V.ORLANDI E 40 Parts list manual

Drawbar coupling E 40
SSSS
IIIIIIII TT EE MM DD TT RR AA NN
OO
OO RR LL DD II
Installation,operating and
maintenance instructions
EE

Registration of the installation and the maintenance operations
Date of the installation of the coupling:
Vehicle data: Type:
Registration number:
Signature:
Signature:
Signature:
Signature:
Km/Miles:
Km/Miles:
Km/Miles:
Km/Miles:
Signature:
Stamp:
Stamp:
Stamp:
Stamp:
Stamp:
Data:
Data:
Data:
Data:
Data:
Maintenance operations carried out:
Maintenance operations carried out:
Maintenance operations carried out:
Maintenance operations carried out:
Km/miles:

Signature:
Signature:
Signature:
Signature:
Signature:
Km/Miles:
Km/Miles:
Km/Miles:
Km/Miles:
Km/Miles:
Stamp:
Stamp:
Stamp:
Stamp:
Stamp:
Data:
Data:
Data:
Data:
Data:
Maintenance operations carried out:
Maintenance operations carried out:
Maintenance operations carried out:
Maintenance operations carried out:
Maintenance operations carried out:

INDEX
0 PRELIMINARY REMARKS
0.1 WARRANTY
0.2 CARE OF THE MANUAL
0.3 HOW TO READ AND USE THE MANUAL
1 GENERAL INFORMATION
1.1 DESCRIPTION OF THE DRAWBAR COUPLING
1.2 UNPACKING
1.3 OPERATING LIMITATIONS
1.3.1 INSTALLATION PRESCRIPTION
2 INSTALLATION
3 OPERATING INSTRUCTIONS
3.1 COUPLING UP
3.2 UNCOUPLING
4 MAINTENANCE
4.1 PERIODICAL MAINTENANCE
5 REPAIRING
5.1 REPLACEMENT OF THE RUBBER BUFFERS AND THE INNER BUSH
5.2 REPLACEMENT OF THE MECHANISM UNIT AND THE COUPLING PIN
5.3 REPLACEMENT OF THE LIFT LEVER SPRINGS
5.4 REPLACEMENT OF THE COUPLING JAW
5.5 REPLACEMENT OF THE WEAR PAD OF THE LOWER BUSH
5.6 REPLACEMENT OF THE UPPER AND LOWER BUSHES
5.7 REPLACEMENT OF THE SECURITY PIN
5.8 REPLACEMENT OF THE JAW LOCK PIN
6 CLEANING
7 DISPOSAL
8 HOW TO TAKE THE COUPLING OUT OF SERVICE
REV. 00
INDEX
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DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS
5
5
5
6
7
7
8
8
8
12
14
16
18
21
9
12
23
24
25
21
22
26
27
28
29
30
31

0 PRELIMINARY REMARKS
0.1 WARRANTY
0.2 CARE OF THE MANUAL
This manual is an integral part of the drawbar coupling and has to follow it wherever
and always, in resale or restitution under warranty. It has to be available for all
operators for quick consultation any time it is necessary.
The end-user is responsable for keeping it in good condition.
The manual has to be replaced with an identical one if wear or other damage
makes the reading impossible.
Note: this manual has 32 pages.
First edition: January 2004
Reprint: .....................
REV. 00
CHAP. 0
PAG.
05/32
V.Orlandi Spa shall take no responsibility for any damage howsoever caused and
including improper or incorrect use, modifications, alterations or abuse.
Use of not original spare parts of V.Orlandi Spa annulls any warranty and
invalidates any homologation.
V.Orlandi Spa reserves the right to make modifications any time.
DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

As well as the descriptive title of each chapter, the following signs have been used to
indicate which measures are required during the different procedures.
Attention and caution
Wear heavy working shoes
Wear working gloves
Read carefully the following paragraph/sentence/chapter
Attention! Risk of a limb injury
Absolute prohibition
Denotes attention and caution, precedes the technical indications
for the different procedures.
0.3 HOW TO READ AND USE THE MANUAL
REV. 00
PAG.
06/32
N
O
T
E
DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS
CHAP. 0

14
25
3
4
5b
13
1
22a
22b
7a
20a
18e
B
A
Nut cover
Castellated nut
Operating handle, upwards
Rear flange
Operating handle, downwards
Front flange
Tie rod
Coupling flange
Coupling jaw
Homologation plate
Warning plate
Coupling pin
Security pin
Mechanism unit
14
25
7a
b5
18e
3
14
22a 22b
13
20a
A
B
1 GENERAL INFORMATION
1.1 DESCRIPTION OF THE DRAWBAR COUPLING
The principal parts of the drawbar coupling are listed below in order to
allow the correct interpretation of the manual which refers mainly to
these parts:
REV. 00
CHAP. 1
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DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

1.3.1 INSTALLATION PRESCRIPTION
The drawbar couplings of the series E40 are suitable for central axle trailers and
steering axle trailers equipped with 40 mm drawbar eyes according to DIN 74051
and ISO 8755.
The drawbar couplings of the series E40 can be installed on the drawbeams of
different hole patterns according to the Directive 94/20/EC and according to ISO
3584. The choice of the coupling must be compatible with the drawbeam and
based on the specification sheet of the product.
1.3 OPERATING LIMITATIONS
Read the following instructions carefully before any operation:
Ensure that the position of the operating handle (22A 22B) is as shown in the
illustration and that the coupling pin (14) is fully visible.
Attention! Risk of a limb injury
1.2 UNPACKING
22a
14
22b
REV. 00
CHAP. 1
PAG.
08/32
DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

This chapter refers to the figures on pages 09-11/32.
Read the following instructions carefully before any operation:
Put on heavy working shoes and working gloves.
Lay the coupling on a solid and stable surface.
Remove the castellated nut (3), rear flange (4), rubber buffer (8a),
second rear flange (5a) and the coupling flange (7a).
2 INSTALLATION
1
4
8a
5a
7a
25
3
24
24
2
N
O
T
E
Installation has to be carried out by skilled personnel
REV. 00
CHAP. 2
PAG.
09/32
DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

Now proceed with installing the drawbar coupling to the chassis drawbeam:
Coupling type Bolt size Bolt strength Torque (M)
Lubricate the threads of the tie rod (25), tighten the castellated nut (3) by hand in
the first instance taking care to ensure the coupling is level horizontally;
Insert the second rear flange (5a), the rubber buffer (8a) and the rear flange (4);
Insert the tie rod (25) with rubber buffer (8b) and front flange (5b) through the
coupling flange (7a) which is already bolted on the drawbeam;
ATTENTION: Use only self-locking nuts
E 403
E 404
E 406
M 14
M 16
M 20
10.9
10.9
8.8
120 Nm
180 Nm
350 Nm
1)
2)
3)
4)
09 °
90°
Fit the coupling flange (7a) in to the central hole of the chassis drawbeam
from the inner side and fix it with the four bolts (24). Tighten the bolts as
follows:
REV. 00
CHAP. 2
PAG.
10/32
DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

Insert the split pin (2) through the castellated nut and the hole on the thread of
the tie rod (25). Open the two halves of the split pin and press them back
against the castellated nut;
Fit the nut cover (1).
6)
7)
Tighten the castellated nut (3) with a torque wrench as follows:
5)
E 403
E 404
E 406
M=350 -
M=500 -
M=500 -
430 Nm
611 Nm
611 Nm
2
25
3
N
O
T
E
Never slacken the castellated nut back to allow the split pin to be
inserted. If necessary, tighten the castellated nut further until one of the
holes in the shaft aligne with one of the castellations in the nut.
REV. 00
CHAP. 2
PAG.
11/32
DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

Attention! Risk of a limb injury
13 13
22a 22b
18e
22a 22b
3 OPERATING INSTRUCTIONS
This chapter refers to the figures on pages 12-15/32.
Read the following instructions carefully before any operation:
Ear working gloves
ATTENTION: Before coupling operation check that the brake of the trailer
is on and that in case of a steering axle trailer the front axle is free to
steer. Make sure that the drawbar eye and the coupling are level or that
the eye is slightly lower so that it runs up the lower jaw. If coupling a
central axle trailer, ensure that the rear support jacks, if fitted, are clear
of the ground first.
Lift the operating handle (22A-22B) upwards as far as it will go (note: minimum
force needed is 200 N).
The coupling pin (14) is now raised. Check that the coupling jaw (13) has
locked, ie. cannot swing from side to side.
The security pin (18e) will now be protruding from its seat.
Reverse slowly the truck, the drawbar eye has to enter the coupling jaw (13)
properly. The push of the drawbar eye against the visible part of the coupling
pin makes the pin (14) fall down immediately and the security pin (18e) is
seated automatically.
1)
2)
3.1 COUPLING UP
14 14
REV. 00
CHAP. 3
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DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

13
18e
22a
18e
22b
ATTENTION: Always ensure that the coupling operation is carried out
properly; check that the operation handle (22A/22B) is down and that
the security pin is fully seated in order to guarantee a secure blocking
down of the coupling pin (14).
ATTENTION: In case the coupling would not close perfectly move the
truck back and forth about 50 cm to assist the drawbar eye to find the
right position and make the coupling close.
If the coupling will not close perfectly it is absolutely forbidden to travel.
Contact the closest workshop for the solution.
OK NO
REV. 00
CHAP. 3
PAG.
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DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

Make sure that the brake of the trailer is on. If uncoupling from a
central axle trailer, lower the the drawbar support leg to the ground
so that it is just starting to take weight. Do not try to push the drawbar
eye high in the coupling, otherwise the eye will interfere with the pin
preventing the uncoupling.
Lift the operating handle (22A-22B) upwards as far as it will go (see point 1
in chapter 3.1 COUPLING UP on page 12/32).
3.2 UNCOUPLING
NOTE: The trailer couplings of the new series E40 can be opened
with the coupling jaw (13) in any position.
1)
N
O
T
E
Do not use any shafts or levers to extend the operating handle. If
the coupling pin does (14) not rise check that all the described
conditions are respected.
If the operating handle is hard to lift, move the truck slightly in order
to release the pressure of the drawbar eye against the coupling pin.
REV. 00
CHAP. 3
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DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

Move the truck forward; The coupling will automatically close as the truck pulls
away from the trailer.
2)
3°3°
3°3°
max.max.
max.max.
ATTENTION: To ensure satisfactory function of the coupling during
coupling and uncoupling the trailer, make sure that the drawbar eye is
within ± 3° of the longitudinal horizontal axis of the coupling.
REV. 00
CHAP. 3
PAG.
15/32
DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

14
22a 22b
4 MAINTENANCE
This chapter refers to the figures on pages 16-20/30.
Wear heavy working shoes.
Read the following instructions carefully before any operation:
ATTENTION: make sure that the coupling is closed ie the coupling pin
(14) and the operating handle (22A-22B) are down during all
maintenance operations.
All moving parts of the coupling are subject to wear caused by normal
use. Extent of wear depends on working conditions and maintenance
operations carried out.
Therefore regular lubrication and maintenance will help prolong the life
and safety of the coupling.
N
O
T
E
REV. 00
CHAP. 4
PAG.
16/32
DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

3
29
24
14
Attention! Risk of a limb
injury.
1)
2)
1)
2)
4)
5)
3)
After the first 500 Km of use:
Check that the torque of the bolts (24) of the coupling flange is within the torque
indicated in point 1 in chapter 2 INSTALLATION, page 10/32.
Check that the torque of the bolts (24) of the coupling flange is within the
torque indicated in point 1 in chapter 2 INSTALLATION, page 10/32;
Check that the tightness of the castellated nut (3) is within the torque indicated
in point 5 in chapter 2 INSTALLATION, page 11/32;
Check that the torque of the bolts (24) of the coupling flange is within the
torque indicated in point 1 in chapter 2 INSTALLATION, page 10/32;
Check that the torque of the castellated nut (3) is within the torque indicated in
point 5 in chapter 2 INSTALLATION, page 11/32;
Check, when the coupling is closed, that
the coupling jaw is free to move;
Open the coupling and check that it works
correctly following the instructions in
chapter 3.1 COUPLING UP on page 12/32.
Grease the mechanism through the grease nipple (29). Always
grease the mechanism with the coupling pin (14) raised (see
point 1 in chapter 3.1. COUPLING UP on page 12/32). Do not
over grease. Too much grease can hinder good functioning of
the mechanism;
After the first 3000 Km of use:
Every 15000 Km:
REV. 00
CHAP. 4
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DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

6)
1)
Check that the coupling jaw is properly
locked in the central position.
Limits shown on page 19/32,
those parts shall be replaced
with new ones immediately.
If during the various checks, any
component wear has exceeded the
N
O
T
E
Depending on the use and at least annually the coupling shall be
checked for wear.
The following checks and controls are recommended:
This chapter refers also to the figure on page 21/32.
Checking the rubber buffers
Take hold of the coupling and check it, by shaking it forcefully. There
should be no play.
If vertical play exceeds 1 mm the inner bush (7c) must be
replaced. If there is any longitudinal play, the rubber buffers
(8a,8b) must be replaced - see chapter 5.1 REPLACEMENT OF
RUBBER BUFFERS AND INNER BUSH, page 21/32.
4.1 PERIODICAL MAINTENANCE
REV. 00
CHAP. 4
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DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

N
O
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E
Checking the threads of the castellated nut and of the tie-rod:
Remove the nut cover (1), split-pin (2) and the castellated nut (3). Check the
condition of the threads of the nut (3) and of the tie-rod (25). In case there are
any signs of play or seizure the parts must be replaced immediately;
Wear check:
Check that the wear of the coupling pin (14) (see chapter 5.2 REPLACEMENT OF
THE MECHANISM UNIT AND THE COUPLING PIN, page 22/32) and of the upper
bush (6) and of the lower bush (10b) (see chapter 5.6 REPLACEMENT OF THE
UPPER AND LOWER BUSHES, page 26/32) are within the recommended limits
shown in the figure;
The wear data below is specified according to the technical
specification ISO TS 20825
2)
3)
X XX XX XX X
25
25M 25P
10b
6
14
10b
“S”“S”
(7)
min. 12
4 max.
Ø 39,9 max.
Ø 31,2 max.
Ø 36.5 min.
Ø 36.5 min.
Ø 29 min.
14
REV. 00
CHAP. 4
PAG.
19/32
DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

Checking the vertical play of the coupling pin:
Check that the vertical play of the coupling pin (14) is no more than 4 mm. The
play “S” is to be measured by pushing the tip of the pin upwards when the
operating handle (22A-22B) is down (see figure on page 19/32).
In case the play exceeds the limit replace the lift lever (15) (see chapter 5.3
REPLACEMENT OF THE LIFT LEVER SPRINGS, page 22/32);
Checking for play in the operating handle:
Check that the free movement of the operating handle (22A-22B) is less
than 10° (degrees) as shown in the figure. In case the limit is exceeded
replace the operating handle (22A-22B) and the lift lever (15) (see chapter
5.3 REPLACEMENT OF THE LIFT LEVER SPRINGS, page 23/32);
Lubrication:
Grease the mechanism unit (20a) through the grease nipple (29) on the right
side of the mechanism box (see the figure on page 17/32).
Always grease the mechanism with the coupling pin (14) raised (see point 1 in
chapter 3.1. COUPLING UP on page 12/32). Do not over grease.
Checking the torque of the screws and bolts:
Check that the torque of the screws (21) is M = 50 Nm and that the torque
of the fixing bolts (24) is as given in point 1 in chapter 2 on page 09/32;
4)
5)
6)
7)
N
O
T
E
Too much grease can hinder good functioning of the mechanism;
Oil the moving parts of the trailer coupling.
22B
24
21
22A
10°
REV. 00
CHAP. 4
PAG.
20/32
DRAWBAR COUPLING E 40
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS