SAF 50S15 User manual

Owner’s Manual
XL-KP11695BM-en-DE Rev. A
Translation of the original owner's
manual
SAF fifth wheel kingpin 50S15 - 90S18

1.1 Dear customer,
This operating manual will help you to familiarise yourself with the SAF-
HOLLAND product and use it for its proper use.
The operating manual contains important instructions on how to operate
the product safely, properly and economically. Adherence to it helps
prevent hazards, faults and reduce down times and increase the reliability
and service life of the product. Read the operating manual through
carefully and follow the instructions accurately.
It must be ensured that all personnel with responsibility for performing
tasks on the vehicle are able to consult the operating manual at all times.
The operating manual must be kept in the glove compartment in the
driver's cabin of the towing vehicle at all times.
1.1 Copyright
This operating manual is classified as in accordance with the law on unfair
competition.
All rights reserved by
SAF-HOLLAND GmbH
Hauptstraße 26
D-63856 Bessenbach
This operating manual contains text and drawings that without the express
permission of the manufacturer cannot be either fully or partly
• duplicated,
• distributed or
• in any other way disclosed.
Any breach or infringement will result in liability for damages.
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Table of Contents
1 Product data.................................................................................. 4
1.1 Product description ................................................................... 4
1.2 Product identification ................................................................ 4
1.3 Type designation ....................................................................... 6
2 Ordering spare parts..................................................................... 11
3 General information..................................................................... 11
3.1 Liability ..................................................................................... 11
3.2 Warranty and general terms and conditions of business ............ 12
3.3 Environmental protection .......................................................... 12
4 Safety............................................................................................. 12
4.1 Target group ............................................................................. 12
4.2 Proper use ................................................................................ 13
4.3 Improper use ............................................................................ 13
4.4 Safety instructions and symbols used ........................................ 13
4.5 Marking used for sections of text .............................................. 14
4.6 General safety instructions ........................................................ 14
5 Installation..................................................................................... 16
5.1 General instructions for installation ........................................... 16
5.2 D Value/fifth wheel kingpin ....................................................... 17
5.3 Welding the flange ................................................................... 19
5.4 Installation of the fifth wheel kingpin ........................................ 21
5.5 Screw home the fifth wheel kingpin .......................................... 23
6 Implementation............................................................................. 23
7 Inspection...................................................................................... 24
7.1 General test instructions ........................................................... 24
7.2 Before each journey .................................................................. 25
7.3 Test schedule ............................................................................ 25
7.4 Wear check ............................................................................... 26
7.5 Lubricate ................................................................................... 28
8 Maintenance.................................................................................. 29
8.1 General maintenance instructions ............................................. 29
8.2 Torques .................................................................................... 29
Table of Contents
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1 Product data
1.1 Product description
The fifth wheel kingpin consists of:
• Pin
• Flange
• Screws
is the connecting shaft between the fifth wheel installed on the tractor
and that installed on the articulated trailer (trailer). The flange is welded to
the bolster plate. The kingpins comply with the applicable standards in
terms of their dimensions beneath the bolster plate.
1.2 Product identification
Pin
Please have the exact part number of the product ready when ordering
spare parts.
The details of the pin are engraved on
the top and bottom –Arrow–, Fig. 1. The
“D-value” is given in kilonewton .
Pin details
Technical designation Value/detail
Manufacturer/brand SAF
permitted D-value: D = 165 kN
Design: 50165S15
Class: H50–X
Part number: 2108 10 0000002 0
Revision: *1
KP-0001
*1
*2
Fig. 1 · Pin example 50S15
1 Product data
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Technical designation Value/detail
Manufacturing site and serial number: *2
Approval number: E1 55R – 01 XXXX
Data-Matrix-Code □: contains documentation and
manufacturing data, which are
centrally stored at SAF-HOLLAND
Flange
Please have the exact part number of the product ready when ordering
spare parts.
The details of the flange are engraved on
the inside –Arrow–, Fig. 2. The “D-value”
is given in kilonewton .
Flange details
Technical designation Value/detail
Manufacturer/brand SAF
permitted D-value: D = 165 kN
Design: 50165S1512 and 90165S1512
Class: H50–X or S
Part number: 2031 10 0000002 0
Revision: *1
Manufacturing site and serial number: *2
Trailer bolster plate thickness: t = 12
Data-Matrix-Code □: contains documentation and
manufacturing data, which are
centrally stored at SAF-HOLLAND
KP-0002
*1
*2
Fig. 2 · Flange example 50S15 or
90S15
1 Product data
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1.3 Type designation
marking
Following example is a description of the type marking Fig. 3. The letters
are marked with “X” and the numbers are marked with “0”.
KP-0011
2
3
4
5
6
( )
1
Fig. 3 · Explanation of the marking
1Size:
• 50 = 2 inches
• 90 = 3.5 inches
2D-value:
• 165 = 165 kN
• 320 = 320 kN
Note:
The D-value was not considered for the type approval.
3Fastenings:
• S = with screws
1 Product data
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• M = with nuts
4Circle diameter of part:
• 15 = 150 mm
• 18 = 180 mm
5Semi-trailer bolster plate thickness:
• 06 = 6 mm
• 08 = 8 mm
• 10 = 10 mm
• 12 = 12 mm
• 16 = 16 mm
6Marking of special types:
• L = steering
Note:
The thickness of the semi-trailer bolster plate is not considered
for the type approval.
Type overview
Type 50S15
Type 50S15 Installation with flange design
+GF+ HOLLAND
Design Trailer plate thickness in mm D-value in kN ECE approval no. D-value in kN type D-value in kN type
50165S1512 12
165 E1 55R–
01 2289 162.4 101 109 165 65
50165S1510 10
50165S1508 8
50165S1506 6
The pins of SAF type 50S15 can be installed with the corresponding flange
designs of +GF+ and HOLLAND.
1 Product data
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Type 50S15L
Type 50S15L
Installation with
flange design
+GF+
Design
Trailer plate thickness in mm D-value in kN ECE approval no. D-value in kN
type
50165S1512L12
165 E1 55R–01
2422 162.4 101 10950165S1510L10
50165S1508L8
The pins of SAF type 50S15L can be installed with the corresponding flange
designs of +GF+.
Type 90S15
Type 90S15 Installation with flange design
+GF+ HOLLAND
Design Trailer plate thickness in mm D-value in kN ECE approval no. D-value in kN type D-value in kN type
90165S1512 12
165 E1 55R–
01 2371 162.4 101 169 165 6790165S1510 10
90165S1508 8
The pins of SAF type 90S15 can be installed with the corresponding flange
designs of +GF+ and HOLLAND.
1 Product data
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Type 90S15L
Type 90S15L
Installation with
flange design
+GF+
Design
Trailer plate thickness in mm D-value in kN ECE approval no. D-value in kN
type
90165S1512L12
165 E1 55R–01
2421 162.4 101 16990165S1510L10
90165S1508L8
The pins of SAF type 90S15L can be installed with the corresponding flange
designs of +GF+.
Type 50S18
Type 50S18 Installation with flange design
+GF+ HOLLAND
Design Trailer plate thickness in mm D-value in kN ECE approval no. D-value in kN type D-value in kN type
50165S1816 16 165 E1 55R–
01 2418 162.4 102 022 165 66
The pins of SAF type 50S18 can be installed with the corresponding flange
designs of +GF+ and HOLLAND.
1 Product data
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Type 50S18L
Type 50S18L
Installation with
flange design
+GF+
Design
Trailer plate thickness in mm D-value in kN ECE approval no. D-value in kN
type
50165S1816L16 165 E1 55R–01
2428 162.4 102 022
The pins of SAF type 50S185L can be installed with the corresponding flange
designs of +GF+.
Type 90S18
Type 90S18 Installation with flange design
+GF+ HOLLAND
Design Trailer plate thickness in mm D-value in kN ECE approval no. D-value in kN type D-value in kN type
90320S1816 16 320 E1 55R–
01 2426 320 102 021 200 63
The pins of SAF type 90S18 can be installed with the corresponding flange
designs of +GF+ and HOLLAND.
1 Product data
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Type 90S18L
Type 90S18L
Installation with
flange design
+GF+
Design Trailer plate thickness in mm D-value in kN ECE approval no. D-value in kN
type
90165S1816L16 320 E1 55R–01
2425 320 102 021
The pins of SAF type 90S18L can be installed with the corresponding flange
designs of +GF+.
2 Ordering spare parts
When ordering original spare parts from SAF-HOLLAND, make sure that
you pay attention to the assembly groups of the respective product.
Third party parts have a negative effect on the function of the product,
have a shorter lifetime and cause risks and hazards which SAF-HOLLAND
cannot evaluate. They also increase the testing requirement.
SAF-HOLLAND has a tight service network of partner companies for
technical support for SAF-HOLLAND products and supply of parts (see back
page or visit us on the internet at www.safholland.com).
For further instructions on identifying spare parts, refer to the
"Aftermarket" section of our homepage www.safholland.com.
Updates are published as necessary on the internet at
www.safholland.com.
3 General information
3.1 Liability
SAF-HOLLAND's "General Terms and Conditions" apply.
2 Ordering spare parts
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SAF-HOLLAND does not accept any liability claims for personal injury or
material damage which are caused by one or more of the following:
• Improper use of the product, Page 13
• disregarding the operating manual or the safety instructions contained
therein,Page 14
• structural changes to the product not carried out by the company,
• improper installation of the product subject to wear,Page 16,
• maintenance work carried out incorrectly or too late Page 25,
• the use of any spare parts other than original SAF-HOLLAND partsPage
11,
• the use of damaged parts,
• disasters due to external influences or force majeure.
3.2 Warranty and general terms and conditions of
business
Refer to the "Sales" section of our home page www.safholland.com for
information on our current warranties and general terms and conditions.
3.3 Environmental protection
All components and consumables used for maintenance, care and repair
must be disposed of in an environmentally friendly manner.
Recyclable components must be cleaned of oil and lubricants and recycled.
When doing so, you must adhere to the disposal instructions for the
respective consumables and the valid national and regional regulations.
4 Safety
4.1 Target group
The Inspection chapter in the owner's manual is restricted exclusively to
use by the owner and personnel authorised and trained by the owner.
The user must ensure that the personnel authorised by him receive regular
instruction on the content of the owner's manual and in particular the
safety instructions it contains.
The chapter on Installation and Implementation is restricted exclusively
to use by the original equipment manufacturer (OEM) and personnel
authorised and trained by the OEM.
4 Safety
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The Maintenance chapter is restricted exclusively to use by authorised
workshops and appropriately trained personnel using the proper tools and
safety procedures.
4.2 Proper use
The product has been constructed using state-of-the-art technology and in
accordance with the recognised rules of technical safety. However, its use
may result in hazards for the operator or third parties or damage to the
device or other objects of material value.
Proper use also includes:
• Adherence to the owner's manual and implementation of the working
steps stipulated in the owner's manual,
• Adherence to the performance limits Fig. 1.2 and of the product,
• Adherence to all installation specifications Page 16,
• Adherence to all maintenance specifications Page 29,
• the use of the listed consumables Page 28 and disposing of them in
an environmentally friendly way Page 12.
Operationally safe functioning can only be guaranteed if all the
instructions, setting and performance limits for the product are adhered
to.
4.3 Improper use
• The use with non-standard or damaged fifth wheel kingpins e.g. bent,
incorrect size or dimensions, fitted on bent trailer bolster plates,
• The attachment of lifting devices,
• Transport of loads in excess of the rated capacity or D-value,
• Use of a tipping device with a kinked tractor,
• Applications other than those recommended.
4.4 Safety instructions and symbols used
The following symbols are used to denote particularly important
information and sections of the text. Make sure that they are always read
and adhered to before working with the product.
Danger!
This safety instruction with the exclamation mark warns
of a possible safety risk or serious and fatal injuries.
4 Safety
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Careful!
This safety instruction with the exclamation mark warns
of possible damage to the product.
Note:
Marking for special user tips and other particularly useful and
important information for efficient work and economical use.
4.5 Marking used for sections of text
• Marking for instructions for actions and information in safety
instructions
1., 2., 3., ... Marking used for working steps
4.6 General safety instructions
It is imperative that you adhere to the following safety instructions
in order to maintain the operational safety and traffic safety of
your SAF-HOLLAND fifth wheel kingpin:
Danger!
Risk of serious traffic accidents due to the loss of traffic
safety and operational safety, which may lead to
serious or fatal injuries!
Operation
• The articulated vehicle must be parked in a straight line
with the trailer during tipping operations.
• No arbitrary modifications may be made to the fifth wheel
kingpin – this also applies to welding work -cancellation
of type approval.
• All planned modifications must be approved by
SAF-HOLLAND in writing before being carried out.
General safety instructions
• The fifth wheel kingpin must only be used for the Page
13intended purposes.
4 Safety
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Danger!
• All instructions in the chapter Liability Page 11 must be
followed.
• The fifth wheel kingpin must only be used in a flawless
and functional condition.
• The device must be checked regularly, at least 2x yearly by
qualified or authorised trained personnel for its
functionality.
• The required personal protective equipment and clothing
for operating, maintenance and repair staff must be
available and must be used.
• The complete owner's manual must be available in legible
condition and at the location of use of the system at all
times.
• The fifth wheel kingpin must only be inspected by a
sufficiently qualified and authorised trained personnel and
repaired in a qualified workshop.
• The fifth wheel kingpin and the treated area of the flange
are not to be painted over
• The personnel concerned must be regularly instructed in all
relevant issues of occupational safety and environmental
protection from this owner's manual, in particular the
safety instructions that it contains.
• When handling the fifth wheel kingpin, the relevant safety
regulations of the respective country apply (e.g.
Berufsgenossenschaft für Fahrzeughaltung [Professional
Association for Vehicle Owners]).
Note:
Have information available at all times: This owner's
manual must be kept in the vehicle.
It must be ensured that all personnel with responsibility for
performing tasks on the vehicle are able to consult the
owner's manual at all times. In addition to the owner's
manual, operating instructions in terms of the German
Occupational Safety and Health Act and the German Work
Equipment Ordinance must also be made available.
4 Safety
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5 Installation
5.1 General instructions for installation
Danger!
Risk of serious traffic accidents due to the loss of traffic
safety and operational safety, which may lead to
serious or fatal injuries!
• All safety instructions must always be followed Page 14.
• Fifth wheel kingpins are components that are subject to
approval. Damaged, deformed or repaired (e.g. welded)
individual parts no longer correspond to the necessary type
approval and must no longer be used. Furthermore,
modifications put traffic safety in danger. When replacing
parts, we recommend the use of genuine spare parts from
SAF HOLLAND GmbH. The use of non-original parts voids
our product warranty.
• The bolster plate must be flat and must not have either
welded seams or sharp edges. Uneven bolster plates cause
an unstable running of the articulated vehicle, a wavering
of the trailer and a significant wear of the fifth wheel
plate, on the lock and on the fifth wheel kingpin.
• The fifth wheel should be completely overlaid by the
bolster plate in each position. We recommend that the
front bolster plates, i.e. on the drive side, be tilted upwards
or strongly tapered.
• The fifth wheel kingpins correspond to the applicable
standards, which according to the kingpin in mounted
condition, must protrude from the bolster plate by a
tolerated length. Before installation, the flatness as well as
the thickness of the bolster plate must therefore be
checked.
• It must be ensured that the bolster plate as well as the fifth
wheel kingpin mounting be correspondingly braced for the
load and the respective D-value Page 17.
• The installation must be performed by articulated vehicle
manufacturers or authorised workshops and by
appropriately trained personnel.
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Danger!
• Before installing the fifth wheel kingpin, all accompanying
parts and the kingpin itself must be checked for damage.
• All tightening torques must always be followed Page 29.
• Observe the legal clauses and approved technical safety
rules for the installation of fifth wheel kingpins in the
respective country of operation.
Note:
• National rules of approval apply for the construction of the
fifth wheel kingpin.
• In Germany, the mounting of fifth wheel kingpins requires
registration (§19 -21 of the Road Traffic Registration
Regulation [StVZO]).
• Furthermore, the requirements of §13 FZV (German
Vehicle Registration Ordinance) regarding data in the
vehicle papers referring to the permitted trailer load must
be fulfilled.
5.2 D Value/fifth wheel kingpin
Danger!
Risk of serious accidents due to the loss of traffic and
operational safety, which may lead to serious or fatal
injuries!
• For safe operation, the calculated D-value must not exceed
the specified D-value or maximum vertical load of the fifth
wheel.
• For operation on construction sites or uneven highways,
do not use the full D-value or fifth wheel vertical load.
Higher forces may exist.
• In order to be able reach the load limits of the maximum
D-value, the installation must be carried out according to
the SAF-HOLLAND installation instructions.
5 Installation
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The specific value for the capacity of each fifth wheel kingpin is the D-
value that can be read on the bottom of the kingpin Fig. 1. The weight of
a vehicle alone is no equivalent for the forces that occur in the coupling
devices. First, the sum of the influencing factors or their relation
determines the force that acts upon the coupling device. This strength
(called shaft strength or D-value for short) is connected to the fifth wheel
vertical load, the weight of the fifth wheel tractor and the weight of the
semi-trailer and will also be disclosed in the type testing.
Calculation according to ECE-R55 chapter 2.11.1
The D-value can be calculated using the
following formula Fig. 4.
D-value calculation formula
Formula symbol, Fig. 4 Definition of terms
D D-value in kN
g Gravity; g = 9.81 m/s2
T Maximum permissible laden weight of
the tractor in t
R Permitted total weight of the
articulated trailer in t
U Permitted fifth wheel vertical load in t
t Ton = 1000 kg
The permitted load data for products from SAF-HOLLAND are given in the
engraved product information Page 4 or can be found in the applicable
type approvals or on our home page www.safholland.com. They apply to
the operation on sealed, tarred roads and road conditions that are
customary in West Europe. In the case of operational conditions which
KP-0007
Fig. 4 · D-value calculation formula
5 Installation
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differ from these, or for OFF ROAD use, please consult customer services
beforehand. When using several coupling devices and components, the
one with the lowest D-value should be observed.
Calculation example
The fifth wheel kingpin should be mounted on an articulated trailer with a
permitted total weight of 31 t, which is pulled by a tractor with a
permitted total weight of 21 t. The fifth wheel vertical load has a weight
of 14 t.
Sought: D-value:
The calculated D-value is 100.8 kN. The
fifth wheel kingpin to be used must
therefore have a D-value of at least 100.8
kN.
5.3 Welding the flange
Careful!
•The welding work must only be carried out by
authorised trained personnel.
•The fifth wheel kingpins must be installed flat and in
the centre, the angled seat must also be checked.
•The pins must be protected against welding splatter.
Welding procedure
When welding the mounting flange, the following welding procedures
and weld materials are permitted:
• Welding procedure
– MAG C (135)
• Protective gas
– M21 or 92%Ar + 8% CO2
• Weld material
– according to EN ISO 14341: 2008
KP-0008
Fig. 5 · D-value calculation example
5 Installation
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• Welding wire
– EMK 8 from Böhler
– Normag 3 from Thyssen
– Carbofil 1 from Oerlikon
or equivalent permitted brands from TÜV.
Welding seam quality
The required welding seam quality must comply with DIN EN ISO 5817–B.
Welding seam thickness
The thickness of the welding seam depends on the combination of plate
thicknesses of the trailer and corresponding mounting flange.
Weld the flange –Item 1– with trailer bolster plate –Item 2– according to
DIN EN ISO 5817-B Fig. 6.
KP-0012
1
2
Fig. 6 · Welding the flange
Welding seam thickness for bolster plate
Trailer bolster plate thickness T in
mm Welding seam thickness “a” in mm
6 4
8 5
10 7
12 8
16 8
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