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DESCRIPTION,

TECHNICAL SPECIFICATION,

OPERATION, AND MAINTENANCE MANUAL

FOR THE ISU-SYSTEM

INNOVATIVER SATTELANHÄNGER UMSCHLAG

INNOVATIVE SEMITRAILER HANDLING UNIT

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DESCRIPTION,

TECHNICAL SPECIFICATION,

OPERATION, AND MAINTENANCE MANUAL

FOR THE

ISU-SYSTEM

INNOVATIVER SATTELANHÄNGER UMSCHLAG

INNOVATIVE SEMITRAILER HANDLING UNIT

Using normal mobile or gantry cranes at cargo

terminals without any special facilities for trailers

to place on pocket wagon types:

6-axis double pocket wagon type TWIN

6-axis double pocket wagon type T3000

4-axis pocket wagon type T5 Contents

Description and Equipment………………………………………………… Page 5-17

Isu system elements single weights and loads ..……… ……………… Page 17

Loading condition ………………………………..…………………………. Page 1 8

Operation and maintenance …………………………………..…………... P age 19-25

Unloading Procedure ….…………………………………………………… Page 26

Service and maintanance plan for ISU elements ………… ………….. Page 26-28

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Connecting spreaderSpreader adjusted to 20’

Lifting belts

Support Cross BeamMobile or permanent loading rampW heel Claw Components

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ISU – Innovative / intelligentTrailer-Transshipment

Loading and unloading of Trailers to common pocket wagon types

without any special means and only by using ordinar y cranes and

lifts at cargo terminals

For the transport of commonly used large size trailers in Europe through the railway

network, special wagons - so called pocket wagons are used. The pocket wagons

have recessed loading pockets to accommodate the wheels of the trailer, so that

trailers with the maximum height of 4m can be transported within the dimensional

requirements of the railway profile.

Placing and lifting of the trailer to or from the pocket wagon is done at the terminal

with existing gantry cranes or mobile cranes. The trailer needs to be fitted with a

lifting ledge at each of its long sides so that it can be fastened with the gantry or

mobile crane and lifted with a so called crane spreader.

Transhipment of trailer with cranes is problematic in general, because in Europe only

a few trailers are fitted with lifting ledges. Also only a small number

fitted with lifting ledges.

Further it is by some types of trailers technically not possible to fit the mandatory

lifting ledges for railway transport.

Fitting trailers with lifting ledges

resulting in payload losses and in

1. ISU-System

The ISU-System enables transhipment of road trailers possible with existing

cranes not requiring additional equipment and installations at terminals to the

following types of pocket wagons:

Transhipment of trailer with cranes is problematic in general, because in Europe only

a few trailers are fitted with lifting ledges. Also only a small number of

types of trailers technically not possible to fit the mandatory

lifting ledges for railway transport.

Fitting trailers with lifting ledges also makes reinforcements of the trailer

resulting in payload losses and incurs additional costs for mandatory approvals.

System enables transhipment of road trailers possible with existing

cranes not requiring additional equipment and installations at terminals to the

following types of pocket wagons:

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Transhipment of trailer with cranes is problematic in general, because in Europe only

of new trailers are

types of trailers technically not possible to fit the mandatory

reinforcements of the trailer necessary

curs additional costs for mandatory approvals.

System enables transhipment of road trailers possible with existing

cranes not requiring additional equipment and installations at terminals to the

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Type TWIN

Type T3000

Type T5

Each wagon comes in its basic version with

one support beam two wheel grippers

These components are placed into the mobile loading ramp at the access road or

terminal prior to transhipment.

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The tractor or semi-trailer placing the trailer onto the mobile loading ramp and

positioning the wheels above the wheel grippers.

For a connecting spreader with lifting belts and 20’ corner fittings is needed for

lifting and placement. This connecting spreader is mounted to the lifting gear of

the gantry or mobile crane.

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The gantry or mobile crane is positioned above the trailer, which is placed on the

loading ramp. The lifting belts at the connecting spreader are connected to the

outer ends of the support beam and the outer ends of the wheel grippers with a

towing-hook.

After that the trailer will be lifted and placed over the pocket wagon with its

kingpin on the support beam facing downwards aligned with the front boogie of

the pocket wagon.

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The trailer, aligned in parallel with the long axis of the pocket wagon, is placed on

the trailer jack and secured.

After that the lifting belts and towing hooks will be detached from the support

beam and the wheel grippers. The wheel grippers are designed to place trailers

with different wheel track width always in the centre of the pocket wagon.

The trailer axis is placed in the centre of the pocked wagon though the wheel

grippers.

Another advantage of this transhipment system is that the wheel grippers are also

used as wheel chock in the loading pocket of the pocket wagon and can fasten

different wheel sizes through an adjustable wheel claw design and also provide

protection for the kingpin in case of bumps.

Here is a description of the elements and components of the ISU Stystem:

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The Terminal equipment:

• The ISU –connecting spreader 20ft.

An ISU connecting spreader with 20ft corner fittings, which is connected to the

gentry or mobile crane, is kept at the terminal.

The connecting spreader is fitted with lifting belts and safety hooks to lift the

trailer with the support beam underneath the kingpin and at its wheel grippers.

The lifting belts are fixed with screwable lifting yokes to make them easily

detachable if required.

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The excess length of the lifting yokes stabilises the trailer in the lifting gear of the

crane.

The arrangement of the 20ft corner fittings at the connecting spreader enables

carrying the gear in a different container wagon in the same train.

• The floor ramp.

The floor ramp helps to place the trailer over the wheel grippers and the support

beams under the axis of the trailer.

The wheel claw and the support beam are embedded in the floor ramp so that

tractors with extremely low ground clearance can also use them.

The wheel grippers can be used as wheel chocks and can be adjusted to

different wheel diameters.

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The drive-on ramps at the floor ramp are fitted with common rubber parts to

prevent slipping of the drive wheels.

The floor ramp is placed on the access road close to the pocket wagon.

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The floor ramp is available in single and double version.

The single floor ramp is used from one end only by the semitrailer driving

forward or backward, while the double floor ramp can be access from both

sides.

The floor ramps are easily assembled from single tracks with cross

connections.

This enables to carry the floor ramp and the connecting spreader together

with its components inside the combi-train.

The wagon equipment:

The wagon equipment consists of the wheel grippers and the support beam,

which mounts the trailer at the same points as in the road traffic.

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The wheel gripper:

The wheel grippers are designed with hinge-like wheel flaps so that it can safely

and gently lift all common wheels.

There are mounting points for the wheel claw belts on the wheel flaps, which

connected to the lifting belts of the connecting spreader allow to claw, hold and lift

the trailer by its wheels.

Die support beam:

The support beam is connected to the connecting spreader with lifting belts and

safety hooks. Therefore the support beam has 4 lifting eyes.

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By lifting the support beam under the king-pin it will be locked automatically.

At the bottom of the support beam is another king-pin which locks automatically

when placed onto the trailer jack on the pocket wagon.

Unlocking of the king-pin at the trailer jack and the support beam happens in the

usual way by pulling the unlocking lever.

.

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For the orientation of the crane operator the position of the trailer jack and the

centre of the support beam are indicated with a red colour stripe.

ISU – system elements single weights:

Floor-ramp single 2,200t = 22000N Floor-ramp double 2,700t = 27000N Support beam with lifting belt 0,340t = 3400N 2 wheel craws with lifting belt 0,400t = 4000N Connecting spreader with lifting belt 1,300t =13000N

1. Loads

a) Single parts load

Wheel grab (Radgreifer) 15t = 150000N Support traverse (Stützbocktraverse) 21t = 210000N

b) Carrier load

Wheel grab (Radgreifer) 15t = 150000N Support traverse (Stützbocktraverse) 18t = 180000N

2. Static study

2.1. Load: Maximal mass of semitrailer 39,0 t

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L o a d i n g c o n d i t i o n

Each pocket of the wagon has two wheel grippers to lift the trailer at the axle side

and one support beam to lift the trailer at the kingpin. Further more each ISU-

Terminal needs minimum one mobile floor ramp in double version for drive-on

with the trailer from both directions and one connecting spreader with 20 feet

connection at the corner castings.

On each pocket of the pocket wagon it is possible to load a 3-axle trailer

according to the EU-regulation with following max. measurements:

Basis for loads distribution was recieved by ISU-SYSTEM. Visualisation is shown on the scheme (see below).

SAnh 39 Tonnen Gesamtgewicht total trailer weight 39 tons

KonturISO 1726

(12t)

24t (27t)

1310 - 13401310 - 1340

ø880 - 1100

7600 - 8000

Max.15 Tonnen90

0-11

00

max.13716 (45 feet)

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Mandrel adapter head for trailer pocket wagons type T3000/T5 and Twin:

Centre brackets are fitted near the wheel grippers for positioning and fixing the

trailer onto the pocket wagons.

Different sizes of mandrel heads at the wheel grippers ensure the trailers exact

positioning in the middle of the base pan.

The pocket wagons T3000 and T5 are fitted with mandrel heads of 38mm

thickness and the Twin Pocket wagons are fitted will mandrel heads of 28 mm

thickness.

Please see drawing no. ISU 3023 for the Twin Pocket wagon and drawing no. ISU

3017 for pocket wagon type T3000 and T5.

Transport of trailer with air suspension:

After the trailer is placed on the pocket wagon and made ready for transport

the air suspension must be empty. According to UIC 596-6 article 7.

TWIN T3000 / T5

Transport of trailer with air brake system:

After connecting the belts to the equipment and before the lifting of the trailer the

air brake has to be opened.

The respective regulations and standards for a correct handling of the mobile or

gantry crane need to be observed and fulfilled.

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In the following the system is described. For the trans-shipment a gantry or mobile crane with connecting spreader and lifting belt is required.

Connecting spreader Gantry or mobile crane Lifting belt

Furthermore a floor ramp has to be used. Here in double version for drive-on from both directions.

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Then two wheel grippers and one support beam are embedded into the floor ramp for lifting the trailer. Support Beam

Wheel gripper The trailer is placed on the floor ramp with its wheels on top of the wheel grippers and the king-pin over the support beam.

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The standard spreader with the connecting spreader is placed above the trailer by the wheel grippers and the support beam. The lifting belts of the connecting spreader are attached to the wheel grippers and the support beam.

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The trailer is lifted by the wheel grippers and the support beam which locks the king-pin… …under the use of a gantry or mobile crane…

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…placed above the pocket wagon …

… and made ready for transport.

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The operators detach the lifting belts from the wheel grippers and the support beam. The support beam and the wheel grippers, which are also used as wheel chocks, remain inside the pocket wagon during transport.

The trailer cargo train is ready for transport to the destination.

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U n l o a d i n g P r o c e d u r e

To unloading the trailer from the cargo train at the arrival station, the following has to be to done: The trailer must be liftted with the standard spreader and the connecting spreader from the cargo train and placed on the floor ramp exactly in between the yellow positioning markers. The axle with the wheel grippers is placed in its position. Very important: Bevore the support beam can be put into position, the lock at the kingpin must be unlocked. Only when the wheel grippers and the support beam are in the correct and exact position, the lifting belts can be removed. The air suspension can be filled up in order to mount the trailer with the tractor.

Service and maintenance plan for ISU elements 1. General the maintenance and repair is used to ensure and restore the operational capability of the ISU elements of a maintenance section of basically the same as that for the corresponding double pocket wagons type. The ISU elements, as well as the double pocket wagons designed for a 6-year maintenance cycle at a stated useful life of 36 years. Wear parts require special maintenance. The following maintenance and service plan is based on an average mileage of the car and load pocket with the ISU elements in the operational use of 150,000 km per year. Furthermore it is assumed that 500 ISU trailer lifting's per year. Basis for the inspection and maintenance are operating railway EEO regulations, provisions of the UIC and the service and maintenance requirements of the recruiting path for the ISU system and the maintenance provisions for lifting.

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2. Maintenance and service levels in the repair and maintenance plan 3 steps be distinguished: 1. step: maintenance by visual inspection during th e first 6 years: Visual inspection of all lifting belts and fasteners for cracks. cross-beam: visual inspection of cross-beam kingpin mechanism at function. and check for ease movement and possibly worn out, damaged or lost parts. Visual inspection on the cross-beam for welding cracks. If paint damage occurs despite these precautions, it can be coloured by using commercial acrylic paint in the appropriate RAL color of the part.

wheel grippers: visual inspection of wheel grippers for welding cracks. Function of the hinge parts to function smoothly and easy to handle Replace any lost items. Grease hinge parts, if necessary. Visual inspection if the guide cones are tight. If paint damage occurs despite these precautions, it can be coloured by using commercial acrylic paint in the appropriate RAL color of the part. daughter spreader: visual inspection of the hinge parts with socket bolts for locking the attached lifting belts. If paint damage occurs despite these precautions, it can be coloured by using commercial acrylic paint in the appropriate RAL color of the part. loading ramp : visually inspect for damaged or lost parts. check all ISU components for visible deformation. If paint damage occurs despite these precautions, it can be coloured by using commercial acrylic paint in the appropriate RAL color of the part.

2. step Revision with reconditioning: The 2. step is used in the 6-year rhythm, alternating with the level 3 executed, after 6, 18 and 30 according to the maintenance of the double pocket wagon. Also work individually as described in step 1: cross-beam : visual inspection of cross-beam kingpin mechanism at function. and check for ease movement and possibly worn out, damaged or lost parts. Visual inspection on the cross-beam for welding cracks. Check and correct any ease attrition parts like the operating lever, replace if necessary; replace kingpin lock system when visible deformation is identified. Visual inspection of weldings and correction if necessary.

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wheel grippers: : Test the function of the hinge parts and check wear and tear. Grease and lock hinge parts and pins. Correct visible deformation. Replace / repair the missing parts. Visual inspection of weldings and correction if necessary. daughter spreader: visual inspection of the hinge parts with socket bolts for locking the attached lifting belts. Visual inspection of weldings and correction if necessary. loading ramp : visually inspect for damaged or lost parts. check all ISU components for visible deformation. If paint damage occurs despite these precautions, it can be coloured by using commercial acrylic paint in the appropriate RAL color of the part. 3.step Revision with full work-up : The 3rd stage is in the 6-year rhythm, alternating with the step 2 executed, after 12 and 24 years after the commissioning of the ISU elements. The work to be performed is similar to those of step 2. 3 Workshop activities : The maintenance work must only be undertaken in suitable workshops . They must have the necessary approvals of the railway supervisory authority and the operating railway. The staff must have the necessary qualifications. In the workshop, the relevant maintenance rules and documentation of the operating railway must exist. Necessary measuring and test equipment must be identified, registered and checked regularly. The workshop should be clean, well lit and heated in winter, so that high- quality results are possible. Storing spare parts and supplies, such as paints and fats must be in clean, dry rooms. For welding, the welding certification in accordance with DIN regulations must be available. The qualification of welders shall comply in accordance with EN 287-1. Compliance with the generally recognized rules for occupational health and safety are guaranteed. Hans Tandetzki Fritz Farke Geschäftsführer Geschäftsführer

ISU System GmbH

Hans Tandetzki /H.Tan 23.09.2009 1. Edition 2. Edition 24.08.2013 3. Edition 12.05.2014