ANNEX VSupplementary provisions
ANNEX V Requirements applying to coupling devices and attachments 1. Scope 1.1. This Annex applies to coupling devices and attachments for L-category vehicles, if fitted. 1.2. This Annex states the requirements which coupling devices for L-category vehicles shall satisfy in order to: 1.2.1. Ensure compatibility when combining L-category vehicles with different types of trailers; 1.2.2. Ensure the safe coupling of the vehicle and trailer under all conditions of use; 1.2.3. Ensure safe procedures for coupling and uncoupling. 2. General requirements 2.1. The coupling devices for L-category vehicles shall be manufactured and attached in accordance with good engineering practice, and shall be safe to operate. They may be approved as separate technical units under this Regulation or approved under UNECE regulation No 55 ( 1 ) . 2.2. The coupling devices shall be so designed and manufactured that in normal use, with proper maintenance and the timely replacement of wearing parts, they will continue to function satisfactorily. 2.3. Every coupling device shall be accompanied by installation and operating instructions giving sufficient information for a competent person to install it on the vehicle and operate it properly. The instructions shall be in the official language or languages of the Member State in which the coupling device will be offered for sale. 2.4. The materials that may be used are those for which the properties relevant to the application are laid down in a standard or those for which the properties are given in the application documentation. 2.5. All parts of the coupling devices the failure of which could result in separation of the two vehicles shall be made of steel. Other materials may be used provided equivalence has been demonstrated by the manufacturer to the satisfaction of the technical service. 2.6. All couplings shall be designed for positive mechanical engagement, and the closed position shall be secured at least once by positive mechanical engagement. 2.7. If equipped with a coupling device, a coupling ball as specified in accordance with Appendix 1, Figure Ap1-1 shall be used on an L-category vehicle. The coupling type shall be chosen and positioned to allow maximum compatibility with a range of trailer types. However, a device other than such a coupling ball may be used, provided the requirements of point 2.8 are met and that the compatibility and interchangeability of trailers is neither necessary nor possible (dedicated combinations). 2.8. Coupling devices shall be designed so as to meet the requirements for case of operation, position, mobility and strength in line with points 2.9, 2.10, 2.11 and points 3, 4 and 5. 2.9. The coupling devices shall be designed and attached so as to achieve maximum safety according to good engineering practice; this also applies to the operation of the coupling. 2.10. It shall be possible for one person safely to couple and uncouple the vehicles without the use of tools. 2.11. It shall be possible to operate the detachable coupling devices easily by hand and without the use of tools. 2.12. When placing products on the market, manufacturers of coupling devices or vehicles shall provide the consumer with guidelines and information in all official languages regarding the impact on driveability of driving an L-category vehicle with a trailer. 3. Requirements for position 3.1. Coupling devices attached to the vehicles shall ensure unhindered and safe operation. 3.2. Coupling balls attached to the vehicles shall correspond to the geometric conditions specified in figure Ap1-2 of Appendix 1. 3.3. The height of the coupling point of a coupling device other than a coupling ball shall correspond to the height of the coupling point of the drawbar of the trailer within a range of ± 35 mm, provided the trailer is in a horizontal position. 3.4. The shape and dimensions of the towing brackets shall correspond to the vehicle manufacturer’s requirements with respect to fixing points and any additional mounting devices required. 3.5. The requirements of the vehicle manufacturer with regard to the type of the coupling device, the permissible mass of the trailer and the permissible static vertical load imposed at the coupling point shall be observed. 3.6. The mounted coupling device shall not obscure the visibility of the rear licence plate and/or lighting components; otherwise a coupling device shall be used which can be dismantled without special tools. 3.7. Manufacturers of towing brackets shall incorporate attachment points to which either secondary couplings or devices necessary to enable the trailer to be stopped automatically in the event of separation of the main coupling, may be attached. 3.7.1. The attachment points for a secondary coupling and/or breakaway cable shall be positioned such that when in use, the secondary coupling or breakaway cable does not restrict the normal articulation of the coupling or interfere with the normal inertia braking system operation. 3.7.2. A single attachment point shall be positioned within 100 mm of a vertical plane passing through the centre of articulation of the coupling. If this is not practicable, two attachment points shall be provided, one on each side of the vertical centre line and equidistant from the centre line by a maximum of 250 mm. The attachment point(s) shall be as rearward and as high as practicable. 4. Requirements for articulation 4.1. The following articulation shall be possible with the coupling device not attached to the vehicle: 4.1.1. An angle of free vertical pitch of 20° above and below the horizontal centre line at all angles of horizontal rotation up to at least 90° each side of the longitudinal centre line of the device. 4.1.2. At all angles of horizontal rotation up to 90° each side of the longitudinal centre line of the device, there shall be an angle of free axial roll each side of the vertical centre line of 25° for three- and four-wheel vehicles or 40° for two-wheel vehicles. 4.2. At all angles of horizontal rotation the following combinations of articulation shall be possible: 4.2.1. In the case of two-wheel vehicles, except where the device is used with one-wheel trailers which tilt with the two-wheel vehicle: 4.2.1.1. Vertical pitch of ± 15° with axial roll of ± 40°; 4.2.1.2. Axial roll of ± 30° with vertical pitch of ± 20°; 4.2.2. In the case of three-wheel vehicles or quadricycles: 4.2.2.1. Vertical pitch of ± 15° with axial roll of ± 25°; 4.2.2.2. Axial roll of ± 10° with vertical pitch of ± 20°. 4.3. It shall be possible to couple and uncouple coupling balls when the longitudinal axis of the coupling ball in relation to the centre line of the coupling ball and mounting: 4.3.1. Is horizontally β = 60° right or left; 4.3.2. Is vertically α = 10° up or down; 4.3.3. Is axially rotated 10° right or left. 5. Requirements for strength 5.1. A dynamic strength test (endurance test) shall be performed. 5.1.1. The endurance test shall be performed with an alternating approximately sinusoidal load with a number of load cycles depending on the material. No cracks or fractures or other visible external damage, or any excessive permanent distortion which would be detrimental to the satisfactory operation of the device, shall occur. 5.1.2. The loading basis for the dynamic test is the D-value shown below. The static vertical load shall be taken into consideration in the direction of the test load relative to the horizontal plane, depending on the position of the coupling point and the static vertical load permitted at the coupling point. Equation 3-1 : where: T = technically permissible maximum mass (in tonnes) of the towing vehicle; R = technically permissible maximum mass (in tonnes) of the trailer; g = acceleration due to gravity (assumed g = 9,81 m/s 2 ). 5.1.3. The characteristic values D and S on which the test is to be based are specified in the manufacturer’s type-approval application, S being the permitted maximum static vertical load (in kg) at the coupling point. 5.2. Test procedure 5.2.1. For the dynamic tests, the sample shall be placed in a suitable rig with a suitable means of force application so that it is not subjected to any additional forces or moments apart from the specified test force. In the case of alternating tests, the direction of force application shall not deviate by more than ± 10° from the specified direction. To avoid unspecified forces and moments in the sample, it may be necessary to have one joint at the point of force application and a second joint a suitable distance away. 5.2.2. The test frequency shall not exceed 35 Hz. The selected frequency shall be well separated from resonant frequencies of the test set-up, including the device being tested. The number of load cycles shall be 2 × 10 6 for coupling devices made of steel. A higher number of load cycles may be required for coupling devices made of other materials. Generally, the crack test is to be performed in accordance with the dye penetration procedure; equivalent other procedures are also permissible. 5.2.3. The coupling devices on test are to be normally mounted as rigidly as possible on a test rig in the actual position in which they will be used on the vehicle. The fixing devices shall be those specified by the manufacturer or applicant and be those intended for its attachment to the vehicle and/or have identical mechanical characteristics. 5.2.4. Test conditions 5.2.4.1. Preferably, couplings shall be tested in original condition as intended for use on the road. At the discretion of the manufacturer and in agreement with the technical service, flexible components may be neutralised if this is necessary for the test procedure and if there is no concern about unrealistic influence on the test result. 5.2.4.2. Flexible components which are obviously overheated due to this accelerated test procedure may be replaced during the test. 5.2.4.3. The test loads may be applied by means of special slack-free devices. 5.2.4.4. The devices submitted for test shall be provided with all design details which may have an influence on the strength criteria (for example electrical socket plates, any markings, etc.). The test periphery ends at the anchorage points or fitting points. The geometric location of the coupling ball and the fixing points of the coupling device relating to the reference line shall be provided by the vehicle manufacturer and shown in the test report. 5.2.4.5. All relative positions of the attachment points with respect to the reference line as shown in Appendix 2, for which the towing vehicle manufacturer shall provide all the necessary information to the towing device manufacturer, shall be repeated on the test bed. 5.3. Test of coupling balls and towing brackets 5.3.1. The assembly mounted on the test bed is subjected to a dynamic test on an alternating stress tensile testing machine (e.g. a resonance pulser). This test shall contain the following: 5.3.1.1. The test load shall be an alternating force and applied to the coupling ball at an angle of 15 ± 1°, as shown in figures Ap2-1 and Ap2-2 of Appendix 2. 5.3.1.2. If the ball centre is above that line parallel to the reference line as shown in figure Ap2-3 of Appendix 2, which contains the highest of the nearest fixing points, the test shall be carried out with an angle (figure Ap2-1 of Appendix 2). 5.3.1.3. If the ball centre is below the line parallel to the reference line as shown in figure Ap2-3 of Appendix 2, which contains the highest of the nearest fixing points, the test shall be carried out with an angle (figure Ap2-2 of Appendix 2). This angle is chosen in order to take account of the vertical static and dynamic load. This test method is applicable only to a permitted static load of no more than: Equation 3-2 : 5.3.1.4. If a greater static load is requested, the test angle shall be increased to 20°. The dynamic test shall be performed with the following test force: Equation 3-3 : 5.3.2. One-piece coupling balls, including devices with non-interchangeable detachable balls and towing brackets with interchangeable balls which can be dismantled (excluding balls on integral support), shall be tested in accordance with 5.3.1. 5.3.3. The test of a towing bracket which can be used with different ball units is to be carried out in accordance with the test requirements of UNECE regulation No 55. 5.4. The testing requirements in point 5.3.1 shall be also applicable to coupling devices other than coupling balls. 6. Coupling heads 6.1. Coupling heads shall be designed so that they can be used safely with the coupling balls described in Figure Ap 1-1 of Appendix 1. 6.2. Coupling heads intended to be fitted to unbraked trailers, shall be fitted with a secondary coupling device or at least attachment point(s) to permit the connection of a secondary coupling device(s). The attachment point(s) shall be positioned such that when in use, the secondary coupling device(s) does not restrict the normal articulation of the coupling. 6.3. An endurance test shall be performed with an alternating test force and a static test (lifting test) on each test sample. 6.4. The dynamic test shall be performed with a suitable coupling ball of appropriate strength. On the test rig, the coupling head and ball shall be arranged as instructed by the manufacturer and in a way corresponding to their attachment in a vehicle. There shall be no possibility of extra forces in addition to the test force acting on the sample. The test force shall be applied along a line passing through the centre of the ball and inclined downwards to the rear at 15° (see figure Ap3-1 of Appendix 3). An endurance test shall be performed on a test sample with the following test force: Equation 3-3 : 6.5. The coupling ball used for the test shall have a diameter of 49 – 0 +0;13 mm in order to represent a worn coupling ball. The lifting force F A shall be increased smoothly and quickly to a value of: Equation 3-4 : and held for 10 seconds, where: C = mass of the trailer (sum of the axle loads of the trailer carrying maximum permissible load) in tonnes. 6.6. If coupling devices other than coupling balls are used, the coupling head shall be tested, as applicable, in accordance with the relevant requirements of UNECE regulation No 55. ( 1 ) OJ L 227, 28.8.2010, p. 1 .