashover when the tipping

body is still quite a distance from the lines! Voltage flashovers on the vehicle can cause

serious burns and electrocution!

This pictogram warns of the dangers of too high wind speeds.

The tipping body may not be tipped with wind speeds higher than 60 kph and in gusts. The

force the wind can exert on the side of the tipping body can cause the vehicle to become

unstable, with the toppling of the vehicle as a consequence!

See

Figure 3.a.

This pictogram (see Figure 3.a.) refers to safety measures to be complied with when

tipping.

The tipping body of your vehicle is a moving part. Always make sure that there is no one in

the immediate vicinity when you move the tipping body.

Make sure that no one can become trapped between the tipping body and the chassis

when lowering the tipping body.

With an automatically opening tailboard it is possible that the board starts moving

unexpectedly for a bystander. Always make sure that there is no one in the unloading zone

when you start unloading!

Also see Specific procedures –§ E2 –Trailer loading and unloading.

As manufacturers of trailers, we would like to improve lorry safety through optimum

distribution of the brake force between the lorry and the trailer.

We therefore recommend that BRAKE SYNCHRONISATION is carried out between the

first 2,000 and 10,000 km each time the lorry is changed in order to achieve the best

possible brake force distribution and pattern of wear. Please contact the lorry manufacturer

for brake synchronisation.

STAS nv –Flanders Fieldweg 45 –8790 WAREGEM (BELGIUM) Instructions for use, tipper trailer –Version 3.1

Tel. +32 (56) / 60 01 91 –Fax +32 (56) / 60 01 95 –e-mail : [email protected] web –- http://www.stas.be Page 4

Figure 3.a. –Sticker for safety instructions during tipping

Some pictograms serve as a reminder in order to guarantee correct use of the

trailer. There are pictograms containing information on:

tyre pressure,

tightening torques for wheel nuts,

the maximum hydraulic system pressure,

trailer loading and unloading instructions,

maximum total weight of tools in tool box,

tightening bolts and nuts and verification of tracking after the first trip of

300 km maximum,

identification of connections.

Carrying out maintenance work on the trailer.

STAS nv –Flanders Fieldweg 45 –8790 WAREGEM (BELGIUM) Instructions for use, tipper trailer –Version 3.1

Tel. +32 (56) / 60 01 91 –Fax +32 (56) / 60 01 95 –e-mail : [email protected] web –- http://www.stas.be Page 5

C GENERAL DESCRIPTION OF THE TIPPER

The tipper consists of:

a chassis part

a tipper part

1. Ch assis part

The chassis consists of an aluminium or an steel frame. The following parts are assembled on the

frame:

Air suspension with air bags (mechanical suspension is an option not covered in this manual).

Axles with associated braking system

Landing legs and wheel accessories

Lighting and signalisation

Reinforced construction at the front for end plate with kingpin and fifth wheel rubbing plate to

ensure the coupling with the lorry.

The trailer is mounted on 9 ton or 10 ton axles as a low maintenance concept. All

axles are fitted with a brake in accordance with the 71/320/EEC and UN/ECE-R13

regulation. The choice of brand for the axles depends on the country or the client.

The axles should always be fitted with universal wheel bolts, universal wheel nuts

and wheel hub centring.

The air suspension will be of the same manufacturer/make as the axles.

2. Ti pper par t

The tipper part consists of a

tipping body,

front cylinder (multi-stage single-acting cylinder),

rear pin hinges.

The tipping body has a certain shape depending on the intended use.

The tipping body is provided with door(s) at the back. The different possible types are described in

§ D.6 –Doors.

Roofing is provided on top of the tipping body. The different possible types are described in § D.7 –

Roof covering.

The different types of tipping body, doors and roofing can be combined with each

other.

3. Di ffer ent types of t ippe r depe nding on intended use

The tipper is designed for use as specified at the time of its purchase. Although most tippers have a

similar appearance, there may be differences depending on the intended use (e.g. in thickness of the

floor and side plates).

Always check that the tipper is suitable for the load to be transported. This

means the type of load, the density of the load (also see § E2.4 –Weights and

tipping angles for various products), and the suitability of the rear doors for

unloading the load. Also remember that the tipping angle can vary depending

on the load.

In the case of doubt do not hesitate to contact STAS nv.

Recommended use

STAS_Bs

Recommended use:

Sand and gravel tipper

Tipper for transporting asphalt (with insulated floor and/or walls).

STAS_Bx

Recommended use:

Sand and gravel tipper.

Tipper for transporting asphalt (with insulated floor and/or walls).

STAS nv –Flanders Fieldweg 45 –8790 WAREGEM (BELGIUM) Instructions for use, tipper trailer –Version 3.1

Tel. +32 (56) / 60 01 91 –Fax +32 (56) / 60 01 95 –e-mail : [email protected] web –- http://www.stas.be Page 6

Recommended use

STAS_Bv

Recommended use:

Sand and gravel tipper.

Transport of asphalt (with insulated floor)

STAS_M

Recommended use:

Freely unloading complex compound products.

Grain and powder products.

STAS_V

Recommended use:

Freely unloading complex compound products.

Grain and powder products

Pallets (not tipped goods)

4. Ti ppin g s yste m

4 . 1 . D e s c r i pt i o n o f t h e s y s t e m

The tipping body of your trailer together with the front cylinder and the rear pin

hinges make up a machine.

The tipping construction is designed according to the prevailing rules of the

machinery directive, directive 89/392/EEC, amended by directives 91/368/EEC,

93/44/EEC and 93/68/EEC and 98/37/EEC and 2006/42/EEC of the Council;

The single-acting cylinder mounted at the front ensures the raising and lowering of the tipping body.

Control of the cylinder is done by the hydraulic system that is assembled on the towing vehicle or a

hydraulic set mounted on the trailer.

A single-line system is used as standard. Here there is one pipe between the hydraulic set (on lorry or

on trailer) and the single-acting cylinder. With a single-line system between the lorry and trailer the

hydraulic set on the lorry must be protected against overpressure. With a single-line system between a

separate hydraulic set on a trailer and single-acting cylinder there is overpressure protection in the

hydraulic set.

With a two-line system there is a separate pressure and return oil pipe. A pressure relief valve is fitted

on the trailer that is connected to the return pipe. The pressure relief valve protects the cylinder from

overpressure.

Two standard makes of hydraulic cylinders are used: HYVA (with max. pressure 170bar) and Edbro

(with a max. pressure of 150 bar).

The pressure of the hydraulic pump that operates the cylinder must be adapted to the maximum

permitted cylinder pressure. This maximum permitted pressure is mentioned on the type plate of the

cylinder and also on a separate pictogram near the hydraulic connections to the cylinder.

Figure 4.1.a. –Cylinder type plate + maximum cylinder pressure pictogram

STAS nv –Flanders Fieldweg 45 –8790 WAREGEM (BELGIUM) Instructions for use, tipper trailer –Version 3.1

Tel. +32 (56) / 60 01 91 –Fax +32 (56) / 60 01 95 –e-mail : [email protected] web –- http://www.stas.be Page 7

4 . 2 . S p e e d a n d m a x i m u m l o a d

The time required to tip is determined by the speed of the cylinder. The speed depends on the oil flow

to the cylinder (with tipping) and the oil flow from the cylinder to the reservoir (with lowering).

The hydraulic pump determines both the oil flow and the maximum oil pressure, and therefore both the

tipping time and the maximum permissible load.

To tip faster the oil flow must be increased. The oil pressure has no influence

on the time needed for tipping.

The system pressure is determined by the weight of the load, and not by the

position of the pressure relief valve or the pump.

5. Tr a iler iden tifi cation

5 . 1 . P o s i t i on o f i d e n t i f i c a t i o n p l a t e a n d t r a i l e r i d e nt i f i c a t io n n u m b e r

For trailers with symmetrically assembled axles (see Fout! Verwijzingsbron niet gevonden.), for

semi-trailers with not symmetrically assembled axles (see Figure 5.1.b):

A: The identification plate is fixed either to the right in the vicinity of the vehicle identification number or

on the first beam of the chassis on the right-hand side.

B: The trailer identification number is stamped in the chassis to the right at the bottom

Figure 5.1.a. –Position identification information with symmetrically assembled axles

Figure 5.1.b. –Position identification information trailers with not symmetrically assembled axles

5 . 2 . I d e n t if i c a t i o n p l a t e

The identification plate is laid out according to European regulation 76/114/EEC.

Figure 5.2.a. –Identification plate

The plate mentions (see Figure 5.2.a.):

Manufacturer's name (1).

EEC authorisation number (2).

Trailer identification number (3).

Legally permissible maximum load of the trailer (4a).

Technically permissible maximum load of the trailer (4b).

Legally permissible maximum load for each of the axles (from front to back) (5a).

Technically permissible maximum load for each of the axles (from front to back) (5b).

Legally permissible maximum load on the fifth wheel (6a).

Technically permissible maximum load on the fifth wheel (6b).

Number national type approval (7).

Trailer type (8).

Variant of trailer (9a).

Version of trailer (9b)

Year of manufacture (10).

Brake schedule reference (11).

Reference number (internal order number) (12)

Product type (13)

The RT value (only applicable for certain export markets).

Swing radius (KS).

Length (L) of trailer.

Width (W) of trailer.

a.min and a.max: the minimum and maximum distance between the front of the towing vehicle

and the coupling device.

b.min and b.max: the minimum and maximum distance between the coupling device and the

rear of the trailer.

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