EN

2016 |07

Vario Curtain Sider Roof

Assembly instructions

www.EdschaTS.com
 Contents

Operation 3 Inserting sliding pillars 36

Hook in sliding pillars 37
Installing batten pockets 38

Designated use 4 Installing battens 39

Guide rails 40
Preassemble bows 41

? General information 5
Mount bows
Preassemble end carriage
42
43
Preassemble end bow 45
Preassemble end carriage / end bow
Assembly
(for use with tarpaulin back cover) 46
Front dimensions 8 Preassemble end carriage / gantry beam (for use with doors) 47
Pre-assemble bulkhead 9 Slide up end carriage 48
Installing the bulkhead 14 End plug / stopper 49
Preparing the rear (PWP SA) 16 Rivet folding joints 50
Rear doors (PWP SA) 19 Mount safety rope 51
Guide rails 20 Safety rope – tension 52
Guide rail package 21 Build roof package 53
Installing the guide rails 33 Drill front locking hole 54
Installing pillar bases 34 Roof mounted 55

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 Operation

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≤ 75 kg / m2 ≤2.3.
75 kg≤ 75
/m kg2 / m≤2 7
1a
1a 1a 1b
1a 1b 1b
1b
2. 2. 2.

2 ≤3.75 kg
≤ 75/kg 2 2
1b 2.
1b
2. ≤ 75
≤ 75 kg /kg
m2 /
2. m 2. 3. m/ m 3.
3.

The Edscha Trailer Systems sliding roofs and their operating com-
ponents are exclusively manufactured for their due employment
on truck specific transport operations. Any usage going beyond
such applications is considered as misuse. For resulting damages
the manufacturer European Trailer Systems GmbH repudiates any
liability; for this the user alone bears the full risk. The “intended
usage” also includes the observance of the operation, care and
maintenance instructions and of the mounting and repair instruc-
tions as prescribed by the manufacturer.
All the arising exclusions of risk and liability
! shall remain valid also if:
• examiners or experts of the technical testing bodies or
experts from officially recognised organisations have
performed acceptance tests;
• official approval exists.

! • 1a 1b Remove roof loads

before starting a trip
! The manufacturer, European Trailer Systems
GmbH, is discharged from any liability if:
! • 2. Roof load ≤ 75 kg / m2

• the Edscha Trailer Systems sliding roof and its components

are changed arbitrarily
• EdschaTS original parts are exchanged against other
! • 3. Cannot be walked on

components;
• the Edscha Trailer Systems sliding roof and its operating
components are not handled and serviced in compliance
with the prevailing Edscha Trailer Systems instructions
The vehicle equipment supplier is obligated in principle to check
whether the products shown satisfy the demands of the user.
© 2016 European Trailer Systems GmbH
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General information

Structure - planning / preparation

1.0 Measure existing vehicle structure

2.0 Planning the structural extension

2.1 Taking important legal factors into account:

Permitted curb weight / total weight

Vehicle dimensions: total height / length / width

Laws / traffic safety / insurance / load safety

2.2 Taking important technical factors into account:

Vehicle structural analysis

Load capacity / material of existing structure

Planned vehicle use / loading possibilities

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General information

Structure - parameters / requirements

Roof track width (e.g. 2520 mm)

Structural length / height / width (e.g. 13500 x 4000 x 2550 mm)

Rear design (e.g. soft door / doors --> effect on end carriage or gantry beam)

Roof design (CS / VP / fixed posts / sliding posts)

Screws

All screws / nuts with lock / galvanised

6.8 8.8 10.9

MA (Nm)
M4 2,2 3,0 4,4
M5 4,5 5,9 8,7
M6 7,6 10 15
M8 18 25 36
M10 37 49 72
M12 64 85 125
M14 100 135 200
M16 160 210 310
M18 220 300 430
M20 310 425 610
M22 425 580 830
M24 535 730 1050
Tightening torques and rigidity classes (see table)

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General information

Vehicle structural analysis - forces / moments

The chassis must be capable of taking up a

bending torque ≥ 10 kNm in the area of the front frame
Prerequisite: roof with longitudinal beams

Distance between posts ≤ 3500 mm

The chassis must be capable of taking up a

bending torque ≥ 4.5 kNm in the post area
Prerequisite: load capacity ≤ 20 kN / running meter

Front wall rigidity ≥ 500 kN area load (0.4 x load capacity recommended)

The chassis must be capable of taking up a

bending torque ≥ 40 kNm in the area of the rear frame
Prerequisite: load capacity ≤ 270 kN

Correct realisation

Tools

Execution of welded seams

Tolerances

Aids

Quality control, tests

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Mb ≥ 5 kNm Mb ≥ 5 kNm

25
≥120 70
25 FH
98 337,5
337,5
98
A

18

Front dimensions
Process step: Preparation of the base frame

Process: Measurement and drilling

Parameters: Edscha TS bulk head

Material: Edscha TS bulk head

Tools: drilling machine

Aids: Folding rule, centre punch

Preparation: Measurement and drilling

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2
C= A - 785mm

D = B - ~150mm

m
-7 85m
C= A 18
A

Pre-assemble bulkhead 01
Process step: pre-assemble bulkhead

Process: Mount individually cut front plate

Parameter: Platform width, installation height

Material: Plywood panel, bulkhead elements (2021), screws

Tools: measurement/marking tools, saw, drilling machine, screw driver

Aids:

Preparation:

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Pre-assemble bulkhead 02
Process step: pre-assemble bulkhead

Process: Mount bulkhead cover (adjust if necessary)

Parameters: Installation width, roof track width

Material: Edscha TS bulkhead cover (2021), screws

Tools: torque wrench, screw driver

Aids:

Preparation:

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Pre-assemble bulkhead 03
Process step: pre-assemble bulkhead

Process: Mount assembly sets

Parameters: roof track width, guide rail package

Material: Edscha TS Montagesätze

Tools: torque wrench

Aids:

Preparation:

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FH

Pre-assemble bulkhead 04
Process step: pre-assemble bulkhead

Process: Mount support angle (adjust if necessary)

Material: Edscha TS support angle, screws

Tools: Screw driver

Aids:

Preparation:

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Pre-assemble bulkhead 05
Process step: pre-assemble bulkhead

Process: Mount protective plate (adjust if necessary)

Material: Edscha TS protective plate, screws / rivets

Tools: Riveting pliers / screwdriver

Aids:

Preparation:

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7
1.

3.
2. 3.

Installing the bulkhead 01

Process step: installing the bulkhead

Process: Align bulkhead and mount

Parameter: Platform width

Material: Pre-mounted Edscha TS bulkhead

Tools: torque wrench, wrench

Aids: crane

Preparation:

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3.

Installing the bulkhead 02

Process step: installing the bulkhead

Process: Screw bulkhead on

Parameter: Torques

Material: pre-assembled Edscha TS bulk head

Tools: torque wrench, wrench

Aids:

Preparation:

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Mb ≥ 40 kNm

Mb ≥ 40 kNm

80

150
40
8
Ø1
128 30

Preparing the rear 01

Process step: preparing the rear

Process: Drill holes for rear frame

Parameters: Platform width, requirements PWP SA

Material:

Tools: measurement/marking tools, drilling machine

Aids:

Preparation:

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10

Preparing the rear 02

Process step: preparing the rear

Process: Screws on rear pillars

Parameters: Platform width, requirements PWP SA

Material: Edscha TS rear pillars 2102, attachment materials

Tools: wrench, torque wrench

Aids:

Preparation:

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11

1.

2.

Preparing the rear 03

Process step: preparing the rear

Process: Mount assembly sets

Parameters: roof track width, guide rail package

Material: Edscha TS assembly sets, attachment material

Tools: wrench, torque wrench

Aids:

Preparation:

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12

Rear doors (PWP SA)

Process step: installation rear frame / rear doors

Process: installation rear frame / rear doors

Parameters: Platform width, installation height, requirements PWP SA

Material: Edscha TS rear frame (2102)

Tools: torque wrench, wrench

Aids: crane

Preparation: See assembly instructions PWP Defender

Assembly instructions PWP Defender:
http://bit.ly/29gZDjr (Sandwich)
http://bit.ly/29qllzM (Snaplock)

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13

Sliding pillar Fixed pillar

Guide rails
Process step: mount guide rails

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14

~250 mm

~50 mm

Guide rail package 01

Weld CurtainSider profile and sliding pillar profile
(top)

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15

~50
mm
~25
0m
m

Guide rail package 02

Weld CurtainSider profile and sliding pillar profile
(base)

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16

0 mm
~25
mm
~50

! See page 38 and

consecutive pages

Guide rail package 03

Weld running rail and rectangular tube
(top)

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17

~5
0
m
m
~2
50
m
m

Guide rail package 04

Weld running rail and rectangular tube
(base)

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18

Guide rail package 05

Join welded profile packages

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19

~2
50
m
m
~5
0
m
m

Guide rail package 06

Weld profile packages
(outside)

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20

mm
50
~2
m
0m
~5

Guide rail package 07

Weld profile packages
(inside)

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21

Guide rail package 08

Join welded profile package with stabilisation tube

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22
m
~250 m
m
~50 m

Guide rail package 09

Weld profile package (with a high profile weight or long
self-supporting lengths the profiles may need to be welded with
preload, see following illustrations)

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23

2.

2.

a a

1.

0 0
0 + X mm

Guide rail package 10

Weld profile package with preload.
Compensate profile deflection through counterload on profile.

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24

0 0
0 + X mm

~50 mm
~250 mm

Guide rail package 11

Join welded profile packages
(base)

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25

0 mm
~25

0 mm
~5

0 0
0 + X mm

Guide rail package 12

Join welded profile packages
(top)

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26

Installing the guide rails

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27

x
x
x ≤ 4000
x

Installing pillar bases 01

Process step: installing pillar bases

Process: installing pillar bases

Parameters: Installation length

Material: Edscha TS pillar bases (LP2)

Tools: measurement/marking tools

Aids:

Preparation:

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28

25

50

13

min. 100mm

Mb ≥ 4,5 kNm

Installing pillar bases 02

Process step: installing pillar bases

Process: installing pillar bases

Parameters: Platform height

Material: Edscha TS pillar bases (LP2)

Tools: measurement/marking tools, drilling machine

Aids:

Preparation:

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29

Detail 1. *
Profilschlitz
1.

2.

Inserting sliding pillars

*Notch to be performed by customer

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30

4.

1.

2.

3.

Hook in sliding pillars

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31

Installing batten pockets

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32

Installing battens

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33

! See page 21 and

consecutive pages

90° b

ab

Guide rails
The rails must be mounted in parallel within a maximum
angle deviation of ± 1° and must be braced against rotation
at the same height in order to ensure perfect roof running.
Measurement a b -> see figure 48

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34

20 Nm
1.
2.

20 Nm

2.
1.

Preassemble bows
Push the bow bracket (right / left) onto the bow from the outside
until the provided mounting holes align. Fasten the bulkhead
bow bracket to the bow on both sides, using the pan head screw
M8x50 and locknut M8 (torque: 20 Nm)

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35

Mount bows

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36

Preassemble end carriage 01

Carry out process on both sides

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37

2.

1.

Preassemble end carriage 02

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38

Preassemble end bow

Carry out process on both sides

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39

Preassemble end carriage /

end bow (for use with tarpaulin back cover)

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40

Preassemble end carriage /

gantry beam (for use with doors)

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41

Slide up end carriage

Push the pre-assembled end carriage into the provided
chambers of the running rail profiles.

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42

20 N
! 10 U m
/min
max.

End plug / stopper

Carry out process on both sides

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43

Rivet folding joints

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44

Mount safety rope

Must be securely connected to vehicle bulkhead

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45

≥ 40 mm

Safety rope – tension

Carry out process on both sides

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46

~25 1.
0

2. (see figure 47)

Build roof package

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47

10

Drill front locking hole

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48

Roof mounted
Difference measurement ‘a’ to ‘b’ when closed ≤ ± 2 mm.
All bows and the end carriage must have the same width within
a tolerance of ± 2 mm in order to allow perfect running of the
roof.

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Structural components side curtains

Post position

cm cm cm

Front

Distance between tarpaulin eyelets with expander cable from the front

cm

Length and width of roof

Exact length of roof: cm

Exact width of roof cm

x cm
Front Rear

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No. 808 837

Your sales partner in India:

European Trailer Systems

c/o RINGFEDER POWER TRANSMISSION INDIA PRIVATE LIMITED
Subject to technical changes · 07 / 2016

Plot No. 4, Door No. 220, Mount-Poonamallee Road, Kattupakkam,

Chennai – 600 056, India
Phone: +91 (0) 44-2679 1411 · Fax: +91 (0) 44-2679 1422
E-mail:sales.india@EdschaTS.com

European Trailer Systems GmbH

Im Moerser Feld 1f, 47441 Moers, Germany
Phone: +49 (0) 2841 6070 700 · Fax: +49 (0) 2841 6070 333 Das Original

www.EdschaTS.com