V.ORLANDI RP10, Installation, Operating And Maintenance Instructions For The Installer And The User

Page 1: ...S S S S I I I I I I I I T T E E M M D D T T R R A A N N O O O OR RL L D DI I Fifth wheel Rp10 Installation operating and maintenance instructions E E ...

Page 2: ...Vehicle data Type Registration number Signature Signature Signature Signature Signature Stamp Stamp Stamp Stamp Stamp Date Date Date Date Date Maintenance operations carried out Maintenance operations carried out Maintenance operations carried out Maintenance operations carried out Km Miles Km Miles Km Miles Km Miles ...

Page 3: ... 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 ...

Page 4: ...H CARRIER PLATE 2 2 DIRECT INSTALLATION 2 3 INSTALLATION WITH WELD ON PEDESTALS 2 4 SETTING UP FOR OPERATION 3 OPERATING INSTRUCTIONS 3 1 COUPLING UP 3 2 UNCOUPLING 4 MAINTENANCE 4 1 PERIODICAL MAINTENANCE 5 CLEARANCE ADJUSTMENTS 5 1 CLEARANCE ADJUSTMENT PROCEDURE 6 ASSEMBLY OF THE OPERATING HANDLE EXTENSION 7 REPAIRS 7 1 FIFTH WHEEL BEARINGS REPLACEMENT 7 1 1 FIFTH WHEEL WITH RUBBER BEARINGS 7 1 ...

Page 5: ... to be replaced with an identical one if wear or other damage makes it impossible to consult NOTE THIS MANUAL HAS 36 36 PAGES First edition July 2004 Reprint V Orlandi Spa shall not be liable for any damage whatsoever and howsoever caused including improper or incorrect use modifications alterations or abuse Use of not original spare parts of V Orlandi Spa cancels any warranty rights and invalidat...

Page 6: ...n Wear safety shoes Wear safety gloves Carefully read the following paragraph sentence chapter Warning Limb injury hazards Strict prohibition Denotes attention and caution precedes useful technical directions for the different procedures 0 3 HOW TO READ AND USE THE MANUAL N O T E FIFTH WHEEL Rp10 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS INSTALLATION OPERATING AND MAINTENANCE INSTRUCTION...

Page 7: ...l Screw for plate insert Homologation plate Operating handle The principal parts of the fifth wheel that are generally referred to herein are listed below for correct interpretation of directions given in this manual 15 24 23 1a 30 31 15 24 30 31 8 22 11b 2c 7 19c A 23 B 13 29 16 1a 1b FIFTH WHEEL Rp10 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS INSTALLATION OPERATING AND MAINTENANCE INSTR...

Page 8: ...CKING The Rp10 Series Fifth Wheels can be assembled onto tractor units pursuant to the requirements of EC Directive no 94 20 EC Class J or in compliance with the ISO 3842 and AS 1773 standard regulations Our Fifth Wheel Rp10 is designed for use with semi trailers fitted with 2 pins in compliance with class H50 requirements as per EC Directive no 94 20 EC and with the ISO 337 standard 11b 7 19c FIF...

Page 9: ...hicle in compliance with instructions provided by the truck manufacturer directly Using appropriate lifting equipment max weight is 150 kg proceed with fifth wheel assembly as required A INSTALLATION WITH CARRIER PLATE section 2 1 page 10 36 B DIRECT INSTALLATION section 2 2 page 11 36 C INSTALLATION WITH WELD ON PEDESTALS section 2 3 page 12 36 Wear safety shoes Wear safety gloves N O T E N O T E...

Page 10: ... on bolts support the fifth wheel pedestal 15 by means of longitudinal and transversal strikers welded onto the fifth wheel carrier mount plate at an angle bond not less than 5 mm Once installation is complete proceed as instructed in section 2 4 SETTING UP FOR OPERATION page 13 36 If unit is installed with flanged screws property class 10 9 and self locking nuts property class 10 striker welding ...

Page 11: ...x1 5 6g fit DIN 692 property class 10 9 screws special 6 mm thickness washers and self braking flanged M16x1 5 6H DIN 6923 property class 10 nuts Torque wrench setting 270 300 Nm Truck side chassis 24 24 Once installation is complete proceed as instructed in section 2 4 SETTING UP FOR OPERATION page 13 36 N O T E FIFTH WHEEL Rp10 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS INSTALLATION OPE...

Page 12: ...e weld on pedestals 31 completely by welding them around the whole pedestal rim as per directions supplied with the fifth wheel homologation documents Re assemble the fifth wheel plate as specified in points 4 and 5 in section 7 1 2 FIFTH WHEEL WITH PIVOT BEARINGS page 29 36 N O T E N O T E All welding operations must strictly be performed only by qualified personnel 1 2 3 4 5 Once installation is...

Page 13: ...n only for the standard type fifth wheels Once installation is complete lubrication of the fifth wheel plate 8 fifth wheel plates featuring self lubricating plate inserts do not require lubrication the jaw lock mechanism 7 11b 2c and the semi trailer king pin is strictly necessary FIFTH WHEEL Rp10 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIO...

Page 14: ...he operator must check that directions are observed at all times and under any circumstance 1 3 1 COUPLING UP Ensure that the jaw 7 is visible and positioned as illustrated If not draw the operating handle 19c upwards whilst pushing it towards the front end of the vehicle then draw it outward towards the vehicle s outside right end until the handle itself snaps into lock position FIFTH WHEEL Rp10 ...

Page 15: ...ng check the semi trailer s height and then act on Caution The fifth wheel mechanisms are spring loaded Warning Limb injury hazards A the pneumatic suspensions if the tractor unit is provided with pneumatic suspensions B on the tractor unit landing gear if the tractor unit is provided with pneumatic suspensions 1 cm 5 25 M SE I TRAILER E COUNT R PLATE S FRONT STRAIGHT EDGE SEMI TRAILER COUNTER PLA...

Page 16: ...the king pin rams against the jaw the wedge closes and the operating handle safety lock kicks in CAUTION always check personally to see that the semi trailer counter plate is completely resting on the fifth wheel surface 2 30 cm 0 SEMI TRAILER COUNTER PLATE 2 cm 0 30 SE I T E M RAIL R COUNTER PLATE S NT RAIG T D FRO ST H E GE FIFTH WHEEL Rp10 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS INS...

Page 17: ...i trailer king pin is repositioned correctly to enable regular coupling If the operating handle 19c will still not turn back into position regularly or if the semi trailer counter plate does not completely rest on the fifth wheel surface vehicle travel is strictly prohibited no matter what Contact the nearest service workshop for necessary intervention Wind the semi trailer landing legs fully up t...

Page 18: ...forwards until the semi trailer king pin has moved out of the fifth wheel coupling point by about 30 50 cm CAUTION If the operating handle 19c is hard to operate on reverse the tractor unit to relieve the pressure put on the fifth wheel jaw by the semi trailer king pin CAUTION contact between the fifth wheel and the semi trailer counter plate must never be broken 1 1 1 1 3 3 19c CAUTION do not use...

Page 19: ...m the tractor unit suspensions completely Ride the tractor unit out and immediately restore the suspension air back up to the level as specified by the truck manufacturer For tractor units having pneumatic suspensions go on to points 5 and 6 CAUTION Never deflate the tractor unit suspensions before uncoupling 30 50 m c N O T E SEMI TRAILER COUNT LA E S ER P T RONT STRAIGHT EDGE F CHAP 3 ...

Page 20: ...y before any operation Wear safety gloves CAUTION during maintenance operations the fifth wheel must be closed i e the wedge 11b must be clearly visible and the operating handle 19c must be regularly back in position The mobile parts of the fifth wheel s jaw lock mechanism 7 11b as well as the contrast ring 2c are subject to standard wear and tear Extent of wear depends on working conditions and m...

Page 21: ...ngs check that the torque 1 2 3 4 Lubricate the fifth wheel plate only for the standard type fifth wheels the jaw lock mechanism 7 11b 2c and the semi trailer king pin Consult page 13 36 For self lubricating fifth wheels inspect the nylon plate inserts for wear Check that the torque wrench setting of the fifth wheel pedestal bolts 15 24 30 screwed onto the tractor unit carrier plate is comprised w...

Page 22: ...r The following checks and inspections are recommended General fifth wheel inspection Check that the fifth wheel plate 8 and the semi trailer counter plate do not show any signs of wear or deformation compromising operation Check that the semi trailer king pin lies perfectly perpendicular to the counter plate Make sure that the fifth wheel plate 8 and pedestals 15 24 30 31 do not show any sign of ...

Page 23: ...late is comprised within the settings provided at page 10 36 section 2 1 INSTALLATION WITH CARRIER PLATE or at page 11 36 section 2 2 DIRECT INSTALLATION For fifth wheels provided with rubber bearings check that the torque wrench setting of the support plate fixing screws page 24 and page 28 36 is comprised between 270 and 300 Nm For fifth wheels provided with pivot bearings check that the torque ...

Page 24: ...king pin The fifth wheel allows for clearance adjustments by manually adjusting the jaw lock mechanism 2c 7 11b It is important however to carefully check the wear levels on the semi trailer king pin before performing any clearance adjustments Wear levels are illustrated in the figure at page 22 36 In the event that the king pin wear does exceed specified limits do not proceed with any clearance a...

Page 25: ...and the unit is ready for a final check run Try pulling off with the tractor with the semi trailer brake on to see whether you can still detect some clearance If the clearance detected is considerable this means that the fifth wheel no longer has any clearance adjustment options In these cases replacement of the jaw lock mechanism is required as per directions in section 7 2 REPLACEMENT OF THE JAW...

Page 26: ...is chapter refers to the figure on page 26 36 Read the following instructions carefully before starting any operation Wear safety gloves Disassemble the operating handle by removing the three M8 bolts 21b 21c Position the operating handle extension 21a in so that it fits under the operating handle and tighten it back up with the three M8 bolts at a 25 30 Nm torque wrench setting 19c 21b 21c 21a ...

Page 27: ...before any operation CAUTION make sure that the wedge 11b and the jaw 7 are clearly visible and the operating handle 19c is regularly back in position 7 1 1 FIFTH WHEEL WITH RUBBER BEARINGS The following steps 1 2 4 5 7 and 8 must also be repeated on the 1 2 Unscrew the four screws 3a and retrieve the washers 25 and nuts 26 Dispose Remove the fixing plate 27 and the lower rubber bearing 28 Dispose...

Page 28: ...estal 30 Lock everything back on using four screws 3a washers 25 and nuts 26 Torque wrench setting 270 300 Nm Warning Limb injury hazards Make sure that the fifth wheel plate 8 is safely anchored and secure for extraction of the upper rubber bearing 29 Dispose as specified in section 9 DISPOSAL page 34 36 Each time the rubber bearings are replaced all the screws 3a the washers 25 and the nuts 26 m...

Page 29: ...e 8 Insert the pin 13 and block it with two screws 3 and the relative safety washers Each time the pivot bearings are replaced all the screws 3 and the safety washers must be replaced as well Dispose as specified in section 9 DISPOSAL page 34 36 Torque wrench setting 25 Nm Make sure that the fifth wheel plate 8 is safely anchored and secure for extraction of the meniscus 14 Dispose as specified in...

Page 30: ...ven at section 7 1 FIFTH WHEEL BEARINGS REPLACEMENT page 27 36 Remove the two contrast ring screws 2a to release the contrast ring 2c Remove the worn contrast ring 2c Dispose as specified in section 9 DISPOSAL page 34 36 Turn out the screw 2a to remove the pin 2b Please make sure that the jaw 7 and the wedge 11b are clearly visible and check to see that the operating handle 19c is well lodged into...

Page 31: ... and lock it on with the two screws 2a using some loctite 243 thread locking compound Anchor the spring 6 onto the jaw 7 and also insert lubrication pipe 4 Unscrew nuts 11c and 19a and slide out the release lever 12 Remove the wedge 11b and the Relative wedge screw 11a Dispose as Specified in section 9 DISPOSAL page 34 36 and replace accordingly Reposition the wedge 11b and the release lever 12 in...

Page 32: ...ection 7 1 1 FIFTH WHEEL WITH RUBBER BEARINGS on page 28 36 Proceed with steps 7 8 9 and 10 in section 5 1 CLEARANCE ADJUSTMENT Load mechanism lock and couple up the semi trailer as per directions in section 3 1 COUPLING UP at page 14 36 Screw in nuts 11c and 19a pack tight with relative screws 11a and 19b then turn them back out for one turn REV 00 CHAP 7 PAG 32 36 INSTALLATION OPERATING AND MAIN...

Page 33: ...bly by carrying out an accurate cleaning session The fifth wheel must also be cleaned prior to use after a long period of disuse Clean the operating handle the coupling up area after having opened and closed the operating handle 19c as well as the adjustment screw using an air jet Use of high pressure water jet machines is allowed only on the coupling up area N O T E 8 Fifth wheel standard plate 1...

Page 34: ... secondo tipologia di materiale The appropriate actions and measures adopted must regularly comply with the local regulations and laws in force at the time of disposal Read the following instructions carefully REV 00 CHAP 9 PAG 34 36 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS FIFTH WHEEL Rp10 ...

Page 35: ...check that the wedge 11b and the jaw 7 are clearly visible and the operating handle 19c is regularly back into position Lift the fifth wheel off with appropriate lifting devices for 150 kg weights and store it into a solid and sturdy container after having cleaned and well lubricated it as per directions in section 8 CLEANING at page 33 36 as well as at page 13 36 Warning Limb injury hazards REV 0...

Page 36: ...NOTES NOTES ...