V.ORLANDI RP10 User guide

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Fifth wheel Rp10
Installation,operating and
maintenance instructions
EE

Registration of the installation and the maintenance operations
Date of the installation of the fifth whee Km/Miles:
Vehicle data: Type: Registration number:
Signature:
Signature:
Signature:
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Stamp:
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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:

Signature:
Signature:
Signature:
Signature:
Signature:
Km/Miles:
Km/Miles:
Km/Miles:
Km/Miles:
Km/Miles:
Stamp:
Stamp:
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Data:
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Maintenance operations carried out:
Maintenance operations carried out:
Maintenance operations carried out:
Maintenance operations carried out:
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INDEX
PAG.
04/36
FIFTH WHEEL Rp10
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS
INDEX
0 INTRODUCTORY NOTES
0.1 WARRANTY
0.2 CARE OF THE MANUAL
0.3 HOW TO READ AND USE THE MANUAL
1 GENERAL INFORMATION
1.1 FIFTH WHEEL DESCRIPTION
1.2 UNPACKING
1.3 INTENDED USE
1.3.1 INSTALLATION PROVISIONS
2 INSTALLATION
2.1 INSTALLATION WITH 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
7.1.2 FIFTH WHEEL WITH PIVOT BEARINGS
7.2 REPLACEMENT OF THE JAW LOCK MECHANISM
8 CLEANING
9 DISPOSAL
10 STRIPPING
5
5
5
6
7
7
8
8
8
14
14
13
18
9
11
12
10
23
24
20
21
26
27
27
27
29
33
34
35
30

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CHAP. 0
PAG.
05/36
0 INTRODUCTORY NOTES
0.1 WARRANTY
0.2 CARE OF THE MANUAL
This manual is an integral part of the fifth wheel and must be kept together with it at
all times and under any circumstance, in resale or restitution under warranty. It has
to be available for quick consultation by all operators whenever necessary.
The end-user is responsible for keeping it in good condition.
The manual has 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 invalidates any homologation.
V.Orlandi Spa reserves the right to make modifications any time.
FIFTH WHEEL Rp10
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

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06/36
CHAP. 0
As well as the descriptive title of each chapter, the following signs have been used
to indicate which measures are required during the different procedures.
Attention and caution
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
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INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

REV. 00
CHAP. 1
PAG.
07/36
19c
11b
22
2c
8
7
B
A
1 GENERAL INFORMATION
1.1 FIFTH WHEEL DESCRIPTION
Fifth wheel plate
Warning plate
Contrast ring
Adjustment screw
Jaw
Wedge
Self lubricating plate insert
Pedestal
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 INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

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CHAP. 1
PAG.
08/36
1.3.1 INSTALLATION PROVISIONS
1.3 INTENDED USE
Read the following instructions carefully before any operation:
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 its slot.
Warning! Limb injury hazards!
1.2 UNPACKING
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
FIFTH WHEEL Rp10
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

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CHAP. 2
PAG.
09/36
This chapter refers to the figures on pages 09-13/36.
Read the following instructions carefully before any operation:
2 INSTALLATION
The fifth wheel sizing and dimensions must conform to the
prescriptions given by the truck manufacturer.
Before proceeding with the fifth wheel installation please inspect to
see that the carrier mount-plate is correctly fixed onto the vehicle 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!
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Installation has to be carried out by skilled personnel.
FIFTH WHEEL Rp10
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

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CHAP. 2
PAG.
10/36
Truck side chassis
Fifth wheel carrier plate
Welded strikers
Welded strikers
15 30
30 15
1)
2)
2.1 INSTALLATION WITH CARRIER PLATE
Fix the fifth wheel pedestal (15) to the trailer carrier plate using twelve
M16x1.5 screws (property class 8.8) with relative self-locking washers and nuts
unified to 8g class of fit;
Torque wrench setting 200 Nm.
To avoid sheer stress 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 can be avoided.
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Torque wrench setting 270-300 Nm.
FIFTH WHEEL Rp10
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

REV. 00
CHAP. 2
PAG.
11/36
2.2 DIRECT INSTALLATION
Set the fifth wheel into its lead position as established by the truck manufacturer.
Fix the fifth wheel pedestals (24) to the “L” profiles on the truck side chassis
using twelve flanged M16x1.5-6g 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.
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FIFTH WHEEL Rp10
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

REV. 00
CHAP. 2
PAG.
12/36
Truck side chassis
Carrier plate
31
31
2.3 INSTALLATION WITH WELD-ON PEDESTALS
Position the fifth wheel onto the tractor unit's carrier plate;
Fix the weld-on pedestals (31) onto the carrier plate with a few welding spots;
Unscrew the fifth wheel from the weld-on pedestals (31) as per points 1 and 2
in section 7.1.2 - FIFTH WHEEL WITH PIVOT BEARINGS - page 29/36;
Proceed with welding the 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.
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All welding operations must strictly be performed only by qualified
personnel.
1)
2)
3)
4)
5)
Once installation is complete, proceed as instructed in section 2.4 -
SETTING UP FOR OPERATION - page 13/36.
FIFTH WHEEL Rp10
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2.4 SETTING UP FOR OPERATION
1)
2)
3)
4)
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Greases resistant to extreme pressure (having high EP properties), water and
high temperatures are recommended;
Said operations are strictly necessary for optimised fifth wheel
functioning and to increase fifth wheel life.
Lubricate the jaw (7) through the grease nipple (5);
Inspect the semi-trailer's counter plate for sufficient lubrication (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 INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS
CHAP. 2
5) Position the operating handle (21a) as illustrated in the frame, then using the
three screws (21b, 21c), screw it in tightly at a 30 Nm torque wrench setting.
8
5
2c
11b
7
21b
21a
21c
21a
21b

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CHAP. 3
PAG.
14/36
11b
7
113333
19c
Warning! Limb injury hazards!
3 OPERATING INSTRUCTIONS
This chapter refers to the figures on pages 14-19/36.
Read the following instructions carefully before any operation:
Wear safety gloves!
The following coupling and uncoupling instructions are most
important;
the 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
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS
19c

REV. 00
CHAP. 3
PAG.
15/36
2)
3)
Check to see that the semi-trailer wheels are locked;
Line the tractor unit up in front of the trailer so that the fifth wheel longitudinal
axle
coincides with the semi-trailer axle.
The semi-trailer counter plate's front straight-edge must touch the fifth wheel
plate (8) about 15-25 cm before the coupling-up point.
If there is no coupling, 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.
1cm
5-25 .
M
SE I-TRAILER
E
COUNT R
PLATE'S FRONT
STRAIGHT-EDGE
SEMI-TRAILER COUNTER PLATE
8
until coupling is achieved as required.
FIFTH WHEEL Rp10
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

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4)
5)
Reverse until the fifth wheel plate (8) is positioned under the semi-trailer's
front end at a distance of about 20-30 cm from the semi-trailer's king pin;
Couple up by reversing towards the king pin in a firm but non-violent
manner:
as 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 TE
M-RAIL R
COUNTER PLATE'S
NTRAIG T D
FRO ST H -E GE
FIFTH WHEEL Rp10
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS
CHAP. 3

REV. 00
PAG.
17/36
CAUTION: inspect to see that the coupling-up procedure has been
conducted correctly; check that the operating handle (19c) has
regularly returned back
into position.
CAUTION: in the event that the operating handle (19c) is not back in
position, try moving the tractor unit forwards for about 50 cm and
then back again so that the semi-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 to stroke end.
6)
FIFTH WHEEL Rp10
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS
CHAP. 3

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PAG.
18/36
1)
2)
3)
4)
3.2 UNCOUPLING
Lock the semi-trailer wheels;
Wind down the semi-trailer landing legs until they touch the ground;
Release the fifth wheel lock mechanism as follows:
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 operating handle (19c) pin locks onto the fifth wheel's
edge rim.
Uncouple the tractor unit by moving slowly 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.
111133
19c
CAUTION: do not use gears or any external mechanism to open up
the fifth wheel.
If the operating handle will not unlock, check that all the required
FIFTH WHEEL Rp10
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS
19c
CHAP. 3

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19/36
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS
FIFTH WHEEL Rp10
SEMI-TRAILER COUNTER PLATE
5)
6)
Deflate the air from 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
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SEMI-TRAILER
COUNT LA E'S
ER PT
RONT STRAIGHT EDGE
F -
CHAP. 3

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CHAP. 4
PAG.
20/36
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSINSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS
FIFTH WHEEL Rp10
4 MAINTENANCE
This chapter refers to the figures on pages 20-22/36.
Read the following instructions carefully 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 maintenance
operations conducted.
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19c
8
11b
7
2c