IMS XST11A User manual

Installation manual
XST11A
XST21A
XST31A
XST22X (W)
XST32X
APPROVED on 13-07-2021
Revision 03
Subject to change without notice.
Latest version and additional information can be found online at www.group-ims.com

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1 CONTENTS
1Contents 2
2Introduction 3
3Safety and environment 4
3.1 Safety regulations 4
3.2 Symbols 4
4Overview of the systems 5
4.1 XST22X - XST22XW - XST32X 5
4.2 XST11A - XST21A - XST31A 6
5Important dimensions and measurement points 7
5.1 Dimensions 7
XST11A –XST21A –XST31A 7
XST22X –XST22XW –XST32X 9
5.2 General tolerances 11
5.3 Measuring points 11
6Production process 12
7Preparation of the chassis 13
7.1 Hole pattern in the underside of the chassis 13
Hole pattern XST11A - XST21A - XST31 14
Hole pattern XST22X - XST22XW - XST32X 14
7.2 Welding parts on the chassis 16
Steering module (Xm) 16
Weld-on assembly plate steering axle (Ab) 18
Weld-on rear steering bridge (Ab) 20
Determining the height of the steering wing(s) and rear steering bridge (H3) 22
XST11A –XST21A –XST31A with weld-on assembly plate 23
XST11A –XST21A –XST31A with bolt-on assembly plates 24
XST22X - XST22XW - XST32X with bolt-on assembly plates 26
XST22X –XST22XW –XST32X with weld-on assembly plates 27
Weld-on or bolt-on assembly plates (Af & Ab) provided with supporting plates 28
8Preparing the axle frame 29
8.1 Preparing the axle mounting 29
8.2 Preparing the steering wing (Af and/or Ab) 30
Steering wing(s) with weld-on steering bridge 30
Shortening the steering wing(s) 31
8.3 Preparing the assembly of the turntable 32
8.4 Installation of the turning table 33
9The cables 34
9.1 XST11A –XST21A –XST31A 34
9.2 XST22X –XST22XW –XST32X 34
9.3 Accessibility of the cable tensioners 34
10 Contact information 35

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2 INTRODUCTION
If you have any questions or remarks about this manual or about your GreenSteering system, you can always
contact us via [e-mail]. Never make presumptions. When in doubt, always contact GreenSteering.
This document contains guidelines for installing the GreenSteering steering system in order to guarantee the
proper functioning of the system. They are not in any way a guideline for the design of your chassis. This remains
the unique responsibility of the chassis constructor. All common principles, technical calculations, designs, etc.
remain applicable. Drawings and images in this manual that are not directly applicable to the steering system are
merely illustrative and do not entail any indication of the design of the chassis itself.
If you derogate from these instructions, you must always request written permission from GreenSteering. Without
this written permission, any liability will invalidate as well as the guarantee on our products.

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3 SAFETY AND ENVIRONMENT
3.1 Safety regulations
The installation of the GreenSteering system must be performed by qualified and experienced personnel.
Make sure that the trailer conforms to all regulations (road regulations, company procedures, health and
safety regulations).
The trailer must be prevented from moving during installation or repair work. Please observe the relevant
safety regulations for installation and/or repair work on commercial vehicles. This holds particularly true for
jacking up and securing the vehicle.
Always wear protective clothing (gloves, safety boots, safety goggles, etc.) and only use recommended
tools.
A second technician must provide assistance when carrying out work with heavy components.
All air lines must be depressurized before components are being removed.
Oil, grease, hydraulic fluids and batteries can contaminate the environment. Follow the correct procedures
for the recycling of these substances.
Tighten all fasteners to the recommended tightening torques, using a calibrated torque wrench.
Do not mount any underride protection onto the rear unit.
3.2 Symbols
In this manual, the following symbols are used:
Symbol
Description
Read this information first!
Important restriction!
Warning: used when failure to follow an instruction correctly can lead to personal injury.
Warning: used when failure to follow an instruction correctly can lead to entrapment.
Risk of falling objects!
Risk for electric shock or damage to the electrical system.

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4 OVERVIEW OF THE SYSTEMS
4.1 XST22X - XST22XW - XST32X

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4.2 XST11A - XST21A - XST31A

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5 IMPORTANT DIMENSIONS AND MEASUREMENT POINTS
5.1 Dimensions
In the design of a trailer with the GreenSteering system, the following dimensions are important:
XST11A –XST21A –XST31A

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A. Trailer length (L)
B. Trailer width (W)
C. Tyre size (TS)
D. Wheel track (TW)
E. Centre point kingpin / front of trailer (F)
F. Centre point kingpin / centre of the axle (K-A1)
G. In case of multiple axles, the distances between the various axles (A1-2) (A2-3), etc.
H. Distance last axle / back of trailer (R)
I. Neck thickness (N1)
J. Underside neck / floor (N2)
K. Top of trailer floor / underside chassis beam (C1)
L. Underside chassis beam / floor (C2)
M. Top trailer floor / floor (C3)
N. Underside pedestals / floor (C4)
O. Chassis beam height (P1)
P. Chassis beam width (P2)
Q. Distance between the chassis beams (P3)
R. Centre / centre chassis beams (P4)

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XST22X –XST22XW –XST32X

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A. Trailer length (L)
B. Trailer width (W)
C. Tyre size (TS)
D. Wheel track (TW)
E. Centre point kingpin / front of trailer (F)
F. Centre point kingpin / centre of the axle (K-A1)
G. In case of multiple axles, the distances between the various axles (A1-2) (A2-3), etc.
H. Distance last axle / back of trailer (R)
I. Neck thickness (N1)
J. Underside neck / floor (N2)
K. Top of trailer floor / underside chassis beam (C1)
L. Underside chassis rail / floor (C2)
M. Top trailer floor / floor (C3)
N. Underside pedestals / floor (C4)
O. Chassis beam height (P1)
P. Chassis beam width (P2)
Q. Distance between the chassis beams (P3)
R. Centre / centre chassis beams (P4)

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5.2 General tolerances
Unless indicated otherwise, GreenSteering produces all its products according to general tolerances:
For plate and tubing: DIN ISO 2768-1m
For turning and milling: DIN ISO 2768-1f
These tolerances are also applicable to the installation of the system.
5.3 Measuring points
GreenSteering uses the centre point of the kingpin as the zero point and always measures from the Y-axis
lengthwise. The axes (X) of the (steered) axle(s) are the fixed measuring point(s) for measuring the axles,
assembly plates, swivel heads and axle frames. Length-wise, we measure from the centre point of the wheels.

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6 PRODUCTION PROCESS
Depending on the production process in your company and the construction of the chassis, you can choose a
version with bolt-on or weld-on assembly plates. A fully integrated system without using the GreenSteering
assembly plate is also possible.
The GreenSteering steering module is always bolt-on. The GreenSteering rear steering bridge is always weld-on.

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7 PREPARATION OF THE CHASSIS
7.1 Hole pattern in the underside of the chassis
During the preparation phase of the chassis, a number of holes are required.
This depends on:
The type of steering.
The choice of weld-on, bolt-on or without assembly plate.
The choice of weld-on, bolt-on or fixed rear steering bridge.
All holes, regardless whether they are meant for the GreenSteering module, or for the assembly plates and rear
steering bridge, always have a diameter of 17.9 mm -0.1/+0.0.
Warning:
Make sure that the holes are positioned as correctly as possible according to the indicated sizes. The
simplifies assembling considerably.
Never drill the holes bigger than 17.9 mm and definitely do not use slotted holes.
If you choose to work without an assembly plate, the indicated holes can be used. This corresponds to the hole
pattern of the turntable bearings. The manufacturer of the turntable bearings dictates that 80% of the turntable
bearing must be supported. Ensure a sufficiently large support and the necessary flatness.
When integrating the turntable bearing assembly in the chassis without using the assembly plate, it is absolutely
essential to take over the alignment centre point as indicated in the provided STP files. This hole with welded tube
is used to put the axle in straight ahead position when adjusting the cables and aligning the axles.

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Hole pattern XST11A - XST21A - XST31
Warning:
Please note: Diameter 17.9 mm -0.1/+0
Hole pattern XST22X - XST22XW - XST32X

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Warning:
Please note: Diameter 17.9 mm -0.1/+0

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7.2 Welding parts on the chassis
Warning:
As every chassis can be constructed in a different way, GreenSteering cannot provide the yellow-
marked parts and needs to be produced by the constructor.
Steering module (Xm)
The steering module must be assembled to the chassis in tensionless condition. Construct the structure of the
chassis in such a way that no torsion can occur at the steering module. The steering module can only resist vertical
forces. If there is a chance that the chassis beams twist sideways because of the superstructure, the necessary
constructive measures need to be taken to prevent this torsion.
7.1.1
Warning:
If no cross bar is provided to support the GreenSteering module in the front, it must at least be
supported with construction steel S355 of minimum 20 mm wide and 320 mm long. This must be
welded fully at the top and sides
( 6).
If cross bars or reinforcements are present above the steering module, they may never be welded to
the casing of the steering module.
If there is play between the underside of one or more cross bars above the steering module, this
must be at least 4 mm.

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If the cross bars are attached to the steering module, it must be assured that these are completely adjacent and no
tension must be caused in the steering module when attaching the eight bolts to assemble the steering module. In
other words: the cross bar must support the steering module along the whole width and may not cause tension in
the casing.
If the transition between the steering module and the fifth wheel-guide plate isn't completely smooth, a slanted
edge may be made to the bottom plate along the whole width, with a maximum height of 2 mm across a length
between 20 and 40 mm.

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Weld-on assembly plate steering axle (Ab)
See Chapter 7.1.1 for the main dimensions of types XST11A –XST21A –XST31A with weld-on assembly
plates.
See Chapter 7.1.2 for the main dimensions of the types XST22X –XST22XW –XST32X with weld-on
assembly plates.
Place the assembly plates in the right position against the underside of the chassis. The chassis needs to
be clean, welding splatter free and must have a regular smooth surface.
The assembly plates have an S-mark on the left and right side to indicate the axis of the
axle(s).
On the front and back there are axis markings to indicate the central
axis with respect to the chassis.
Warning:
These markings are important, because the position of the axle(s), as well as the position of the
assembly plates with respect to the chassis, must always be as precise as possible in order to
guarantee correct steering.

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Reinforce the plates on top with the provided gusset plates.
Finish welding according to the image below, or reinforce the chassis so that at least the same effect is
reached.
Warning:
Except for attaching possible assembly plates for lubrication or other pipes, each adaptation to the
axle frame must always be approved by GreenSteering in writing. Please note: these extra holes
and the possible consequences thereof remain the full responsibility of the chassis builder.
/

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Weld-on rear steering bridge (Ab) Position
The position of the rear steering bridge is always
measured from the centre line of the rear Y/Y axis.
The two holes for attaching the cable pulleys are 515
mm behind the centre line Y/Y
The height (H3) is always equal to the steering wing
above the steering axles. This height is again
determined by the thickness of the floor + cross bars
and the control cables (see: ‘Determining the height
of the steering wing(s) and rear steering bridge (H3)’,
chapter 0).
You are advised to leave space (red
parts on figure) above the openings of
the stainless steel shafts to attach the
cables and cable pulleys. This simplifies
the work enormously when assembling
the circlips to the stainless steel shafts of
the cable pulleys.
If, for constructive reasons, a cross bar
needs to be placed above one of these
openings, then make sure that the
distance H2 is at least 35 mm. You are
advised to reinforce the web plates on
both sides of the chassis, between the
flanges (H) of the bars alongside the rear
steering bridge (yellow marking).
The thickness (D) of this plate must be at
least 10 mm. Dimension (W) is the width
of the rear steering bridge +
reinforcement.