EN Installation and operating instructions
1 Explanation of symbols... 3 2 Safety information... 2.1 Safety information for installation... 2.2 Safety information for maintenance... EN Table of contents 3 Proper usage... 5 3.1 Application... 3.2 Design... 5 5 Assembly instructions... 7.1 Assembling pivots....1.1 with Silentbloc bushes....1.2 with brass/bronze wear bushes....2 Assembly of mounting / repair welding....3 Assembling a height adjustment system.... Note on GZU, GZL, GZHL, GZLG, GZV, GZHU....5 Note on GZN 12 and 26....6 Note on GZLV (pneumatically lockable)....7 Note on GSG and GSZ (pivoting drawbar eyes)... 7 7 8 8 9 10 11 11 13 5 Inspection and maintenance notes... 1 5.1 Inspection... 5.1.1 Mounting and securing elements... 5.1.2 Pivot play... 5.1.3 Drawbar struts, drawbar eye shaft, welding seams... 5.1. Towing eyes... 5.1.5 Height adjustment system... 5.2 Maintenance... 2 1 1 1 1 15 15 16
Explanation of symbols EN 1 WARNING! Means that death, serious physical injury or significant material damage can occur if the relevant safety instructions are not followed. ATTENTION! Means that slight physical injury or material damage can occur if the relevant safety instructions are not followed. ADVICE! Contains additional important information. 3
2 Safety information When handling towing hitches, tractor units, drawbar trailers and drawbars, the relevant safety regulations for the country in question (for example "Berufsgenossenschaft für Fahrzeughaltung" in Germany) have to be observed. The appropriate safety information in the owner's handbook for the tractor unit and the drawbar trailer are applicable and must be followed. 2.2 Safety information for maintenance Only use the specified lubricants for maintenance work. The servicing work should only be completed by trained personnel. The licensing regulations of the appropriate country must also be complied with. The following safety information applies to the operating, servicing and assembly work. Safety information directly linked to the activity is listed again individually. ADVICE! Technical modifications reserved. The latest information can be found at www.jost-world.com 2.1 Safety information for installation Only genuine JOST spare parts must be used. Damaged and repaired (e.g. repair by deposition welding) individual parts must not be used. The manufacturer of the drawbar will not accept any warranty claims if installation is carried out incorrectly. The drawbar must only be installed by authorised companies. Follow the instructions provided by the vehicle manufacturer, for example regarding the type of fastening, overall vehicle length, axle load, clearance, etc.
Proper usage 3.1 Application 3.2 are the connection between the tractor and the steerable drawbar trailer. They are designed for mounting on a pivot support. are parts that are subject to type approval and that connect vehicles, and are therefore subject to the highest safety requirements. They may only be operated with the compliant towing hitch is an towing eyes that have been approved. Changes of any kind (except for the ones allowed under.2) exclude guarantee claims and type approval is forfeited and thus the vehicle operating licence as well. Note Special models with a certificate for the issuance of individual authorisation in accordance with 13 FzTV in connection with 22a StVZO are given individual approval (TP No.). The associated certificate is sent separately and is to be provided with the vehicle papers. EN 3 Design The permissible load conditions for drawbars can be seen on the inscription on the factory name plate or the product overview table or the respective catalogue pages. They apply to the intended use in compliance with the Directive 9/20 EC or ECE-R55. In the case of additional dynamic stress, e.g. operation on uneven road surfaces, construction sites and forestry, the D value should not be fully exploited or a stronger drawbar should be used i.e. enquiries should be made at ROCKINGER. Decisive for the selection of a drawbar is the D value as well as the permissible front axle load of the turning steering frame onto which it is to be attached. Specifications for the permissible maximum weight of the trailer can be used as an orientation guide and serve only as a recommendation. The suitability of a drawbar for the combination of vehicles can be checked using the specified D value. ROCKINGER has appropriate EC and ECE type approved drawbars for almost all vehicle combinations. In order to meet the requirements of the market, further type approvals are planned, and existing ones are being extended and added to. For this reason, all drawbars are subject to changes that are conducive to technical progress. 5
3 Proper usage Truck and steerable drawbar trailer: The D value T Greater deviations may lead to premature wear or even damage to the drawbar. R Identification instructions are components which must be identified. The permissible load conditions can be seen on the inscription on the factory name plate. D 1 Zuggabeln_001 6 Theoretical drawbar force between truck and trailer, calculated reference value of forces between the moving masses. The D value can only be calculated by the permissible total weight of both measures (truck and steerable drawbar trailer). 5 Calculating the D value (kn): 2 D = g x T x R [kn] T+R D T R g Drawbar value [kn] Total weight of the truck in t Total weight of the steerable drawbar trailer in t Acceleration due to gravity 9.81 m/s2 = = = = The calculated D value may be less than or equal to than the D value of the drawbar. 1 2 3 5 6 3 Zuggabeln_006 Type Article No. Maximum D value in kn EC approval Maximum front axle load Av in t ECE-R55 approval When combining vehicles, it must be ensured that the angle (up or down) of the towing eye is not greater than 3 to the horizontal axis. 6
Assembly instructions.1 Assembling pivots We primarily recommend the use of Silentbloc bushes for the bearing of drawbars. Screw Silentbloc EN Self-locking nut Silentbloc bushes reduce wear and maintenance work and increase comfort..1.1 with Silentbloc bushes Screws (M 30-8.8) should primarily be used to fasten the drawbar. The torque of the self-locking nut should be 00 Nm for this. This effectuates the clamping action of the Silentbloc which ensures the functionality of the radial motion using the rubber element. When first assembling the screw, it should be inserted with standard lubricating grease or assembly paste, to facilitate disassembly at a later point in time. The bearing does not need to be lubricated. Washer Zuggabeln_002 Spring bolts can also be used to fasten Silentbloc bushes. The assembly instructions (see Chapter.1.2) are also to be observed. In order to avoid damage to the silent block bushes, the vertical pivoting angle of the drawbar should not exceed ± 20. Using Silentbloc bushes for drawbar is fitted with a drawbar height adjustment device is therefore not recommended. 7
Assembly instructions.1.2 with brass/bronze wear bushes Bolt Bush Castle nut Zuggabeln_003 Bush.2 Assembly of mounting / repair welding There are boreholes and eyeholes on the cross struts for attaching fastening fixtures for the mounting of height adjustment systems, dummy couplings and the like. Furthermore, additional mounting points can be mounted on the longitudinal struts using suitable clamping fixtures (e.g. spring shackles for GHE). Washer Bolt regularly greased (according to the trailer s specified maintenance intervals), or be connected to a centralised lubricating system. Self-locking nut If the aforementioned options are not sufficient, hooks or eyeholes can be welded onto the longitudinal struts. When doing so, it must be ensured that they are circumferentially fillet welded (a = 3 mm) to the profile centreline. ATTENTION! Modification or repair welding and straightening work on drawbars is strictly prohibited. Washer Zuggabeln_00 During assembly, it must be ensured that the drawbar remains vertically movable; in the bearing, however, it must be free from play. For fastening, spring bolts may be used in combination with washers/castle nuts/split-pins or washers/self-locking hex-nuts. The torque of the castle nut should be at least 180 Nm. The spring bolt should be lubricated with standard lubricating grease or assembly paste prior to assembly. During operation, the spring bolt must be 8
Assembly instructions.3 Assembling a height adjustment system EN Type GHD The drawbar must clear the ground. Ground clearance must be at least 200 mm, even when dropping the drawbar from the horizontal position. mi n. The height adjustment system must be constructed such that the drawbar can be adjusted to the height of the towing hitch funnel on the tractor by one person without the use of tools or other aids. The drawbar eye must be free to move horizontally at least 300 mm up and down horizontal to the road surface with the height adjustment system In this area, the drawbar must be infinitely adjustable or in steps no greater than 50 mm, measured at the drawbar eye. The height adjustment system may not impair the light manoeuvrability of the drawbar after successful coupling. 200-00 The height adjustment system is to be assembled such that the mounted drawbar fulfils requirements for ground clearance and height adjustment of the drawbar eye. 10 0 Lo = 05 Lmin = 165 R = 3 N/mm max. 50 L 110 110 20 Ø x) (3 60 Zuggabeln_007 First of all make the fastening point on the trailer bogie. There are three ways of making the fastening. It must be ensured that this connection remains freely movable, it must not become caught on the external tube. 9
Assembly instructions By lifting the drawbar into a horizontal position, the GHD height adjustment device can now be connected to the connection point on the cross brace. After installing the GHD height adjustment device, it must be adjusted to a horizontal position depending on the weight of the drawbar by turning the adjustment toggle handle.. Note on GZU, GZL, GZHL, GZLG, GZV, GZHU Extendable towing pipe: The fixing and clamping screws are to be tightened with a torque of 300 Nm in accordance with the information on the associated catalogue page. The towing pipe may not be greased. ATTENTION! The threaded rod must be unscrewed at least 100 mm to allow adjustment downwards (as specified in 22a of the Road Traffic Licensing Regulation). 10
Assembly instructions Type GZV, length adjustment of the drawbar ATTENTION! If the splint cannot be inserted, you must continue to screwing up to the next splint all cover. Never turn the castle nut backwards!.6 Note on GZLV (pneumatically lockable) Connection of the compressed air supply 1 2 1 Zuggabeln_008 Remove the M18 screws (1), slide the drawbar (2) into the required position and reinstall the screws (1), tightening them with a torque of 330 NM..5 Zuggabeln_009 Note on GZN 12 and 26 The tightening torque of the castle nut (SW70) is min. 500 Nm. 11 EN
Assembly instructions The connection must be made when the system is depressurised and as specified by the vehicle manufacturer. If you have any doubts, the compressed air connection must be secured by a separate pressure relief valve on the braking system. The spring loaded cylinder can be connected in a single or double-acting version. Connection thread M12 x 1.5 For a single-acting connection, the second connection on the cylinder must be protected from dirt using a filter. The compressed air valve is not supplied. Max. operating pressure 8 bar The compressed air valve must be selected so that the spring loaded cylinder is not pressurised whilst the vehicle is moving. The compressed air valve must be protected from dirt, unintentional operation and actuation by others. Install the pneumatic lines so that they cannot be crushed or chafed. Length adjustment of the drawbar 1. Pull out the securing device (1) on the spring loaded cylinder as far as it will go. 2. Open the lock using the compressed air valve. 3. Adjust the drawbar to the required length by moving the tractor vehicle.. Lock the new position using the compressed air valve. Move it forwards all backwards slightly if necessary to reach the required locking position. 5. Push in the securing device (1) as far as it will go. 6. Check the lock. 1 1 Zuggabeln_010 ATTENTION! The secured locking status (1) must be checked before every trip. Driving operations must only be carried out with the lock in a correctly closed and secured position. 12
Assembly instructions.7 Adjust the drawbar clearance EN Note on GSG and GSZ (pivoting drawbar eyes) Types GSZ and GSG, pivoting the drawbar eye 5 1 2 3 3 Zuggabeln_011 1. Undo the castle nuts (2 and 3). 2. Adjust the setscrews ( and 5). 3. Tighten the lock nuts (2 and 3) with a max. tightening torque of 120 Nm. 2 1 3 2 Zuggabeln_012 1. Remove the spring cotter (). 2. Unscrew the locking toggle nut (3) and remove it together with the pin bolt (2). 3. Swivel the drawbar eye through 180.. Insert the pin bolt (2) and toggle nut (3) and tighten them by hand (the toggle nut (3) must be installed on the drawbar eye side). 5. Secure it from coming loose using the spring cotter (). 13
5 Inspection and maintenance notes are subject to normal wear due to stress occurring during normal operation. Therefore, they must be checked with respect to the following criteria at regular intervals and, if necessary, repaired. 5.1.2 Pivot play 5.1 No play is allowed for silent bearings. Inspection Inspect the drawbar before every trip to ensure it is safe for road use. Depending on the conditions of use, but at the latest every 10,000 km or every month, the drawbar must be inspected to ensure it is functional, not worn, the fastening elements are complete, the specified tightening torques are satisfied and for signs of damage, deformation cracking and excessive corrosion. It must be repaired if necessary. 5.1.1 Mounting and securing elements Mounting and securing elements may not be loose or damaged. Loose mounting elements are to be tightened according to the specified torques, damaged mounting or securing elements must be replaced. 1 Longitudinal play max. 2 mm, latitudinal play max. mm for bronze and plastic bearings. Separation of bearing material is not permissible (Technical Inspection Authority data sheet 712). 5.1.3 Drawbar struts, drawbar eye shaft, welding seams Drawbar struts (longitudinal or latitudinal), drawbar eye shafts and welding seams may not exhibit any mechanical damage or be overly corroded. with deformations, cracks or breakages as a result of improper use are no longer roadworthy. They may neither be straightened nor repaired in any other way but must be replaced by new drawbars.
Inspection and maintenance notes 5.1. Towing eyes In order to achieve a long tool life of the towing eye, one has to grease the towing eye before initial operation or after longer operation with viscous, if possible water-proof, grease (EP3). Towing eyes may not be damaged or worn. Knocked out or loose wear bushes must be replaced in time. ATTENTION! Danger of accident Distorted or twisted towing eyes may not be straightened under any circumstances. 1 Wear limit: 2 b e b1 max. (mm) c min. (mm) e2 min. (mm) 705 1.5 28.0 22.0 7053 52.5 1.5 23.5 Heavy duty / ECE 52.5 1.5 21.0 Drawbar eye CH 1.5 36.5 29.5 11026 1.5 38.0 22.0 Scand. 57 mm 59.5 19.0 - DIN/CH Measuring with bush Measuring without bush 5.1.5 Height adjustment system Height adjustment systems must not be loose, damaged or corroded. Damaged or overly corroded parts of the height adjustment system must be replaced. The functionality of the height adjustment system must fulfil the requirements specified in section.3. c Zuggabeln_005 Type GH/GHD Periodic lubrication of the adjustment toggle or adjustment nut using the maintenance intervals specified for the trailer. 15 EN 5
5 Inspection and maintenance notes 5.2 Maintenance In order to achieve a long tool life of the towing eye and locking bolt, one has to grease the towing eye before initial operation or after longer operation with viscous, if possible water-proof, grease (EP3). Grease spring pins thoroughly during installation and after lengthy use using multi-purpose grease (NLGI 2). The bearing must be greased in the same way on pivot drawbar eyes. The Silentbloc (rubber/metal bearing) does not require any maintenance. Regrease the drawbar eye, locking bolt and, if necessary, the spring pin after cleaning with a pressure washer. Type GZLV Regrease the slide surfaces of the drawbar after frequent length adjustments or after cleaning with a pressure washer. 16
JOST, Germany, Tel. +9 6102 295-0, tkd-technik@jost-world.com, www.jost-world.com 1.0