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VBG 795V
2005-04-19 38-134800k
General
VBG 795 V, part no.: 09-052000
The VBG 795V coupling is designed for centre axle
trailers, full trailers with boggiefront axles and dollys
that use a Ø 57.5 mm drawbar eye as per the VBG
standard.
The coupling should be mounted to a drawbeam which
fulfi ls the requirements of ISO 3584 cat. 3. The web
thick-ness in the middle of the drawbeam must be 1330 mm with an inner clearance of at least 160 mm.
easiest to mount it to a VBG drawbeam, all of which
meet these requirements.
The coupling has a high-quality corrosion resistance
through electrolytic pre-treatment and a top-coat with
very high wear resistance. To maintain the high quality
of the surface treatment, VBG recommend that no
futher paint is added to the coupling. If the coupling is
over-painted, you run the risk of operational problems,
a sticking signal/indicator pin or that important information is overpainted. Moving parts, plates and
decals must all be thoroughly covered if the coupling
is repainted.
It is
1. Nut cover
2. Castellated nut
3. Split pin
4. Bearing plate, inner
5. Bolt kit
6. Rubber bearing
7. Drawbeam sleeve
8. Bushing
Identify all parts before installation. Installation shall be
done in a proper and competent manner. Always follow
the instructions.
All directives and instructions should be kept in the
vehicle for future service and maintenance.
Contents
Mounting instructions ........................2
Safety check ......................................6
Service – maintenance ......................9
Driver instructions ...........................12
Spare parts list Power actuator .......16
Spare parts list VBG 795V ...............17
9a. Bar spacer washers 4 mm
9b. Bar spacer washer 10 mm
10. Bearing plate, outer
11. Rubber bearing
12. Coupling jaw
13. Mechanism
14. Guiding funnel
a
Drawbeam
sleeve
Drawbeam
5–8,5 mm
Spacers
Mounting instructions
Mounting of drawbeam sleeve
• Mount the drawbeam sleeve (a) with four screws as
per the drawing. Flat washers with a minimum hardness
of 200 HB must be under both bolt head and nut.
Tightening torque M20 quality 8.8 (dry): 370 Nm.
Mounting of coupling
• Lubricate the coupling jaw (b) and all its threads with
grease. This prevents rust and makes future service
work easier.
• Fit the attachment parts as shown in the fi gure. Fit the
bar spacer washers on the drawbeam sleeve collar so
that the dimension 5–8,5 mm is achieved. The number
of washers depends on the thickness of the drawbeam,
and the 10 mm washer should be outermost. See fi gure.
Mount accessories such as the coupling mouth extension (c) according to the drawing.
Tightening torque castellated nut 1500 – 2000 Nm.
b
c
d
• Lock the castellated nut with split pin. It is very important that the split pin is completely within the gates
of the castellated nut and is secured as per the picture.
• Lubricate the the castellated nut and the nut cover
with grease.
• Mount the nut cover.
• When the coupling is reassembled after service, a new
split pin must always be used.
Lubrication
Lubricate the coupling weekly with VBG mechanism oil
or similar thin oil. For the maximum effect, the coupling
should be open when it is being lubricated.
VBG do not recommend the use of central greasing
systems.
Lubrication points (see adjacent drawing).
•
Function check
Carry out the function check on page 5.
2
Mounting of a power actuator
If the coupling is to be equipped with a power actuator,
follow the directions below.
ca 5°
Mounting of the actuator on the bracket
• Turn the shaft on the actuator clockwise until it can go
no further and then turn it back approx. 5º.
• Bolt the actuator tightly onto the bracket with the four
screws. Tightening torque M8 quality 8.8 (dry): 25 Nm.
e
i
f
e
h
f
g
Mounting the power actuator on the
coupling
• Remove the two split pins (e) and the right hand
bushing (f).
• Mount the adapter (g) on the hexagonal shaft and fi t
with the roll pin (h) through the hole in the adapter.
• Tap the hexagonal shaft to the left and lock the hook
on the adapter into the hook on the spring.
• Assemble the bushing (f) on the left side and refi t the
split pin.
• Remove the two screws on the right side of the
mechanism (i).
• Place the bracket and actuator on the coupling. Lock
the bracket securely with the two long M12 screws
which accompanied the power actuator unit.
Tightening torque M12 quality 8.8 (dry): 90 Nm.
3
Alt. A
Alt. B
Mounting of the control box
• Mount the control box close to the coupling so that the
operation of the coupling can be watched. The control
box must be positioned so that it is well protected from
vibration, impact, dirt and ice formation.
Mount the control box as shown in Alt. A or B.
NOTE! Electrically controlled control boxes are not
permitted.
Warning!
Never put your fi ngers in the coupling mouth because of the danger
of them being crushed.
2
4
The vehicle´s auxiliary
air system
1
Ø 6
Ø 6
Ø 8
• Turn the handle on the control box to service position
according to “Service position control box” on page
6.
• Connect the supply line to the control box output
(marked 1).
• Connect the other 2 pipes to the control box outputs
(2 and 4). Fit the protective cover.
• Connect the pipe from output 4 on the control box to
the front output of the actuator. The pipe from output 2
is connected to the rear output of the actuator.
• Connect the supply line to the vehicle´s auxiliary air
system. Working pressure 8 bar.
Maximum pressure 10 bar.
Always follow the truck manufacturer’s body building
instructions.
NOTE! Do not connect to the braking system.
Fitting the Pipes
4
+
Brown
Inductive
sensor
Black
Blue
Signal
–
Signal: red and green lamp, (24 V max. 2 W)
60
80
40
100
20
120
approx 1 mm
g
Mounting of inductive sensor
• Change the cover of the original lock indicator for
the cover modifi ed for the inductive sensor. Open the
coupling so that the indicator pin is out. Wind the inductive sensor in until it touches the indicator pin. Wind the
inductive sensor back one turn (the distance between
the indicator pin and the inductive sensor should now
be approximately 1 mm).
Tighten the nuts (g), tightening torque max. 2 Nm.
• If VBG’s Indicator kit (part no. 09-099200) is used –
connect the inductive sensor according to the mounting
instructions. Otherwise connect the inductive sensor to
the vehicle’s electrical system (24 V). See wiring diagram
above. Follow the truck manufacturer’s instructions.
• When the coupling is closed and secured a green
lamp in the cab should light up.
• When the coupling is open, a red lamp in the cab
should light up. If the green lamp comes on when the
coupling is open, adjust the gap between the sensor
and lock pin so that the red lamp comes on.
5
a
Air supply on
Safety check
Carry out the safety check once a week. If the check
shows that any of the wear limits have been exceeded
or that the coupling´s function is reduced, rectifi cation
must be carried out immediately.
Before any work or service is carried out on the coupling
all air supply to the coupling must be cut off. Cut off
the air supply by turning the control box’ red handle a
quarter turn anti-clockwise to OFF.
If the coupling has been damaged
Service position
air supply off
Function check
• Check that the coupling bolt can be raised easily
and that the handle and coupling bolt remain in the up
position.
• Open and close the coupling and check that it corresponds as per the pictures below. If an inductive
sensor is used, item (d) must be complied with.
ALWAYS check that the coupling is closed and secure
before driving. All criteria for closed coupling must be
fulfi lled before you start driving.
a
b
Open coupling
(a) The handle is raised approx. 90º
(b) The indicator pin is out
(c) The coupling bolt is up
(d) Red lamp on in the cab
ab
as a result of jack-knifi ng, driving
into a ditch, or being hit from behind, you must stop and replace
the coupling.
Warning!
Never put your fi ngers in the coupling mouth because of the danger
of them being crushed.
Closed, secure coupling
(a) The handle is down
(b) The indicator pin is completely in
(c) The coupling bolt is down
(d) Green lamp on in the cab
c
• When the coupling is closed, there must be approx.
10 mm
10 mm clearance in the handle before the indicator/
locking pin moves outwards.
c
6
Attachment
• Check that the coupling can be rotated in its mounting. The coupling must be closed when the rotation is
carried out.
Wear limits
A Coupling pin max Ø 55.0 mm
B Drawbar eye max Ø 59.5 mm
Vertical play
B
in the coupling bolt max 5.0 mm
A
Lubrication
Lubricate the coupling weekly with VBG mechanism oil
or similar thin oil. For maximum effect, the coupling
should be open when it is lubricated.
Lubrication points (see drawing on the left)
•
7
Safety check contd.
d
e
f
• Fold out the yellow handle (d). Simultaneously
press on the mark “Press” on the handle and turn the
handle anti-clockwise to “OPEN”. Then turn it back to
“CLOSE”.
The coupling pin should remain in the up/open position.
• Connect to the trailer according to the driver instructions on page 14-15.
Air leaks
• Check that there is no audible air leakage from the
valve (e), the connection to the auxiliary air system (f),
pipes (g) or actuator (h).
Operation check - power actuator
g
• In extreme cold, minor air leaks can occur. These can
be eliminated by cutting off the air supply by turning
the control box’s red handle (d) a quarter of a turn anticlockwise to OFF.
Contact the nearest workshop for corrective measures.
h
8
Service - maintenance
• It is important to remember that a coupling is a safety
critical item and should be treated as such. Proper
preventive maintenance, inspection and lubrication are
essential for a long, safe and trouble-free service life.
B
• The length of service intervals depends on the type of
trailer, load, road- and weather conditions etc. Servicing
A
F
C
F
can best be carried out when other work or inspection
of the vehicle is done, for example every 60 000 or 90
000 km.
• At least once a year the coupling must be dismounted
and inspected for wear, corrosion, cracks or de-formation. Worn out or damaged parts must be replaced.
• If the daily overhaul or safety check shows that any
D
of the wear limits have been exceeded or that the
coupling´s function is reduced, repairs must be carried
E
out immediately.
• The fact that one of the coupling´s wear limits have
been exceeded indicates that other parts need service
as well. Therefore, always remove the coupling from the
drawbeam when changing the mechanism and bushings. Check the mounting parts and the drawbeam and
replace worn out rubber bearings and bushings.
a
d
Wear limits
b
e
c
A inner diameter max 59.5 mm
B outer diameter min 57.0 mm
C inner diameter max 45.7 mm
D outer diameter min 42.5 mm
E outer diameter min 55.0 mm
F Wear plate mark on wear plate
Vertical play
in the coupling bolt max 5.0 mm
Wear parts
(a) Mechanism
(b) Upper and lower jaw bushings
(c) Drawbar eye wear ring
(d) Rubber bearings and drawbeam sleeve bushings
(e) Wear plate
Change of mechanism and bushings
If the coupling is equipped with a power actuator, the air
supply to the control box must be cut off before work
with the coupling is started.
• Remove the mechanism by loosening the four screws
and lift the mechanism from the coupling jaw.
• Remove the wear plate.
9
Service – maintenance contd.
• Change the guide funnel if damaged. Minor damage
and deformations on the funnel are accepted, the guide
funnel is a seperate part from the coupling jaw and as
long as the function is not reduced there is no need to
replace the funnel.
• Change the bushings using VBG service tools. Press
out the old bushings from below and press in the new
bushings from above as per the fi gure.
The bushings must not be welded in.
Use tool no 12 as a
guide in the upper jaw
3
1
2
12a
3
bushing.
Place the tool on the
bushing before assembly.
5a
Removing
Lower jaw bushing
Removing
Upper jaw bushing
2
10
Fitting
Upper jaw bushing
Use tool no 9 as a
guide in the lower
jaw bushing.
9
10
Fitting
Lower jaw bushing
• Mount the wear plate. Tightening torque 47 Nm.
• Put the new mechanism on the coupling jaw and fi t
the screws, but do not tighten completely.
• Carry out the function check on page 6.
• Tighten the screws.
Tightening torque M12 quality 8.8 (dry): 90 Nm.
10
Lubricate the coupling with VBG mechanism oil. For
maximum effect, the coupling must be open when it is
being lubricated.
Lubrication points (see drawing on the left)
•
Attachment check
• Remove the coupling jaw and clean the shaft of rust
h
F
G
and rubber residue.
• Check that the coupling jaw is neither bent, nor has
cracks or any damage due to electrolysis.
• Check the wear limits as per below:
F max. Ø 67.2 mm (without bushings)
G min. Ø 61.6 mm
• Check that there is no cracks forming or deformation
on the drawbeam (i) and that the drawbeam sleeve (j) is
properly attached.
Tightening torque M20 quality 8.8 (dry): 370 Nm.
j
i
l
k
Change of Indicator/locking pin
• Loosen the three bolts holding the lid.
• Remove remaining parts.
• Clean the bearing surfaces for the locking pin (k) and
lubricate with thin grease. Check that the centring pin
(l) is correctly fi tted.
• Mount the parts according to the fi gure.
11
Driver instructions
Uncoupling without power actuator
1
Warning!
Never put your fi ngers into the coupling mouth because of the danger of
them being crushed.
Stand by the coupling handle.
Lift the handle 90º, the handle
locks. The coupling is now open.
2
For functional and road safety reasons, only
those steps described in the Driver instructions
may be carried out using the control box,
power actuator, or air lines during coupling
and uncoupling.
If the coupling does not go to locked position
after repeated attempts at coupling, the power
actuator must be uncoupled immediately. Contact the nearest workshop for fault de-tection
and remedial measures.
Uncouple the trailer. The coupling
is closed when the trailer is disconnected.
12
Coupling without power actuator
1
2
4
Stand by the coupling handle.
Lift the handle 90º, the handle
locks. The coupling is now open.
Connect to the trailer.
STOP
GO
38-08100
Check that the Indicator pin is completely in.
If the Indicator pin is not completely in, the coupling is open and
driving is not, under any circumstances, permitted!
Contact nearest workshop for remedial measures.
5
0 mm ~10 mm
Check that there is approx. 10 mm movement of the handle before
the indicator pin moves outwards. If there is no free movement
of the handle the coupling is open and driving is not, under any
circum-stances, permitted! Contact nearest workshop for remedial
measures.
6
The trailer is secured and driving
can begin.
13
Uncoupling
1
Warning!
Never put your fi ngers into the coupling
mouth because of the danger of them being
crushed.
1+2
1
3
Simultaneously press on the handle where it says “Press” and turn the
handle anti-clockwise to “OPEN”. Then turn it back to “CLOSE”.
2
2
1
2
Uncouple the trailer. The coupling
is closed when the trailer is disconnected.
Before any work or service is carried out on the coupling
all air supply to the coupling must be cut off. Cut off the
air supply by turning the control box’ red handle a quarter
turn anti-clockwise to OFF.
14
Coupling
1
1+2
1
3
Simultaneously press on the handle where it says “Press” and turn the
handle anti-clockwise to “OPEN”. Then turn it back to “CLOSE”.
2
2
1
2
Couple to the trailer.
3
GO
Check that the signal pin goes fully in, and that the green warning
lamp in the cab is on. The coupling is closed and secured, and the
truck can now be driven.
4
The trailer is secured and driving
may begin.
5
STOP
If the red lamp comes on and the signal pin is not completely in, the
coupling is open and the truck must under no circumstances be driven!
Contact nearest workshop for remedial measures.
15
AUSTRALIA
TRANSPEC LIMITED
P O Box 217 1 Cherry Lane
AU - 3028 P.O LAVERTON, VIC 3028
Tel +61 3 92 67 24 44
Fax +61 3 93 69 48 26
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WABCO Belgium S.A. - N.V.
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BE – 1702 GROOT-BIJGAARDEN
Tel +32 24810900
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VBG PRODUKTER A/S
Industribuen 20-22
DK – 5592 EJBY
Tel +45 6446 1919
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Ümera 26
EE-13816 TALLINN
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Faks +372 6230621
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H KRAATZ OY
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FI - 02330 ESPOO
Tel +358 9 8093100
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ONSPOT Sàrl
14 Route de Sarrebruck
FR - 57645 MONTOY-FLANVILLE
Tel +33 3 8776 3080
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RINGFEDER VBG GMBH
Oberschlesienstrasse 15
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GREAT BRITAIN
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OSAL OSKAR ANDERSSON
Tangarhofdi 4
IS - 110 REYKJAVIK
Tel +354 587 6619
Fax +354 187 7719
IRELAND
NEWBRIDGE METAL PRODUCTS LTD
Industrial Estate
IE - NEWBRIDGE, Co Kildare
Tel +353 45 431 502
Fax +353 45 433 747
ISRAEL
H KLEIN & SONS LTD
P O Box 1093
Industrial Area-North
IL - ASHDOD 77109
Tel +972 8856 4330
Fax +972 8856 4324
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Via Lanzo 52
IT - 10040 VAL DELLA TORRE (TO)
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JP - TOKYO 150
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