Installation and Operating Instructions
Contents
1. 204 07 Aus Type 101 04 18 2007 16 12 aa as 1 amp RINGFEDER Trailer Couplings mamm Installation and Operating Instructions Fitting Operation Maintenance Repair Automatic Trailer Coupling Type 101 AUS Range of application These installation and operating instructions apply to automatic trailer coupling RINGFEDER type 101 AUS Type 101 AUS is approved to connect with drawbar eyes 50 according to DIN 74053 and drawbar eyes D50 in accordance with the EU directive 94 20 and ECE55 01 as well as drawbar eyes ISO 1102 and in addition with heavy duty drawbar eyes 50 having a correspondingly high D value Summary Fitting Operation Maintenance Repair 10069949 04 2007 204 07 Aus Type 101 04 18 2007 16 12 eo 2 Installation 1 Remove castle nut 42 2 Pull tension washer 40 rubber spring 36 and bar guide 38 from the drawbar 1 3 Fit bar guide 38 contrary to the driving direction to the inner face of the rear drawbeam Caution Max thickness of the drawbeam 35 mm 4 Tighten the bar guide 38 together with the drawbeam using 4 bolts grade 8 8 and 4 safety nuts grade 8 The heads of the screws have to be mounted on the side of the coupling head outer side of the drawbeam Under screws and nuts you have to use washers DIN 125 hardness min 200HV Bolt length bolt shank washer thickness nut length at least 2 threads Flange Design d2 Thread Tightening Torque Wrench2. max Amm n E ad 204 07 Aus Type 101 04 18 2007 16 12 o 7 Repair Disassembly from the vehicle Sa e Remove protecting cap 44 fig 1 Remove cotter pin 43 fig 2 Unscrew castellated nut 42 fig 3 Completely pull out coupling head from the bar guide 38 fig 4 Remove tension washer 40 and rubber spring 36 from the bar guide 38 Remove thrust washer 37 and rubber spring 36 from the drawbar shaft fig 4 Stripping down of the coupling head 1 2 A ag 8 Detach and remove fastening parts 32 34 and 9 of the top cap 26 fig 5 Disassemble locking springs 25 and coupling bolt 23 including lifting sleeve 24 fig 6 7 Remove wear plate 7 from the coupling mouth Detach hexagonal screws 14 at the tab washer 12 fig 8 Remove tab washer 12 and return spring 11 fig 8 Remove bottom guide bush 6 fig 9 Remove coupling body 3 with the remaining fitted parts from the drawbar 1 fig 10 Remove top guide bush 2 fig 11 Assembly of the coupling head 1 2 3 amp 8 9 10 il 12 Drive in top guide bush 2 to the drawbar 1 fig 11 Fit coupling body 3 on to the drawbar 1 fig 10 Grease bottom guide bush 6 and drive through coupling mouth into the draw bar The threaded holes of the bottom guide bush must be transverse to the longitudinal axis of the coupling fig 9 Insert return
3. Top guide bush Coupling body Manual safety device Bottom guide bush Special plastic plate Wearing plate cast iron Return spring Tab washer Spring arm Coupling bolt Locking spring End cap cpl Hexagon screw M10 x 115 10 9 Rubber spring Thrust washer Bar guide Bearing bush Tension washer Castellated nut M45 x 3 Cotter pin 8 X 80 Protecting cap Hand locking lever combination design B Hand lever design B Plug for sensor hole 10 pieces Axle with locking lever Repair kit Pos 2 6 7 23 43 amp RINGFEDER Trailer Couplings mam A certified company in accordance with DIN EN ISO 9001 2000 and ISO TS 16949 2002 and DIN EN ISO 14001 1996 VBG GROUP TRUCK EQUIPMENT GMBH Oberschlesienstr 15 D 47807 Krefeld Postfach POB 130655 D 47758 Krefeld Phone 49 0 21 51 835 0 Facsimile 49 0 2151 835 200 www ringfeder de info ringfeder de P 11 12 OS 12 16 04 18 2007 _Type 101 204 07 Aus T
4. of wear on the coupling bolt and drawbar eye bush these components must always be kept clean and lubricated In case of hard running of the coupling mechanism the coupling head has to be lubricated over the tapered grease nipple 5 The trailer coupling should as far as possible not be cleaned by a steam cleaner high pressure cleaner If this cannot be avoided the trailer coupling itself should be closed beforehand After such cleaning the bearings of the coupling body should be greased with WD40 or a similar high grade permanent lubricant After that also the coupling bolt is to be greased and the coupling head be lubricated over the tapered grease nipple 5 Safety check P On its safety check the trailer coupling is to be inspected as described below Functional check by repeatedly opening and closing the coupling 1 Clean coupling bolt 23 and measure its smallest outside diameter in the bulged area Wear limit of coupling bolts in accordance with ISO standard 50 mm bolt couplings 46 5 mm Should the wear limit be reached the coupling bolt and the pertaining locking springs 25 included in the delivery of the coupling bolt have to be replaced by new ones Measure axial play of the coupling bolt 23 For this purpose close the trailer coupling and push the coupling bolt from underneath upward by means of an appropriate tool If the axial play should exceed 5 mm the hand lever locking lever assembly has to be replac
5. 4 18 2007 16 12 aa as 4 Operation 1 The trailer coupling is closed and secured resp coupled that is to say the towing eye is inserted the coupling bolt in its lower position the safety device is engaged the safety bar bolt locates over the coupling bolt the securing knob is in its internal engaged position Releasing and opening of the trailer coupling The coupling can only be opened when the coupling jaw is in the central posi tion or in the lateral end positions To release the trailer coupling the securing knob is pulled out and turned ahead until it has reached its external engaged position The trailer coupling now is released Fig 1 To open the coupling the hand lever is moved to its upper end position and then released This will cause the coupling bolt to lift up and the towing eye may be extended Due to the extension of the towing eye the coupling mechanism is again released and thus the coupling repeatedly closed and secured Opening the trailer coupling to couple the towing eye To open the trailer coupling proceed as described under item 2 above The coupling lever is in its upper end position the coupling is set ready for its next engagement When inserting the towing eye the coupling mechanism is released by lifting the coupling bolt The coupling closes automatically which means that the coupling bolt is inserted through the towing eye bush in its lower position in the guide bush The safety device is eng
6. Size e1xe2 mm mm standard thread mm 160 x 100 21 M20 a 410 Nm 30 5 Fit tension washer 40 without any other components of the towing device to the bar guide 1 and fully tighten the castle nut 42 by hand Measure the dimension X see figures 1 4 Remove castle nut 42 and tension washer 40 again 6 Fit the coupling head assembly including the front rubber spring 36 and thrust washer 37 to the bar guide 38 If required regrease drawbar 1 and contact surfaces of thrust washer 37 and bar guide 38 Caution Never grease the rubber spring 7 Fit the rear rubber spring 36 and tension washer 40 Caution Never grease the rubber spring 8 Grease the contact surfaces of the castle nut 42 and tension washer 40 Screw on and tighten the castle nut 42 until the previously measured dimension X is reached again and secure by means of a cotter pin 43 Min tightening torque of the castle nut M45x3 700 Nm using a wrench or nut with a wrench size of 70 mm To reach the dimension X and the next hole position for the cotter pin even higher tightening torques may be required Caution Always tighten to the next hole position 9 Fit and push on the protective plastic cap 44 carefully 10 Straighten the coupling 11 For a retro fit please refer to the relevant statutory regulations D ype 101 04 18 2007 16 12 OS 3 204 07 Aus T Figures 1 4 204 07 Aus Type 101 0
7. aged that is to say that the safety bar bolt locates over the coupling bolt the securing knob is in its internal engaged position the coupling is closed and secured the towing eye is gt engaged Fig 2 Check that after each coupling process the safety device is fully engaged If the securing knob is not in its internal engaged position the trailer coupling is unsecured and the whole procedure must be repeated Fig 1 Fig 2 Trailer coupling Trailer coupling disengaged uncoupled closed and secured 204 07 Aus Type 101 04 18 2007 16 12 aa a 5 Service and maintenance It is most important to always realize that the trailer coupling is a safety part and be handled as such Regular service maintenance and lubrication is a prereguisite for a safe and long term troublefree service life The degree of loading and thus the wear of a trailer coupling also depend on the type of trailers the loads roads and climatic conditions The wear limits given under safety check must not be fallen short of for example coupling bolt diameter nor exceeded for example bore hole diameter bottom guide bush If daily inspection of the vehicle in operation shows that the function of the trailer coupling has been impaired or strong signs of wear are sensible it is imperative that a safety check as described below be carried out immediately and if necessary the specific wearing parts be exchanged In order to limit the degree
8. ed Control clearance of the coupling bolt 23 in the bottom guide bush 6 The maximum admissible clearance must not exceed 2 5 mm If necessary the coupling bolt plus pertaining locking springs 25 or the bottom guide bush resp or both have to be replaced by new ones Control max diameter of the bottom guide bush 6 in the area of the coupling bolt seat e g by means of a slide gauge Admissible inner dia max 36 5 mm Should the wear limit be reached the bottom guide bush has to be replaced by a new one D 204 07 Aus Type 101 04 18 2007 16 12 aa a 6 4 Control bearing clearance of the drawbar 1 in the drawbar guide 38 Should the clearance between drawbar shaft and bearing bush 39 exceed 1 mm the plastic bearing bushes 39 in the bar guide 38 have to be replaced Together with these also the rubber springs 36 should be replaced by new ones 5 Control wear of the wear plate 7 The wear plate should be kept cleanest possible and free from grease as grease consolidates dust and thereby the wear considerably increases due to the abrasive effect in trailer operation If the wear plate shows strong signs of wear and tear 4 mm and more it has to be replaced by a new one 6 Control axial play longitudinal play of the bearing For this purpose vigorously move the drawbar not the guiding funnel of the mouth back and forth in longitudinal direction using both hands There must not be any axial
9. n attend to always using new corrosion resisting cotter pins Moreover when replacing component parts of the trailer coupling only ori ginal RINGFEDER spare parts are to be used since otherwise a safe perfor mance cannot be safeguarded and every guarantee ceases 204 07 Aus Type 101 04 18 2007 16 12 ie 9 p i i k TAE ei _ OE p ET 1 i im Hrn OE La A i ik im gj 1 1 P a f a E ee a F f tr m fe a z 5 E E E a il N kandi ej 1 UG NET AER E E EA ce a Ar EG 3 Li Eo A Loi A N ol E N AS IIA IIA 7 peed Po bere ere Sal ee eee NT AN Tier Fe 1 2 t EN MS RE 204 07 Aus Type 101 04 18 2007 16 12 i 10 ae a 204 07 Aus Type 101 04 18 2007 16 12 eo 11 W Spare parts Pos 7 7a 11 12 18 23 25 26 32 36 37 38 39 40 42 43 4 45 45a 48 92 No 14 991 384 14 991 760 14 991 073 14 991 407 6 998 321 9 996 770 7 995 610 14 991 399 7 998 341 14 991 375 14 991 273 14 991 367 14 991 359 14 994 568 14 994 472 14 994 463 14 994 876 14 994 496 6 997 732 12 991 533 14 994 455 14 991 262 14 991 376 9 122 900 14 991 383 14 991 632 Type 101 AUS Designation
10. play longitudinal play between the drawbar 1 and the bar guide 38 otherwise the rubber springs 36 have to be replaced When replacing the rubber springs at the same time the plastic bearing bushes 39 in the bar guide 38 have to be exchanged as well 7 Control pivot bearing of the coupling body 3 for longitudinal play maximum admissible longitudinal play at the upper bearing 1 mm maximum admissible longitudinal play at the lower bearing 1 mm When the maximum admissible bearing clearances have been reached the trailer coupling must be repaired 8 Control coupling body 3 for smooth running For this purpose move coupling body with the trailer coupling closed to the right CB and to the left In case of stiffness the bearings of the coupling body have to be roughly cleaned and greased with WD 40 or a similar high grade permanent lubricant so that the coupling mouth is smoothly running By the force of the return spring the coupling body must automatically return recoil into its central position Important note To fix the castellated nut with a cotter pin attend to always using new corrosion resisting cotter pins Moreover when replacing compo nent parts of the trailer coupling only original RINGFEDER spare parts are to be used since otherwise a safe performance cannot be safeguarded and every guarantee ceases Pivot bearings of the coupling body 7 8 ON Br TH PE 4 T T an
11. spring 11 fig 8 Screw on tab washer 12 fig 8 Insert wear plate 7 in coupling mouth and screw up Insert coupling bolt 23 including lifting sleeve 24 the way that the axis of the pin 24 is transverse to the longitudinal axis of the coupling fig 7 Insert locking springs 25 fig 6 Fill in new grease into the housing Refit top cap 26 and screw up fig 6 Slip on rubber spring 36 and thrust washer 37 to the drawbar 1 fig 5 Grease drawbar shaft Assembly to the vehicle 1 2 Ol ge te Grease bearing surface of the thrust washer 37 on the bar guide 38 Fit tension washer 40 without any other components of the towing device to the bar guide 1 and fully tighten the castellated nut 42 by hand Measure the dimension X see figures 1 4 Remove castellated nut 42 and tension washer 40 again Fit the complete coupling head assembly to the bar guide 38 fig 4 Slip on rubber spring 36 and tension washer 40 to the drawbar shaft Screw on castellated nut 42 and tighten according to fitting instructions item 8 fig 3 204 07 Aus Type 101 04 18 2007 16 12 Di 8 p 6 Drive in new cotter pin 43 and secure properly fig 2 7 Slip on protecting cap 44 fig 1 8 If necessary adjust coupling head horizontally to the vehicle by using a lever Caution Never grease the rubber springs Important Note To fix the castellated nut with a cotter pi
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