VBG 795V User manual

12
3
4
5
67
8
5
10
9a
9b
12
11 13
14
VBG 795V
2005-04-19 38-134800k
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
1. Nut cover
2. Castellated nut
3. Split pin
4. Bearing plate, inner
5. Bolt kit
6. Rubber bearing
7. Drawbeam sleeve
8. Bushing
General
VBG 795V, 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
fulfils the requirements of ISO 3584 cat. 3. The web
thick-ness in the middle of the drawbeam must be 13-
30 mm with an inner clearance of at least 160 mm. It is
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 informa-
tion is overpainted. Moving parts, plates and
decals must all be thoroughly covered if the coupling
is repainted.
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

2
a
b
d
c
5–8,5 mm
Mounting instructions
• Lock the castellated nut with split pin. It is very impor-
tant that the split pin is completely within the gates
of the castellated nut and is secured as per the pic-
ture.
• 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.
Function check
Carry out the function check on page 5.
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).
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 figure. 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 figure.
Mount accessories such as the coupling mouth exten-
sion (c) according to the drawing.
Tightening torque castellated nut 1500 – 2000 Nm.
Drawbeam
sleeve
Drawbeam Spacers

3
f
i
ee
g
h
f
ca 5°
Mounting of a power actuator
If the coupling is to be equipped with a power actuator,
follow the directions below.
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 fit
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 refit 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.
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.

4
Ø 6
Ø 8
4
Ø 6
21
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.
Fitting the Pipes
• 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.
The vehicle´s auxiliary
air system
Warning!
Never put your fingers in the coup-
ling mouth because of the danger
of them being crushed.

5
+
–
20
40 60 80
100
120
approx 1 mm
Brown
Black
Blue
Inductive
sensor
g
Signal
Signal: red and green lamp, (24 V max. 2 W)
Mounting of inductive sensor
• Change the cover of the original lock indicator for
the cover modified for the inductive sensor. Open the
coupling so that the indicator pin is out. Wind the induc-
tive 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.

6
a
b
c
ab
c
10 mm
a
• When the coupling is closed, there must be approx.
10 mm clearance in the handle before the indicator/
locking pin moves outwards.
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, rectification
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.
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 cor-
responds 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
fulfilled before you start driving.
Warning!
Never put your fingers in the coup-
ling mouth because of the danger
of them being crushed.
If the coupling has been damaged
as a result of jack-knifing, driving
into a ditch, or being hit from be-
hind, you must stop and replace
the coupling.
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
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
Service position
air supply off
Air supply on

7
A
B
Attachment
• Check that the coupling can be rotated in its moun-
ting. 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
in the coupling bolt max 5.0 mm
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)

8
Safety check contd.
ef
h
g
dOperation check - power actuator
• 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 posi-
tion.
• Connect to the trailer according to the driver instruc-
tions 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).
• 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 anti-
clockwise to OFF.
Contact the nearest workshop for corrective measu-
res.

9
a
d
e
bc
C
F
F
D
E
A
B
Service - maintenance
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.
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
Wear limits
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
• 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.
• The length of service intervals depends on the type of
trailer, load, road- and weather conditions etc. Servicing
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-forma-
tion. Worn out or damaged parts must be replaced.
• If the daily overhaul or safety check shows that any
of the wear limits have been exceeded or that the
coupling´s function is reduced, repairs must be carried
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 bush-
ings. Check the mounting parts and the drawbeam and
replace worn out rubber bearings and bushings.

10
• 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 figure.
The bushings must not be welded in.
Use tool no 9 as a
guide in the lower
jaw bushing.
Use tool no 12 as a
guide in the upper jaw
bushing.
Place the tool on the
bushing before as-
sembly.
3
5a
13
2
2
9
12a
10
10
• Mount the wear plate. Tightening torque 47 Nm.
• Put the new mechanism on the coupling jaw and fit
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.
Removing
Lower jaw bushing Fitting
Lower jaw bushing
Removing
Upper jaw bushing Fitting Upper jaw bushing
Service – maintenance contd.

11
i
j
k
l
F
G
h
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
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
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 fitted.
• Mount the parts according to the figure.
• 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.

12
1
2
Driver instructions
Warning!
Never put your fingers into the coup-
ling mouth because of the danger of
them being crushed.
Uncouple the trailer. The coupling
is closed when the trailer is dis-
connected.
Stand by the coupling handle.
Lift the handle 90º, the handle
locks. The coupling is now open.
Uncoupling without power actuator
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. Con-
tact the nearest workshop for fault de-tection
and remedial measures.

13
1
2
STOP
GO
38-08100
4
6
5
0 mm ~10 mm
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.
Connect to the trailer.
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.
The trailer is secured and driving
can begin.
Stand by the coupling handle.
Lift the handle 90º, the handle
locks. The coupling is now open.
Coupling without power actuator

14
1 2
1
2
12
3
1+2
Simultaneously press on the handle where it says “Press” and turn the
handle anti-clockwise to “OPEN”. Then turn it back to “CLOSE”.
Uncouple the trailer. The coupling
is closed when the trailer is dis-
connected.
Uncoupling
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.
Warning!
Never put your fingers into the coupling
mouth because of the danger of them being
crushed.

15
Coupling
1 2
1
2
3
4
12
3
1+2
GO
5
STOP
Simultaneously press on the handle where it says “Press” and turn the
handle anti-clockwise to “OPEN”. Then turn it back to “CLOSE”.
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.
Couple to the trailer.
The trailer is secured and driving
may begin.
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.

AUSTRALIA
TRANSPEC LIMITED
P O Box 217 1 Cherry Lane
AU - 3028 P.O LAVERTON, VIC 3028
Tel [phone]
Fax [phone]
BELGIUM/LUXEMBOURG
WABCO Belgium S.A. - N.V.
Petrus Bayensstraat 70
BE – 1702 GROOT-BIJGAARDEN
Tel [phone]
Fax [phone]
DENMARK
VBG PRODUKTER A/S
Industribuen 20-22
DK – 5592 EJBY
Tel [phone]
Fax [phone]
ESTONIA
GOKART AS
Ümera 26
EE-13816 TALLINN
Tel [phone]
Faks [phone]
FINLAND
H KRAATZ OY
Ruukinmestarintie 9
FI - 02330 ESPOO
Tel [phone]
Fax [phone]
FRANCE
ONSPOT Sàrl
14 Route de Sarrebruck
FR - 57645 MONTOY-FLANVILLE
Tel [phone]
Fax [phone]
GERMANY
RINGFEDER VBG GMBH
Oberschlesienstrasse 15
DE - 47807 KREFELD
Tel [phone]
Fax [phone]
GREAT BRITAIN
FONTAINE INTERNATIONAL
EUROPE LTD.
Enterprise Way
GB - LOWTON WA3 2AG
Tel [phone]
Fax [phone]
ICELAND
OSAL OSKAR ANDERSSON
Tangarhofdi 4
IS - 110 REYKJAVIK
Tel [phone]
Fax [phone]
IRELAND
NEWBRIDGE METAL PRODUCTS LTD
Industrial Estate
IE - NEWBRIDGE, Co Kildare
Tel [phone]
Fax [phone]
ISRAEL
H KLEIN & SONS LTD
P O Box 1093
Industrial Area-North
IL - ASHDOD 77109
Tel [phone]
Fax [phone]
ITALY
NORDAUTO Torino S.R.L.
Via Lanzo 52
IT - 10040 VAL DELLA TORRE (TO)
Tel [phone]
Fax [phone]
JAPAN
SHINKO BOEKI CO LTD
Shibuya Central Bldg
3-14 Udagawa-cho, Shibuya-ku,
JP - TOKYO 150
Tel [phone]
Fax [phone]
NETHERLANDS
WABCO AUTOMOTIVE B.V.
Postbus 8704
NL - 3009 AS ROTTERDAM
Tel [phone]
Fax [phone]
NEW ZEALAND
TRANSPORT SPECIALTIES LTD
P O BOX 98-971
NZ - S.A.M.C., Wiri, AUCKLAND
Tel [phone]
Fax [phone]
NORWAY
VBG PRODUKTER A/S
Postboks 94 Leirdal
NO - 1009 OSLO
Tel [phone]
Fax [phone]
POLAND
HYVA POLSKA Sp. z o.o.
ul. Mysliwska 68
PL - 30718 KRAKÓW
Tel [phone]
Fax [phone]
SWEDEN
VBG PRODUKTER AB
Box 1216
SE - 462 28 VÄNERSBORG
Tel [phone]
Fax [phone]
Branch office:
VBG PRODUKTER AB
Kronoskogsvägen 8
SE - 903 61 UMEÅ
Tel [phone]
Fax [phone]
SWITZERLAND
AGL für LASTWAGENZUBEHÖRE
Postfach
CH – 6048 HORW
Tel [phone]
Fax [phone]
SWITZERLAND
AMBOFIX METALLBAU
U. Ambühl
Am Schachenrain 36
CH – 4562 BIBERIST
Tel [phone]
Fax [phone]
TANZANIA
SUPERDOLL TRAILERS MANUFACTURE CO. LTD
P:O Box 16541
TZ - DAR ES SALAAM
Tel [phone]
Fax [phone]
VBG PRODUKTER AB
Herman Kreftings gata 4
Box 1216
SE-462 28 VÄNERSBORG
Tel [phone]
E-mail [email protected]
www.vbg.se