- September V1.1

Transcription

1 User guide TD-X steering system (0301) - September V1.1

2 Table of Contents Contents Preface... 3 Chapter 1: Safety & environmental consideration... 4 Symbols... 4 Safety regarding operation... 4 Environmental considerations...4 Chapter 2: Description...5 Acronyms... 5 Components...5 Principle operation... 6 Chapter 3: Operation... 7 Couple and uncouple a steered semi-trailer...7 Couple:... 8 Uncouple:... 8 Driving with a steered semi-trailer... 9 Vulnerability of the steering system... 9 Steering characteristics and swing out of a steered semi-trailer...10 Chapter 4: Maintenance Maintenance of the TD-X steering system...11 Maintenance schedule Type designation Lubricants...13 Grease specifications...13 Cleaning Lubrication of the TD-X steering system Daily check of the TD-X steering system U-TDX0301EN

3 Preface About this guide: This guide is written for the driver or other user of the TD-X steering system and contains the necessary information about the use of the TD-X steering system. For the service technician we provide a separate maintenance and repair guide containing the necessary information regarding the maintenance and repairs of the TD-X steering system. This guide is available at our website At first delivery of the TD-X steering system a separate installation guide has been provided. Proper usage: The TD-X steering system is not designed for use on its own. It is designed for mounting on a semi-trailer as a steering system. Modifications of any kind may affect the safety level of the device. In addition, the modifications render the warranty void and will also void the homologation of the vehicle. If the TD-X steering system is not used correctly, all warranty claims against the manufacturer and supplier of the TD- X steering system will be rendered void. The device must not be used until it has been established that the semi-trailer on which the system has been installed complies with the national regulations for road traffic. The system is only allowed to be taken into operation in conjunction with the owner's manual for the truck as well as for the semi-trailer. Danger: All safety information is compiled in chapter 1. The required safety information is repeated and marked with symbols in the various chapters where the user is in danger. Contact details: TRIDEC Transport industry development centre bv 5692 GA Son, The Netherlands Phone: +31(0) Fax: +31(0) info@tridec.com Legal and copyright: No part of this document may be reproduced and/or published by print, photocopy, microfilm or by any other means without prior written permission from TRIDEC. The figures and specifications used in this guide are compiled with upmost care. However, we cannot be held responsible for any inaccuracies or omissions. TRIDEC reserves the right to change parts technically without notifying in advance. For information about this subject please contact TRIDEC. Copyright TRIDEC, Son, The Netherlands This version is a translation, the original version is written in Dutch (NL) Date of issue: 18 September 2014 Version: 1.1 U-TDX0301EN

4 User guide Chapter 1 Safety & environmental consideration The following sections contain information about the safety of the TD-X steering system. Sections: Symbols on page 4 Safety regarding operation on page 4 Environmental considerations on page 4 Symbols The following symbols are used in this guide: Table 1: Used symbols Description Description Description Danger for injury or life threatening situations! Risks for electrical shocks and/or damage to the electrical system! Important restriction! Danger for injury or life threatening situations by breaking parts. Risks for system damage! Read this information first! Risks for crushing! Risks for falling pieces! Safety regarding operation Operation of a semi-trailer with TD-X steering system contains risks. Apply the relevant regulations which are applicable your country (for example: road traffic regulations, company procedures, occupational health and safety regulations) when operating a semi-trailer with the TD-X steering system installed. General instructions when operating a semi-trailer include TD-X steering system: NEVER attempt to use or bring a semi-trailer with installed TD-X steering system on public roads as long as it has not been established that the complete semi-trailer complies with the national regulation for road traffic. Read the operation instructions BEFORE coupling and starting to operating the semi-trailer with installed TD-X steering system. Carry out the daily inspection BEFORE coupling the semi-trailer to the truck or start to drive. The driver of the truck is ALWAYS responsible for operating the TD-X steering system. NEVER steer the semi-trailer with TD-X steering system when people are close to moving or steering parts of the semi-trailer. Environmental considerations Hydraulic fluids, oil, greases and batteries are pollutants that can seriously pollute the environment. Return these substances to the designated authority or appropriate waste disposal company for recycling U-TDX0301EN

5 Chapter 2 Description of the TD-X steering system The following sections contain information about the TD-X steering system: Acronyms on page 5 Components of the TD-X steering system on page 5 Principle operation of the TD-X steering system on page 6 Acronyms FWU: (Fifth Wheel Unit) This is the transfer mechanism for the steering system between the truck and semi-trailer. FWU's must be installed in the trailer chassis. The main parts of the FWU are the fifth wheel housing, the turntable, fifth wheel plate, the kingpin, steering wedge, and the journal which is connected to the steering rod. AMF: (Axle Mounting Frame) This is the transfer mechanism for the steering system between the trailer chassis and the steered rear axle of the semi-trailer. The AMF must be installed in the trailer chassis. The main parts of the AMF are the frame, the turntable, the steering beam, and the cross members. Components of the TD-X steering system (1) FWU (G), (1b) optional FWU (K), (2) king-pin, (3) steering wedge, (4) steering rod, (5) rod guidance's, (6) AMF, (7) transfer lever, (8) second steering rod's, (9) leaf spring bracket plates (optional), (10) mudguard support (optional) Figure 1: Component overview of the TD-X steering system U-TDX0301EN

6 User guide Principle operation of the TD-X steering system (1) FWU, (2) steering rod, (3) rigid axle, (4) AMF nr 1, (5) fifht wheel plate, (6) rod guidance s, (7) transfer lever, (8) rod to AMF nr 2, (9) rod to AMF nr 1, (10) AMF nr 2 Figure 2: Principle operation of the TD-X steering system The TD-X steering system is a "articulated steering system". This steering system minimises the used road space of the truck trailer combination in curves. Semi-trailer combinations that are equipped with steering axles are much more manoeuvrable than semi-trailer with fixed axles. The TD-X steering system is mainly developed for distribution puropses. By the X steering the load will be spread over the axles when especially when driving with a partly unloaden semi-trailer. This will reduce the risk of overloading the FWU. The type-designation " TD-X" stands for the Dutch words "push/pull rod", the X stands for the fact that the front axle steers to the oposite direction. The steering forces are created when the truck changes direction. During driving in a bend the steering wheels of the semi-trailer will always steer automatically. The steer angle of the semi-trailer is proportional to the steering movement of the truck. While steering, the rotational movement between the truck and semi-trailer is transmitted to the FWU by the kingpin and a wedge that drops into the fifth wheel. A steering rod (2) establishes a pivoting connection between the fifth wheel plate (5) and the transfer lever (7), Both AMF's are connected with rods (8,9) to the transfer lever to establishes a pivoting connection in the steering system. If the semi-trailer is equipped with multiple axles, the principle operation of the system is similar. The steering angle of the both AMF's is determined by the centre-to-centre of the steering rod's bearing journals at the FWU and the gear ratio of the transfer lever. For stability a small caster forces a steered axle to the straight forward position when driving forward U-TDX0301EN

7 Chapter 3 Operation of the TD-X steering system The following sections contain information regarding the operation of the TD-X steering system. Sections: Important: Before starting to operate a trailer with the TD-X steering system installed, FIRST read the chapter Safety & environmental consideration on page 4 Couple and uncouple a steered semi-trailer on page 7 Driving with a steered semi-trailer on page 9 Couple and uncouple a steered semi-trailer Coupling requires attention, be aware of the warnings and always follow the steps below: Danger: SEMI-TRAILER CAN SLIDE SIDEWARDS WHEN INCORRECTLY COUPLING OR UNCOUPLING. During coupling the semi-trailer is lifted by the fifth wheel, which raises the legs from the ground. This may allow the semi-trailer to slide side wards. Therefor it is of great importance that the truck's riding height is set correctly when coupling to a semi-trailer. Figure 3: During coupling the semi-trailer can slide off! U-TDX0301EN

8 User guide Couple: Caution: An incorrect coupling height can lead to undesirable movement of the semi-trailer. Caution: Coupling or uncoupling at an angle can cause misalignment and/or damage to the system. Figure 4: Coupling a steered semi-trailer 1. Make sure that the fifth wheel of the truck is at the same coupling height as the turntable plate of the semi-trailer. 2. Drive the truck under the semi-trailer in a straight line. 3. The semi-trailer must NOT be coupled at an angle. Uncouple: Caution: Coupling or uncoupling at an angle can cause misalignment and/or damage to the system. Figure 5: Uncoupling a steered semi-trailer 1. Make sure that the truck trailer combination is on a flat horizontal surface. 2. Extend the trailer legs far enough that the trailer will remain at the same height during un-coupling. 3. Drive the truck in a straight line out from under the semi-trailer. 4. The semi-trailer must NOT be un-coupled at an angle U-TDX0301EN

9 Operation of the TD-X steering system Driving with a steered semi-trailer Danger: Inattentive driving will cause accidents and/or damage to the steering system! Driving with a steered semi-trailer requires attention; take care of the vulnerability and the behaviour of the steering system. Vulnerability of the steering system Caution: Inattentive driving in to a road that makes a sharp angle or inclination causes damage to the steering system! When driving, always take care that neither the front nor the rear position of the trailer section above the fifth wheel contact or strain any part of the steering system when entering a road that makes a sharp angle of inclination. Examples are level crossings and loading docks or the embarkation/disembarkation ramps of a ferry boat. Tip: When entering a road that makes a sharp inclination, stop to check (or let your relief driver check) the space between truck and semi-trailer, and drive slowly. When there is minimal space left, don't go further but stop and find an alternative route. Figure 6: Vulnerability of the steering system! U-TDX0301EN

10 User guide Steering characteristics and swing out of a steered semi-trailer Danger: When turning, the semi-trailer can swing out of the drive line! Causing danger to other road users! The steering characteristics of a non-steered semi-trailer differ from those of a steered one. The centre of rotation of the semi-trailer (point A) is closer to the truck for a steered semi-trailer than for a non/steered semi-trailer. This has influences on the turning radius and the required road space of the semi-trailer and makes it possible to manoeuvre more easily through narrow streets. Always remember when entering a bend/corner (point B) that the rear corner of a steered semi-trailer will swing out further than a non-steered semi-trailer. Tip: Practice first and get used to the steering characteristics of a steered semi-trailer, before driving into narrow streets and heavy traffic. (1) characteristics of a non-steered semi-trailer, (2) characteristics of a semi-trailer that includes the TD-X steering system, (A) centre of rotation of the semi-trailer, (B) swing-out of the semi-trailer, (C) turning radius of the semi-trailer, (D) required road space Figure 7: Characteristics of a non-steered semi-trailer compared with a steered semi-trailer Danger zones of a semi-trailer include steering system are indicated in red. Figure 8: Danger zones of a steered semi-trailer U-TDX0301EN

11 Chapter 4 Maintenance of the TD-X steering system The following sections contain information regarding the maintenance of the TD-X steering system. Important: Before starting FIRST read the chapter Safety & environmental consideration on page 4 Sections: Maintenance of the TD-X steering system on page 11 Type designation on page 12 Lubricants on page 13 Cleaning on page 13 Lubrication of the TD-X steering system on page 14 Daily check of the TD-X steering system on page 15 Maintenance of the TD-X steering system Danger: In order to ensure the safety of service mechanics, the driver, and others, the maintenance events of the TD-X steering system must be carried out by skilled service mechanics. Negligence can put the service mechanic, the driver and others at great risk. Danger: Maintenance doesn't only have influences the length of life of the system, but also ensures a secure and safe operation of the system. Maintenance and repair guidelines are described in the "Maintenance and repair guide of the TD-X steering system" located at our website Maintenance schedule Table 2: Maintenance schedule Item: Interval: Performed by: Daily check Daily before operation Driver/operator First maintenance event After the first km / 2 months Skilled service mechanic Maintenance Every km / 3 months Skilled service mechanic Maintenance (extended) Every km / 24 months Skilled service mechanic U-TDX0301EN

12 User guide Type designation The TD-X steering system has an identification decal located on the FWU near the steering wedge. Another decal with the serial number is fixed to the AMF near the grease nipples. The serial number is stamped on the FWU below the grease nipples at the edge of the profile and on the AMF at the left side of the grease nipples on the top of the frame. The serial number is also stamped on one side of the steering rod's middle section. (1) turntable type decal, (2) stamped serial number, (3) identification decal of the TD-X steering system, (4) stamped serial number Figure 9: Location of identification numbers (A) type, (B) serial number, (C) year of manufacture, (D) Dutch national approval number Figure 10: Product identification decal of the TD-X steering system Table 3: Explanation of the identification number SE S TD-X G / XXXXX-X-XXX Description: S Steering system E or T/D/V Number of axles on the semi-trailer (E=1, T=2, D=3, V=4 or 5) 15 or 18 Max load FWU in tonnage (1 t = 1000 kg) 10 Number of steered axles (10=1, 20=2, etc.) S Not applicable TD-X Type of steering system G or K Type of FWU (G = bolted version, K = extra low version) XXXXX-X-XXX Serial number U-TDX0301EN

13 Maintenance of the TD-X steering system Lubricants Restriction: ONLY apply the specified lubricant in the TD-X steering system, other lubricants are NOT permitted. Caution: REPLACE lubricants of the TD-X steering system as specified in the maintenance schedule. Grease specifications Lubricate the TD-X steering system with grease that complies with NLGI-class 2 specification. If the system has a central lubrication system use grease that complies with NLGI-class 0 or 2 specification, verify specifications with the manual of the central lubrication system. Table 4: Grease specifications NGLI class 2: NGLI class 0: (central lubrication) Thickener Calcium, Sulfonate, Lithium Calcium, Sulfonate, Lithium Drop point >180 C >180 C Temperature range -20 C to 100 C -20 C to 110 C Viscosity from base oil at 40 C > 280 mm² > 600 mm² Shell 4 ball test > 250 kg > 220 kg For lubrication process: Lubrication of the TD-X steering system on page 14. Cleaning The following items must be taken into account when cleaning the TD-X steering system with a high pressure washer or steam cleaner: 1. The maximum allowed pressure is 100 BAR (10.0 Mpa). 2. Maintain a minimum distance of 30 cm between the nozzle of the pressure washer and the surface being cleaned. 3. Don't pressure wash electrical components and connectors (if available). 4. Don't use aggressive cleaning solvent which can be harmful for the paintwork and seals. 5. Use a dry cloth and if required a degreaser to clean control boxes. 6. Always lubricate the TD-X steering system after cleaning with a high pressure washer. U-TDX0301EN

14 User guide Lubrication of the TD-X steering system Lubricate the TD-X steering system with grease that complies with NLGI-class 2 specification. If the system has a central lubrication system use grease that complies with NLGI-class 0 or 2 specification, verify specifications with the manual of the central lubrication system. Lubricants on page 13 Caution: When lubricating the TD-X steering system, ensure that the lubricating points are thoroughly lubricated, so that the grease extrudes and forms a collar around the seal of the component (such as: turntables). 1. Drive the truck-trailer combination in a straight line. 2. Clean the lubricating nipples and surrounding area and remove the caps from the nipples. (see figure). 3. Apply grease to all grease nipples of front and rear turntables. 4. Turn the truck to right so that the truck-trailer combination will stand in an angle of approximately 45 degrees. 5. Apply grease to all grease nipples again to evenly spread the grease across the turntable. 6. Turn the truck to left so that the truck-trailer combination will stand in an angle of approximately 45 degrees in the other direction. 7. Apply grease to all grease nipples again to evenly spread the grease across the turntable. 8. Return the truck-trailer combination back to the straight ahead position. 9. Remove excess grease that escapes from under the seals of the turntable bearings. 10. Fit the caps to the grease nipples. (1) lubrication nipples on FWU, (2) lubrication nipples on the AMF nr 2, (3) lubrication nipples on the AMF nr 1, (4) lubrication nipples at transfer lever Figure 11: Lubrication points of the TD-X steering system U-TDX0301EN

15 Maintenance of the TD-X steering system Daily check of the TD-X steering system Table 5: Items to check: Danger: Negligence of the daily check can put the driver and others at great risk. The following items must be considered when performing the daily check on the TD-X steering system: 1. Check the FWU housing (a), the king pin (b), the steer wedge (c) and the turntable plate (d) for damages and or loose bolts. Also check the bolt connection to the steering rod (e). 2. Check the connection from AMF to chassis (a), the turntable (b), the leaf spring bracket plates (optional) (c), the leaf spring (d), and the mudguard support (e) for damages, cracked welds and or loose bolts. Check also the bolt connection to the steering rod (f) 3. Check the steering rod for damages or loose bolts (a), and also check the rod guides for damages or loose bolts (b) and wear (c). 4. Check if the FWU and the AMF are sufficiently lubricated. 5. Check if the steering system operates correctly and without noises when steering. 6. Check if the truck trailer combination drives in a straight line when steering straight ahead. 7. Report damages and or strange noises immediately to your service provider. 8. Never drive with a semi-trailer which has damage, loose or lost bolts, excessive wear or a lack of maintenance. U-TDX0301EN

16 U-TDX0301EN September 2014 TRIDEC,Transport industry development centre bv, Ekkersrijt 3060, 5692 GA Son - the Netherlands Tel , Fax , info@tridec.com,