Rockinger RO 400 User manual

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Modellreihe
Series
Type
Vollautomatische Anhängekupplung
Automatic Trailer Coupling
Attelage de remorque entièrement automatique
Montage- und Betriebsanleitung
Installation and operating instructions
Instructions de montage et d’utilisation
DE
EN
FR
ROi400

ROCKINGER
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GB
Table of contents ROi400
Safety instructions 18
1. Fitting 19 – 22
1.1 Before installation 20
1.2 Installation 20 – 22
2. Operation 23 – 24
2.1 Hitching 23
2.1 Check 23
2.2 Closing coupling manually 24
3. Maintenance 24 – 27
3.1 Care 24
3.2 Inspection 25 – 27
Technical data 28 – 29
Upgrade kits 29
Official note
When fitting the trailer coupling the regulations for fitting mechanical
fastening systems in accordance with Appendix 7 of Directive
ECE R 55 and the national regulations for commercial vehicles
must be observed.
Subject to technical changes without prior notice
The coupling must be installed by
authorised personnel!
Read these instructions carefully
before fitting!
!
Series ROi400
technical release 1
ECE E1 55R-01 0350 Typ ROi400-G 150
ECE E1 55R-01 0351 Typ ROi400-G 145
ECE E1 55R-01 0352 Typ ROi400-G 135
Suitable for:
– drawbar eyes 40
DIN 74054 and class S (ECE)

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GB
Safety instructions ROi400
The safety instructions are summarised in a single chapter. In
any situation where the user of the trailer coupling is at risk,
the safety instructions are repeated in the individual sections
and marked with the warning symbol shown here.
When handling hitches, prime movers and trailers the relevant safety regula-
tions in the respective country must be observed (e.g. Berufsgenossen-
schaft in Germany). Any safety instructions in the operating manual of the
tractor vehicle and the trailer remain valid and must be observed.
For operation, maintenance and assembly the safety instructions listed
below must be observed. Further safety instructions are then given in the
individual case which relate directly to the respective activity.
Safety instructions for operation
x The hitch may only be operated by authorised persons.
x The installation and operating instructions of the respective hitch retain
their validity and must be observed.
x Only use the hitch and the towing eye of the trailer if they are in perfect
technical condition.
x Only carry out hitching / unhitching operations on firm, level ground.
x During hitching, nobody may stand between the tractor vehicle and the
trailer.
x After every hitching operation the correct locked status of the trailer
coupling must be checked by means of the control pin or the remote
indicator. Only drive the rig in the correctly locked status.
x The remote indicator does not exempt the driver from the obligation to
check before driving off subject to StVZO (Regulations Authorising the
Use of Vehicles for Road Traffic). Before driving off, among other things,
the coupling status of the mechanical connection device for the tractor
vehicle and the trailer must be checked.
Safety instructions for maintenance
x For maintenance work, only use the prescribed lubricants.
x Maintenance work may only be carried out by qualified personnel.
Safety instructions for installation
x Installation may only be carried out by authorised workshops.
x Installation must be carried out in compliance with the relevant accident
prevention regulations and the technical regulations for mechanical
equipment..
x Only original components may be used.
x Instructions and installation guidelines of the vehicle manufacturer must
be observed, e.g. type of fastening, clearances etc.
x All screwed connections must be tightened with the prescribed tightening
torque.
x Work may only be carried out on the trailer coupling when it is closed.
Risk of injuries!
The installation of the hitch on the prime mover must be carried out in
accordance with Annex 7 of Directive ECE R 55-01 and must be checked
accordingly. As applicable, the relevant licensing regulations in the respective
country must be observed.
§§ 19, 20 and 21 StVZO apply in Germany. The mechanical remote control
and the mechanical remote indicator are equipment with safety compo-
nents. This is why the installation must be documented.
The hitch, the remote control and the remote indicator are
connection devices which require model approval and are
subject to the highest safety requirements.
Alterations of any kind shall cause the warranty to lapse and invalidate the
type approval, which in turn invalidates the vehicle operation permit.
!
!

9
8
T
7
6
5
4
3
1
2a
10
2c
2b
1. Fitting ROi400
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01Sealing cap
02a Cheese-head screw
02b Spacer bushing (2)
02c Hexagon nut
03 Hexagon nut
04Conical cap
05Rubber buffer
06Protective buffer cap
07Bearing
T Vehicle cross member
08Protective buffer cap
09Rubber buffer
10 Jaw with drawbar
Fig. 1
Mounting technical release 1
GB

1.1 Before installation
Note: Please comply with following when fitting hitch:
– applicable national regulations
– vehicle manufacturer’s specifications
– clearance for axial rotation of coupling head of at least e 25h
Fig. 1 and 2 depend on technical standard
x Unscrew 3
x Remove 4, 5, 6 and 7, 8and 9 remain on 10
Note:
x 1and 2in equipment pack, do not remove grease from 6, 8
and 10!
1.2 Installation
x Install the bearing (7) onto the inner side of the cross member (T)
x Secure with 4 hexagon bolts (DIN 931, grade 8.8)
and self-locking nuts, grade 8.
Size of bolts, nuts and torque to be chosen, see table
Note: Observe manufactures’ instructions in case different bolts
and nuts are recommended!
ATTENTION:
Mount bolt heads on the side directed towards the jaw (outside the
cross member) to avoid impairing movability of the hitch (see Fig. 2)
(UVV Fahrzeuge, VBG 12,
KBA-Merkblatt)
1. Fitting ROi400
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GB

1. Fitting ROi400
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GB
Torque of bolts on the bearing
Size of Size of Width Tightening ROCKINGER
hitch bolts across flats torque1set of bolts
S (mm) (Nm) part no.
150 M 20 30 410 70971
145 M 16 24 210 70952
135 M 14 22 135 70970
1) Tightening torque for screws use a torque meter to fix according to DIN
ISO 6789, class A or B
Grip (thickness) of cross member (s. fig. 3)
Size of hitch: 145 / 150 135
Central-axle-trailer: 11 – 35 mm 11 – 32 mm
Drawbar trailer: max. 35 mm max. 32 mm
x Insert spring cap (8) (concave side facing 9) onto 7
x Shaft of hitch 10 with 9into 7(do not remove grease, if necessary
regrease with EP3 grease)
x (6) concave side facing 5), 5and 4(like 6) onto 10
Grip Flange
thickness
Screw length
Fig. 2

1. Fitting ROi400
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1.2 Mounting ROi400 technical release 1
x Tighten 3, tightening torque 500Nm1(350 Nm1by G 135)
x Locate 1 x 2b onto 2a
x Slide 2a and 2b through the bore in 3
x Locate1 x 2b onto 2a and tighten with 2c:
tightening torque 25 Nm1
x Fit the sealing cap (1) to protect against corrosion.
Note: Before painting, it is essential to close hitch and grease or cover
coupling pin. After painting clean and regrease the coupling pin.
1Tightening torque, screws are to fix with a torque wrench
at DIN EN ISO 6789, classe A or B
GB

2. Operation ROi400
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GB
2.1 Hitching
Note: The relevant national regulations (f.e. safety-at-work) must be
observed when hitching and unhitching.
No one must stand between the vehicles!
x To engage, press hand lever upwards until it engages
x Check whether funnel is locked.
x Position drawbar eye in centre of funnel
x Disengage brake on front axle of turntable drawbar trailer
x Set drawbar eye to height of coupling point (centre of funnel).
x Slowly reverse prime mover
When hitching to a central-axle trailer (see fig. 3):
x Reverse prime mover very slowly
x The drawbar eye must be inserted into the middle of the jaw.
Otherwise the jaw, the drawbar eye or the drawbar support legs
might be damaged.
Kontrolle:
After each hitching procedure, it is essential to check that the hitch is
correctly closed and locked.
The lock-control pin must not protrude out of its guide after
hitching (see fig. 4)
If the lock-control pin protrudes from its guide (in the dark detectable
by touching it), the hitching procedure has been
carried out incorrectly and there is the risk of an accident!
Driving a trailer in that condition is not allowed.
If not correctly coupled:
– move the prime mover forward (approximately 1 m)
– check again
In-cab status indicator upgrade kit available for retrofitting.
Fig. 3
Tractor unit with drawbar trailer
Tractor unit with rigid trailer
Fig. 4

2. Operation ROi400
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2.2 Closing coupling manually
(e.g. for tow-rope)
x Raise coupling pin with suitable tool
GB
3. Maintenance ROi400
3.1 Care
Before starting maintenance work on the hitch ensure that hitch is
closed. Risk of Accident! (see para. 2.2)
x Lubricate coupling bin, support ring and drawbar eye with heavy-
duty grease (EP3) which is waterproof if possible before first use
and after extended period in use.
x Under harsh operating conditions or severe exposure to dirt or
water regrease automatic unit (A) when coupling is open (see fig. 5):
– use multi-purpose grease NLGI 2
– intervals: 6 months or 50,000 km
x Lubricate lower funnel bearing (F) with EP3 grease.
Note: Close coupling before cleaning with high-pressure washers
(see para. 2.2).
x After cleaning, relubricate coupling pin and support ring with EP3
grease.
Fig. 5
A
F

3. Maintenance ROi400
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GB
Please note following when carrying out repairs on coupling
(e.g. changing coupling pin):
x Remove as much of old grease as possible.
x Relubricate with multi-purpose grease (NLGI 2; temperature range
–40hbis 120hC)
3.2 Inspection
Bearing:
– Longitudinal play
x Grip coupling head (not jaw funnel) with both hands when
uncoupled and move vigorously in longitudinal direction (see fig. 7):
No longitudinal play is allowed.
– Vertical play
x Open hitch.
x Move coupling head up and down with appropriate tool (see fig. 8):
Vertical play may not exceed 3 mm measured at coupling head
(centre axis of coupling pin).
Coupling pin:
Check wear using ROCKINGER reference gauge (order no. 57026)
(see Fig. 8):
Coupling pin may be used until diameter of crowned section has worn
to less than 36.5 mm, after which it must be replaced.
Fig. 7
Fig. 9
Fig. 8
ı
ı

3. Maintenance ROi400
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Fig. 9
Fig. 10
GB
Vertical play in coupling pin (see fig. 9) may not exceed 2mm.
Lower bush:
Check wear using ROCKINGER reference gauge (order no. 57290).
Max. admissible internal diameter of lower bush is 31.5 mm.
Passage below pin must be free.
Please consult repair leaflet (available on request) for details of
replacing.
Support ring:
Support ring for drawbar eye must be replaced if drawbar eye could
touch lower bush because of wear or if wear limit Hmin. of 14 mm
(see Fig. 10) has been reached.
Lower bush must not be damaged under any circumstances as
this will impair closure of coupling.
Take care to prevent risk of accident!
Always grease support ring to reduce wear (please consult repair
leaflet, available on request, for details of replacing).
v
b

3. Maintenance ROi400
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Check lockof the funnel:
Note: The funnel must be locked in its central position when coupling
is opened to be prepared for coupling on!
x Push the funnel sidewards
x Move handlever in locking direction (up)
x Release funnel
x The funnel must swing back in central position and be locked again
x If not, justify the central position by the lower unit as below.
Adjustment for technical release 1:
x Loosen screws (17) and bring the funnel into the central position:
x Open coupling: Funnel lock should be inserted
x Tighten screws (17) – Tightening torque 85 Nm.
x Both ends of torsion springs (R) must lie slack free (S) against the rib
of the funnel. Between the spring holder (H) and the lay-on points of
the torsion springs should also be no gap.
x In case there is gap you can close it very easilyby bending the spring
holder with a screwdriver (M) (see fig. (S = 0).
x Please, check the lock and movement of the funnel again
1) Tightening torque for screws use a torque meter to fix according
to DIN ISO 6789, class A or B
GB
M
R
H
17
R
Fig. 11

Series ROi400
ECE E1 55R-010350 Typ ROi400-G 150
ECE E1 55R-010351 Typ ROi400-G 145
ECE E1 55R-010352 Typ ROi400-G 135
or drawbar eyes 40
DIN 74053 und ECE-Class S
Flange size to
ECE R 55-01
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Technical data ROi400
Coupling open
Tightening torque
for SW 70: 500 Nm
(for SW 55: 350 Nm)
informative sticker
for “safety indicator”
Fitting clearance min. 230 mm
(min. 180 mm)
Coupling
closed
Centre line
of drawbar
Mont screw heads
for attachment on
coupling head
side
Size a b c d e f KL max.
(mm) (mm) (mm) (mm) (mm) (mm) (mm)
135 120 055 155 090 15 74 32
145 140 080 180 120 17 84 35
150 160 100 200 140 21 94 35
Nameplate
position
dimension for releasing safety
mechanism for drawbar eye
GB
Technical data
for ROi400
technical release 1

Technical data ROi400
part no. CENTRAL-AXLE TRAILER
hand lever hand lever size hole pattern maximum maximum maximum static maximum weight
upwards downwards D-value* Dc-value* vertical load** V-value*
(mm) (kN) (kN) (kg) (kN) (kg)
400A36001 400B36001 135 120x 55 70 70 0700 24 30
70 70 0500 26,4 30
400A46001 400B46001 145 140x 80 100 91.5 1000 31,2 34
400A51001 400B51001 150 160x 100 130 90 1000 35 35
** Calculation see catalogue or internet: http//www.jost-world.com
** When using a central-axle trailer, the vertical load should amount to at least 4% of the trailer weight, in order to prevent increased wear caused by bouncing of the drawbar eye.
Upgrade kits remote operation part no.
Mechanical remote operation power assistent opening ROE 71599FA
Pneumatic remote operation power assistent opening
and closing ROE 71461
Mechanical remote operation ROE 71676
Upgrade kits remote control part no.
Electronical remote indicator RI-BE ROE 71546
Electrical remote indicator RI-BC ROE 71654
Repair instructions and parts list to be obtained upon request!
Upgrade kits technical release 1 ROi400
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GB

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