WALTERSCHEID ZWL 30 User manual

BA_TASC_400013 Version c
MONTAGE- UND BETRIEBSANLEITUNG
INSTALLATION AND OPERATING INSTRUCTIONS
INSTRUCTIONS DE MONTAGE ET D'UTILISATION
30.03.2022
Walterscheid GmbH | Hauptstraße 150 | D-53797 Lohmar
Tel.: [phone] | Fax: [phone]
www.walterscheid.com
ZWANGSLENKUNG ZWL 30 UND ZWL 50
ZWANGSLENKUNGSBAUTEILE - NACHRÜSTSATZ
FORCED STEERING DEVICE ZWL 30 AND ZWL 50
FORCED STEERING COMPONENTS - RETROFIT KIT
DIRECTION FORCÉE ZWL 30 ET ZWL 50
COMPOSANTS DE DIRECTION FORCÉE - KIT DE MISE À NIVEAU
WICHTIGE HINWEISE:
siehe separates Dokument BA_TASC_400002, www.walterscheid.com/downloads/
IMPORTATANT NOTES:
see separate document BA_TASC_400002, www.walterscheid.com/downloads/
NOTES IMPORTANTES:
voir annexe ou document séparé BA_TASC_400002, www.walterscheid.com/downloads/

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FORCED STEERING DEVICE ZWL 30 AND ZWL 50
1. TECHNICAL DATA AND DESIGNATIONS:
DESCRIPTION AND APPLICATION:
Forced steering components are used to transfer steering forces between the towing vehicle and
trailer. The central element for connection to the handlebar of the trailer can be a 50 mm ball or a 30
mm pin. A spherical cap 50 in accordance with ISO 26204 Figure 2 or a spherical plain bearing 30 in
accordance with DIN ISO 12240-4 is mounted as a counterpart on the piston rods of the steering cylin-
ders of the forced steering systems.
TYPES AND CHARACTERISTIC VALUES:
Type Connecting element Counterpart adm. steering force
(Order
-
No.)
[
kN
]
ZWL 50 ball 50 Spherical cap 50
(8004721)
20
ZWL 30 pin 30 spherical plain bearing 30
(8004838)
40
Table 1
CONNECTING DEVICES:
The ball 50 and spherical cap 50 must ensure the same swivel angles as the ball coupling 80 accord-
ing to ISO 24347:2005. These are +/- 60 degrees in the horizontal direction and +/- 20 degrees in the
vertical and axial directions.
WARNING:
The ball 50 of the ZWL50 is not suitable for connection with ball couplings of class B50
according to ECE-R 55. The steering forces that are introduced into the connection device
via the ZWL components must not exceed
the values in table 1
.
IMPORTANT:
To avoid injury, protective gloves, safety glasses and safety shoes must be
worn during all dismantling/ assembly actions described in this chapter.
Environment:
Lubricants can enter the environment. Environmental pollution: Collect, store and correctly dispose of
lubricants in suitable containers.
2. INSTALLATION:
INSTALLATION OF FORCED STEERING COMPONENTS
NOTE:
The pertinent regulations (e.g. Accident Prevention Regulations for Vehicles) and the at-
tachment guidelines of the vehicle manufacturers must be observed when installing the
f
orced steering components
!

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8
IMPORTANT:
If the vehicle owner does not have the appropriate skilled workers and the necessary
technical equipment, the installation of forced steering components may only be per-
formed
by a specialist workshop.
The ball 50 or the bolt 30 has to be mounted in the distance given by the trailer manufacturer according
to the ball 80. Usually this is corresponding to the measurements of ISO 26402 (see Figure 1). In case
of application of Walterscheid-towing frames this is generally given. To reach these or other dimensions
Walterscheid offers different distance plates.
IMPORTANT:
Due to the variety of options for the correct operation of the ZWL, it is necessary to seek
advice from our technical sales department. For the relevant contacts, see www.walter-
scheid.com.
2.1 FORCED STEERING DEVICE (ZWL-KU) FOR TOWING FRAMES WITH FIX BALL 80:
(see Figure 2-10,12)
> Due to the installation of forced steering device to a towing frame, 2 threaded holes (M20) must be
available at the towing frame in a horizontal distance of 50 mm or 55 mm (see figure 2).
> The ZWL with a horizontal distance of 55 mm are particularly suitable for towing frames of the KK
design with a longer coupling point (see Fig. 8).
> Fix the forced steering device with 2 hexagon head screws (M20) to the coupling frame. Tightening
torque: 660 Nm.
> For a better force transmission into the steering rod, forced steering devices with 3 fixing holes to
allow an adjustment of ± 15° are available (see fig. 4 and 6).
2.2 FORCED STEERING DEVICE (ZWL-KB) FOR TOWING FRAMES WITH BALL-TYPE SILDER (KB, KBK, KBX):
(see Figure 11 and 13)
> In combination with ball-type slider KB, KBK or KBX, remove the locking pin on the corresponding
side.
> Mount the M20 (3) screw into the forced steering device. If necessary, use distance plates in be-
tween to reach the distance of 250 mm or other distances.
> Mount the anti-twist protection (5) in order to the above shown figures. A sufficient area of support
should be given as well at the coupling frame as at the ball support. Maybe use distance rings.
> Fix the forced steering device to the coupling frame by using the hexagon screw (5) and screw nut
(4). Tightening torque: 660 Nm.
> Turn the stud screw (2) against the guide rail on the towing frame and minimize the play from the
connection. Secure the stud screw (2) of the nut (3).
2.3.1 FORCED STEERING DEVICE FOR BALL-TYPE DRAWBAR (KBa-MODEL) WITH ADAPTER 525:
(see Figure 14)
The adapter 525 (2) is mountable on both sides. Check clearance before installation.
> Drill two Ø 16 H11 holes (6) into the ball-type drawbar (1) according to the assembly drawing (see
Figure 15) on that side, where the forced steering device should be fixed. In some ball-type drawbars
you can find a countersink at the position where the Ø 16 hole should be placed.
> Install the 2 dowel pins 16x100 – ISO 8752 (4) flush with the surface of the adapter and the ball-
type drawbar (1).
> Additionally, fix the device with a hexagonal screw M20x50-DIN EN ISO 4017-10.9 (5) from bottom
side into the ball-type drawbar (1). Tightening torque: 660 Nm.

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9
> Mount ZWL50KUN (3) using hexagon head screws M20x80 (4) as described under 2.1.
If adapters are mounted on both sides of the ball-type drawbar, it is necessary to replace the lower
retainer pin with the separately available collar bolt. This allows the retainer to be removed for adjust-
ment when the adapters are fitted. To assemble and disassemble the collar bolt, the retainer housing
must be dismantled.
2.3.2 FORCED STEERING DEVICE FOR BALL-TYPE DRAWBAR (KBa-MODEL) WITH RETAINER NH8300ZWL:
(see Figure 16)
On ball-type drawbars with retainer NH8300ZWL (2), on both sides ZWL can be mounted. Check
clearance before installation.
> Mount ZWL50KUN (7) using hexagon head screws M20x80 (4) as described under 2.1.
2.4 SPHERICAL CAP RESP. SHERICAL PLAIN BEARING:
(see Figure 17-20)
The spherical cap 50 (Figure 17) or the spherical plain bearing 30 (Figure 20) is mounted to the piston
rods of steering cylinders with an M30x2 thread. When using the spherical cap 50 on freely rotatable
piston rods of steering cylinders, the anti-rotation device (see Figure 18) must also be used.
3. OPERATION:
WARNING:
The pertinent safety regulations must be observed when connecting the connecting ele-
ment and counterpart.
No one may stand between the vehicles. The forced steering components may only be
operated
in
locked
state, i. H. with closed
retainer or secured bolt.
3.1 COUPLING
3.1.1 ZWL50:
(see Figure 9)
> Remove the spring pin (3) of the retainer pin (5) and pull out the pin.
> Swing the retainer (2) through 90° into the lateral position.
> Move the ball-type trailer shank at the steering rod over the ball 50 (1).
> Swing the retainer (2) back so that it is above the ball-type trailer shank.
> Secure with the retainer pin (5) and the spring pin (3).
3.1.2 ZWL50N:
(see Figure 10)
> Unlock the retainer (2) by pulling the ring (3) on the locking pin and swivel it through 90 ° into the
lateral position.
> Move the ball-type trailer shank at the steering rod over the ball 50 (1).
> Swing the retainer (2) back so that it is above the ball-type trailer shank.
> Secure the ZWL by loosening the locking pin on the ring (3)
3.1.3 ZWL30:
(see Figure 6 and 7)
> Remove the linch pin of the locking pin and pull it out.

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> Put the hinge bearing at the steering rod into the opening of ZWL30.
> Push the bolt into the hole of the support and the hinge bearing.
> Secure with the linch pin.
3.2 UNCOUPLING:
> The execution works vice versa according to point 3.1.
4. MAINTENANCE
(see Figure 9 and 10)
As part of the vehicle maintenance, the contact surfaces between the connecting element and the coun-
terpart must be lubricated and the attachment of the spherical cap or spherical bearing checked for
tightness.
The retainer (2) should be pulled out completely at regular intervals, depending on the schedule density,
and any dirt in the bearing has to be eliminated. The retainer pin (5) or the pin screw (5) must be removed
beforehand for this purpose. Subsequently re-grease the bearing.
REPLACING THE BALL 50:
If the dimension falls below the wear limit according to Table 2, the ball must be replaced. If the vertical
play of the hitched coupling exceeds 1,5 mm, and the retainer is not adjustable any longer, the appro-
priate parts must be replaced, e.g. retainer, ball or ball-type trailer shank.
> Remove the nut M30 (7) as well as the washer 31 (6) below the ball 50
> Press out the ball (1) from below, using a suitable press.
> Centre the new ball and press it in up to the stop, likewise using a press.
> Mount with washer (6) and nut M30 (7). Tightening torque 1000 Nm. Retain the nut with Loctite.
REPLACING THE PIN 30:
If the dimension falls below the wear limit according to Table 2, the pin must be replaced.
4.1 CARE
The forced steering components unit must always be cleared of dirt and corrosion in order to en-
sure perfect functioning.
4.2 CLEANING AND LUBRICATION
> All moving parts must be lubricated regularly (depending on the period of use) and checked for
ease of movement.
> If there is a grease nipple on the cap, the ball can be supplied with grease via the central lubrica-
tion.
> Avoid cleaning with high pressure cleaners if possible. If this does happen, the parts must be re-
lubricated.
> For relubrication, remove the old grease and lubricate the coupling head with fresh grease. For
lubrication use a water-resistant, multi-purpose grease (Grease type: lithium saponified, consistency
class: NL-GI2).
IMPORTANT:
Use only original Walterscheid spares when replacing parts. If the vehicle owner does not
have the appropriate skilled workers and the necessary technical equipment, the replace-
ment
may only be performed
by a specialist workshop.

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WEAR LIMITS:
Designations Nominal dimension Wear limit dimension Gauge
[mm]
[mm]
Ball S 50 50 49 X
Spherical cap S

50 inner 50,1 51 X
Spherical cap S50 outer 70 69 -
Pin  30 30 28,5 -
Sherical plain bearing  30 30 31 -
Table 2
For convenient checking of some wear limits, a separately available Walterscheid test gauge can be
used.
If the wear limits are reached, the ball coupling and/or the ball must be replaced.
WARNING:
SAFETY NOTES:
> The user is obliged to always operate the forced steering components in perfect condi-
tion and to forbid its use by unauthorised persons.
> Unauthorised conversion or modification of the forced steering components is not per-
mitted.

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BILD 1
FIGURE 1
Figure 3 ISO 26402— Location of connecting point(s) of tractor (50 mm ball) in relation to 80 mm
ball
-
type coupling device
BILD 2
FIGURE 2
BILD 3
FIGURE 3
BILD 4
FIGURE 4
BILD 5
FIGURE 5
Gerade Anordnung mit
Kugel 50 / Straight
arrangement with ball
50 / Arrangement droit
avec la boule 50
Typ/type: ZWL50KU
Winkelige (15°) Anord-
nung mit Kugel 50 /
Angular arrangement
with ball 50 /
Arrangement angulaire
avec la boule 50
Typ/type:
ZWL50KUW15
Gerade Anordnung mit
Kugel 50 / Straight
arrangement with ball 50 /
Arrangement droit avec la
boule 50
Typ/type: ZWL50KUN
Winkelige (15°) Anord-
nung mit Kugel 50 /
Angular arrangement with
ball 50 / Arrangement
angulaire avec la boule
50
Typ/type:
ZWL50KUNW15

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BILD 6
FIGURE 6
BILD 7
FIGURE 7
Gerade Anordnung mit
Bolzen 30 / Straight
arrangement with pin 30 /
Arrangement droit avec le
boulon 30
Typ
/type:
ZWL30KU
Winkelige (15°)
Anordnung mit Bolzen 30
/ Angular arrangement
with pin 30 / Arrangement
angulaire avec le boulon
30
Typ
/type
: ZWL30KUW15
BILD 8
FIGURE 8
ZWL50KUN
ZWL50KUN2

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BILD 9
FIGURE 9
Legende:
1 ..... Kugel 50
2 ..... Niederhalter 50
3 ..... Federstecker
4 ..... Stellschraube
5 ..... NH-Bolzen
6 ..... Scheibe
7
.....
Mutter M30
Legend:
1 ..... ball 50
2 ..... retainer 50
3 ..... spring pin
4 ..... adjusting bolt
5 ..... pin screw
6 ..... washer
7
.....
nut M30
Légende :
1 ..... boule 50
2 ..... dispositif de retenue 50
3 ..... goupille fendue
4 ..... vis de réglage
5 ..... boulon de maintien
6 ..... rondelle
7
.....
écrou de vis M30

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BILD 10
FIGURE 10
Legende:
1 ..... Kugel 50
2 ..... Niederhalter 50N
3 ..... Ring
4 ..... Stellschraube
5 ..... Stiftschraube
6 ..... Scheibe
7 ..... Mutter M30
Legend:
1 ..... ball 50
2 ..... retainer 50N
3 ..... ring
4 ..... adjusting bolt
5 ..... pin screw
6 ..... washer
7 ..... nut M30
Légende :
1 ..... boule 50
2 ..... dispositif de retenue 50N
3 ..... bague
4 ..... vis de réglage
5 ..... boulon de maintien
6 ..... rondelle
7 ..... écrou de vis M30

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BILD 11
FIGURE 11
Legende:
1 ..... Kugelträger
2 ..... Stiftschraube
3 ..... Mutter M16
4 ..... Mutter M20 oder M24
5 ..... Sechskantschraube M20x200
oder M24x200
6 ..... Verdrehsicherung
Legend:
1..... ball carrier
2..... stud screw
3..... nut M16
4..... nut M20 or M24
5..... hexagon screw M20x200
or M24x200
6..... anti-twist protection
Légende :
1 ..... porte-boule
2 ..... boulon de maintien
3 ..... écrou de vis M16
4 ..... écrou de vis M20 ou M24
5 ..... vis à tête hexagonale
M20x200 ou M24x200
6 ..... dispositif anti-torsion

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BILD 12
FIGURE 12
Anhängebock mit fester Kugel 80 und ZWL50KUN
Towing frame with fixed ball 80 and forced steering device ZWL50KUN
Support d
'
a
ttelage avec boule fixe 80 et ZWL50KUN
BILD 13
FIGURE 13
Anhängebock mit Kugelbock KB und ZWL50KBN
Towing frame with ball coupling 80 and forced steering device ZWL50KBN
Support d
'
a
ttelage avec boule d'attelage KB et ZWL50KBN

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BILD 14
FIGURE 14
Legende:
1 ..... Kugelbalken KBa
2 ..... Adapter 525
3 ..... Distanzstück
4 ..... Spannstift 16x100
5 ..... Sechskantschraube M20x50
6 ..... Bohrung 16 H11
7 ..... ZWL50KUN
Legend:
1 ..... ball drawbar KBa
2 ..... adapter 525
3 ..... distance plate
4 ..... dowel pin 16x100
5 ..... hexagon screw M20x50
6 ..... hole 16 H11
7 ..... ZWL50KUN
Légende :
1 ..... barre à boules KBa
2 ..... adaptateur 525
3 ..... espaceur
4 ..... goupille 16x100
5 ..... vis à tête hexagonale M20x50
6 ..... trou 16 H11
7 ..... ZWL50KUN
BILD 15
FIGURE 15
Montagezeichnung
/
assembly
drawing
/
dessin d'assemblage

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BILD 16
FIGURE 16
Legende:
1 ..... Kugelbalken KBa
2 ..... Gehäuse 8300 ZWL
3 ..... ZWL50KUN
4 ..... Sechskantschraube M20x80
Legend:
1 ..... ball drawbar KBa
2 ..... housing 8300 ZWL
3 ..... ZWL50KUN
4 ..... hexagon screw M20x80
Légende :
1 ..... barre à boules KBa
2 ..... logement 8300 ZWL
3 ..... ZWL50KUN
4 ..... vis à tête hexagonale M20x80
BILD 17
FIGURE 17
Kugelkalotte 50 / spherical cap 50 / calotte sphérique 50

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BILD 18
FIGURE 18
Verdrehsicherung / anti-rotation device / dispositif anti-rotation
BILD 19
FIGURE 19

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BILD 20
FIGURE 20
Gelenklager 30/ spherical plain bearing 30 / rotules lisses 30