Fifth wheel Rp10

Installation,operating and GB
maintenance instructions

ORL
S I S T E M I D I
DI
T R A I N O
Registration of the installation and the maintenance operations

Vehicle data: Type Registration number:

Date of the installation of the fifth whee Km/Miles:

Date: Stamp Signature:

Maintenance operations carried

Km/Miles:

Date: Stamp: Signature

Maintenance operations carried

Km/Miles:

Date: Stamp: Signature

Maintenance operations carried

Km/Miles:

Date: Stamp: Signature

Maintenance operations carried

Km/Miles:

Date: Stamp: Signature

Maintenance operations carried

Km/Miles:

Data: Stamp: Signature

Maintenance operations carried

Km/Miles:

Data: Stamp: Signature

Maintenance operations carried

Km/Miles:

Data: Stamp: Signature

Maintenance operations carried

Km/Miles:

Data: Stamp: Signature

Maintenance operations carried

Km/Miles:

Data: Stamp: Signature

 PAG.
FIFTH WHEEL Rp10 04/36
INDEX
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS REV. 00

INDEX
0 INTRODUCTORY NOTES 5
0.1 WARRANTY 5
0.2 CARE OF THE MANUAL 5
0.3 HOW TO READ AND USE THE MANUAL 6

1 GENERAL INFORMATION 7
1.1 FIFTH WHEEL DESCRIPTION 7
1.2 UNPACKING 8
1.3 INTENDED USE 8
1.3.1 INSTALLATION PROVISIONS 8

2 INSTALLATION 9
2.1 INSTALLATION WITH CARRIER PLATE 10
2.2 DIRECT INSTALLATION 11
2.3 INSTALLATION WITH WELD-ON PEDESTALS 12
2.4 SETTING UP FOR OPERATION 13

3 OPERATING INSTRUCTIONS 14
3.1 COUPLING UP 14
3.2 UNCOUPLING 18

4 MAINTENANCE 20
4.1 PERIODICAL MAINTENANCE 21

5 CLEARANCE ADJUSTMENTS 23
5.1 CLEARANCE ADJUSTMENT PROCEDURE 24

6 ASSEMBLY OF THE OPERATING HANDLE EXTENSION 26

7 REPAIRS 27
7.1 FIFTH WHEEL BEARINGS REPLACEMENT 27
7.1.1 FIFTH WHEEL WITH RUBBER BEARINGS 27
7.1.2 FIFTH WHEEL WITH PIVOT BEARINGS 29
7.2 REPLACEMENT OF THE JAW LOCK MECHANISM 30

8 CLEANING 33

9 DISPOSAL 34

10 STRIPPING 35
 PAG.
FIFTH WHEEL Rp10 05/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP.

REV. 00
0

0 INTRODUCTORY NOTES
0.1 WARRANTY
V.Orlandi Spa shall not be liable for any damage whatsoever and howsoever
caused, including improper or incorrect use, modifications, alterations or
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.

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: .....................
 PAG.
FIFTH WHEEL Rp10 06/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP.

REV. 00
0

0.3 HOW TO READ AND USE THE MANUAL

As well as the descriptive title of each chapter, the following signs have been
used to indicate which measures are required during the different

Attention and caution

Warning! Limb injury hazards!

Strict prohibition

Wear safety shoes!

Wear safety gloves!

Carefully read the following paragraph/sentence/chapter

N
O Denotes attention and caution, precedes useful technical
T directions for the different procedures.
E
 PAG.
FIFTH WHEEL Rp10 07/36
CHAP. 1
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS REV. 00

1 GENERAL INFORMATION

1.1 FIFTH WHEEL DESCRIPTION

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:

23 A

22 19c
2c 7
29 16
B

13

1a
1b 11b
8
15 24 30 31

1a Adjustment screw 23 Screw for plate insert

2c Contrast ring 15-24
Pedestal
7 30-31
Jaw
8 Fifth wheel plate 19c Operating handle
11b Wedge A Warning plate
22 Self lubricating plate insert B Homologation plate
 PAG.
FIFTH WHEEL Rp10 08/36
CHAP. 1
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS REV. 00

1.2 UNPACKING

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!

19c

11b

1.3 INTENDED USE

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.

1.3.1 INSTALLATION PROVISIONS

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.
 PAG.
FIFTH WHEEL Rp10 09/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS CHAP.

REV. 00
2

2 INSTALLATION

This chapter refers to the figures on pages 09-13/36.

Read the following instructions carefully before any operation:

N
O Installation has to be carried out by skilled personnel.
T
E

Wear safety shoes!

Wear safety gloves!

N
O The fifth wheel sizing and dimensions must conform to the
T prescriptions given by the truck manufacturer.
E

N Before proceeding with the fifth wheel installation please inspect

O to see that the carrier mount-plate is correctly fixed onto the
T
E vehicle in compliance with instructions provided by the truck
manufacturer directly.

N
Using appropriate lifting equipment (max weight is 150 kg),
O
T proceed with fifth wheel assembly as required:
E 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.
 PAG.
FIFTH WHEEL Rp10 10/36
CHAP. 2
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS REV. 00

2.1 INSTALLATION WITH CARRIER PLATE

1) 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.
2) 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.
N
O If unit is installed with flanged screws (property class 10.9) and self-
T locking nuts (property class 10), striker welding can be avoided.
E

Torque wrench setting 270-300 Nm.

15 30

30 15

Welded strikers Welded strikers

Fifth wheel carrier plate
Truck side chassis

N
O Once installation is complete, proceed as instructed in
T
E
section 2.4 - SETTING UP FOR OPERATION - page 13/36.
 PAG.
FIFTH WHEEL Rp10 11/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP.

REV. 00
2

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

Torque wrench setting 270-300 Nm.

24

24

Truck side chassis

N
O Once installation is complete, proceed as instructed in section 2.4
T - SETTING UP FOR OPERATION - page 13/36.
E
 PAG.
FIFTH WHEEL Rp10 12/36
CHAP. 2
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS REV. 00

2.3 INSTALLATION WITH WELD-ON PEDESTALS

N
O All welding operations must strictly be performed only by
T qualified personnel.
E

1) Position the fifth wheel onto the tractor unit's carrier plate;

2) Fix the weld-on pedestals (31) onto the carrier plate with a few welding

3) 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;

4) 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;

5) 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.

31

31

Carrier plate

Truck side chassis

N
O Once installation is complete, proceed as instructed in section 2.4
T
E
- SETTING UP FOR OPERATION - page 13/36.
 PAG.
FIFTH WHEEL Rp10 13/36
CHAP. 2
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS REV. 00

2.4 SETTING UP FOR OPERATION

1) 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;

2) Greases resistant to extreme pressure (having high EP properties), water

and high temperatures are recommended;

3) Lubricate the jaw (7) through the grease nipple (5);

4) Inspect the semi-trailer's counter plate for sufficient lubrication (only for
the standard type fifth wheels);
N
O Said operations are strictly necessary for optimised fifth wheel
T functioning and to increase fifth wheel life.
E
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

21a 8

21b

21b 7
21a
5 11b
2c
21c
 FIFTH WHEEL Rp10 PAG.
14/36
CHAP. 3
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSREV. 00

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.

Warning! Limb injury hazards!

3.1 COUPLING UP

1) 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.

19c
19c

1 3 7

11b
 PAG.
FIFTH WHEEL Rp10 15/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP. 3

REV. 00

Caution! The fifth wheel mechanisms are spring-loaded.

Warning! Limb injury hazards!

2) Check to see that the semi-trailer wheels are locked;

3) 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:

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.
until coupling is achieved as

m.
15-25 c

AILER
SEMI-TR NTER
COU NT
FRO
PLATE'S T-EDGE
H
STRAIG

SEMI-TRAILER COUNTER PLATE

 PAG.
FIFTH WHEEL Rp10 16/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP.

REV. 00
3

4) 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
5) 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.

ER 20-30 cm.
SEMI-TRAIL E'S
PLAT
COUNTER T-EDGE
AIGH
FRONT STR m.
20-30 c

SEMI-TRAILER COUNTER PLATE

CAUTION: always check personally to see that the semi-trailer

counter plate is completely resting on the fifth wheel surface.
 PAG.
FIFTH WHEEL Rp10 17/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP. 3

REV. 00

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

6) Wind the semi-trailer landing legs fully up to stroke end.

 PAG.
FIFTH WHEEL Rp10 18/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP. 3

REV. 00

3.2 UNCOUPLING

1) Lock the semi-trailer wheels;

2) Wind down the semi-trailer landing legs until they touch the ground;

3) 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

19c
19c
1

1 3

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

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.

4) 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: contact between the fifth wheel and the semi-trailer

counter plate must never be broken.
 FIFTH WHEEL Rp10 PAG.
19/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS CHAP.

REV. 00
3

R
SEMI-TRAILE
L A TE 'S
COUNTER P DGE
IGHT-E
FRONT STRA .
30-50 cm

SEMI-TRAILER COUNTER PLATE

N
O For tractor units having pneumatic suspensions, go on to points 5
T
E and 6.

5) Deflate the air from the tractor unit suspensions completely;

6) Ride the tractor unit out and immediately restore the suspension air back
up to

CAUTION: Never deflate the tractor unit suspensions before

uncoupling.
 PAG.
FIFTH WHEEL Rp10 20/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP. 4

REV. 00

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.

19c

2c
7

11b

N
O The mobile parts of the fifth wheel's jaw lock mechanism (7, 11b) as
T well as the contrast ring (2c), are subject to standard wear and tear.
E
Extent of wear depends on working conditions and maintenance
operations conducted.
 PAG.
FIFTH WHEEL Rp10 21/36
CAP. 4
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSREV. 00

After the first 500 km of use:

Check that the torque wrench setting of the fifth wheel pedestal bolts (15-
24-30)
screwed onto the tractor unit carrier plate is comprised within the settings
provided at page 10/36 - section 2.1 INSTALLATION WITH CARRIER PLATE
Inspect the welding on the weld-on pedestals (31) - consult section 2.3
INSTALLATION WITH WELD-ON PEDESTALS at page 12/36 and check to see
there is no weld breakage and cracks that might lead to operation
hazards.
At regular 5000 km intervals:
1) Check that the torque wrench setting of the fifth wheel pedestal bolts
(15-24-30) screwed onto the tractor unit carrier plate 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. Inspect the welding
on the weld-on pedestals (31) - consult section 2.3 INSTALLATION WITH
WELD-ON

2) For fifth wheels provided with rubber bearings, check that the torque
wrench setting of the support-plate fixing screws (page 24 and 28/36) is
comprised between 270 and 300 Nm. For fifth wheels provided with pivot
bearings, check that the torque ;

3) Open the fifth wheel and inspect that it

functions correctly according to directions
given in
Section 3.1 COUPLING UP at page 14/36;
5

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
 FIFTH WHEEL Rp10 PAG.
22/36
CHAP. 4
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSREV. 00

N In the event that during inspections, wear and tear of deformed

O
or worn components is found to be in excess of the wear levels
T
E as specified further on herein.

4.1 PERIODICAL MAINTENANCE

N
O
Depending on its use and at least annually, the fifth wheel must
T be checked for wear. The following checks and inspections are
E recommended.

Checking the rubber buffersBrake empty semi-trailer and move the tractor
unit slowly. If there is any movement of the fifth wheel plate against any of
the fifth wheel supports in excess of 3 mm, proceed with buffer
replacements consult section 7.1 FIFTH WHEEL BEARINGS at page 27/36.

General fifth wheel inspection

A) Check that the fifth wheel plate (8) and the semi-trailer counter plate
do not show any signs of wear or deformation compromising
B) operation;
Check that the semi-trailer king pin lies perfectly perpendicular to the
C) counter plate;
Make sure that the fifth wheel plate (8) and pedestals (15-24-30-31) do

Wear inspections
A) Inspect the fifth wheel jaw lock mechanism (2c, 7, 11c) and the semi-
trailer king pin for wear. Check that wear is limited to the levels
illustrated in the figures below;
B) Check the self-lubricating insert for wear (as per figure below).
Original dimension
Ø 73

Wear of the nylon plate insert

min.
5
max.
65

Ø 71
min.
Ø 49
min.
Original dimension
Ø 58.8
 FIFTH WHEEL Rp10 PAG.
23/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP. 5

REV. 00

If wear is found to be within limits given but inspection shows that there is
some clearance in the fifth wheel mechanisms and semi-trailer king pin,
proceed with clearance adjustments as specified in subsequent section 5
CLEARANCE ADJUSTMENTS at page 23/36.

N
O The wear data is specified according to the ISO TS 20825
T standard requirements.
E

Screwed onto the tractor unit carrier plate 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 wrench setting of the pivot fixing screws is at least
25 Nm.
Lubrication checksLubricate the fifth wheel plate (only for standard type fifth
wheels), the jaw lock mechanism and the king pin.

5 CLEARANCE ADJUSTMENTS

This chapter refers to the figures on pages 23-25/36.

Read the following instructions carefully before any operation:

Wear safety shoes!

Wear safety gloves!

N
The fifth wheel and the semi-trailer king pin are subject to wear,
O
T that may vary subject to use and maintenance frequency.
E
 PAG.
FIFTH WHEEL Rp10 24/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP.

REV. 00
5

Wear will lead to clearance forming between the jaw lock mechanism
(2c, 7, 11b) and the semi-trailer 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.

In the event that the king pin wear does exceed specified limits,
do not proceed with any clearance adjustment whatsoever. In
these cases, the king pin has to be replaced (consult the use
and maintenance manual supplied with the semi-trailer
accordingly).

5.1 CLEARANCE ADJUSTMENT PROCEDURE

1) Couple up the semi-trailer to the tractor unit as per directions in section
3.1 COUPLING UP at page 14/36;

2) Position trailer on an even surface;

3) Lock the semi-trailer wheels then slightly reverse with the tractor unit;

4) Loosen the adjustment screw counter nut (1b);

5) Unscrew the adjustment screw (1a) for ten turn-outs or anyway until it is
no longer contacting the wedge (11b);
6) Pull on the operating handle (19c) then release it so that it lodges back
into its correct position;

7) Screw the adjustment screw (1a) back up until you feel it contacting
the wedge (11b);

8) To guarantee a default clearance ranging between 0.2 - 0.4 mm, turn

the adjustment screw (1a) in for another 1.5 to 2 turns;
 PAG.
FIFTH WHEEL Rp10 25/36
CHAP. 5
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS REV. 00

19c

2c

11b

1a
1b

9) Tighten the adjustment screw counter nut (1b) back up, taking care not
to rotate the adjustment screw (1a) whilst doing so;

Torque wrench setting 100-120 Nm.

The adjustment procedure is finished and the unit is ready for a final check

Try pulling off with the tractor with the semi-trailer brake on, to
N
see whether you can still detect some clearance. If the
O clearance detected is considerable, this means that the fifth
T wheel no longer has any clearance adjustment options.
E In these cases, replacement of the jaw lock mechanism is
required, as per directions in section 7.2 - REPLACEMENT OF THE
JAW LOCK MECHANISM, at page 30/36.
 PAG.
FIFTH WHEEL Rp10 26/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP. 6

REV. 00

6 ASSEMBLY OF THE OPERATING HANDLE EXTENSION

This chapter refers to the figure on page 26/36.

Read the following instructions carefully before starting any

operation:

Wear safety gloves!

1) Disassemble the operating handle by removing the three M8 bolts (21b

21c);
2)
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

21b

21a
21c 19c
 PAG.
FIFTH WHEEL Rp10 27/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS CHAP.

REV. 00
7

7 REPAIRS

This chapter refers to the figures on pages 27-32/36.

Read the following instructions carefully before any operation:

Wear safety shoes and safety gloves!

7.1 FIFTH WHEEL BEARINGS REPLACEMENT

CAUTION: make sure that the wedge (11b) and the jaw (7) are
clearly
visible and the operating handle (19c) is regularly back in

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) Unscrew the four screws (3a) and retrieve the washers (25) and nuts
(26). Dispose

2) Remove the fixing plate (27) and the lower rubber bearing (28).
Dispose as specified in section 9 - DISPOSAL - page 34/36;

3a

3a
 PAG.
FIFTH WHEEL Rp10 28/36
CHAP. 7
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS REV. 00

3) Lift the fifth wheel plate (8) using appropriate lifting devices for 150 kg
weights;

Warning! Limb injury hazards!

4) 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;

5) Position in the new upper rubber bearing (29)

making sure that the arrow marker points 8
towards the front end of the tractor unit;

6) Rest the fifth wheel plate (8) back onto the

Pedestal (30);
3a
7) Lodge in the new lower rubber
bearing (28) making sure that the
arrow marker points towards the
front end of the tractor unit and
the fixing plate (27);

29

30
8) Lock everything back on
using four screws (3a),
washers (25) and nuts (26); 28

Torque wrench setting 270-300 Nm.

27

N Each time the rubber bearings are

O replaced all the screws (3a) the washers 25
T (25) and
E 26
the nuts (26) must be replaced. Dispose as
 PAG.
FIFTH WHEEL Rp10 29/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS CHAP. 7

REV. 00

7.1.2 FIFTH WHEEL WITH PIVOT BEARINGS

N
The following steps 1, 3 and 5 must also 3
O
T be repeated on the fifth wheel's
E opposite side.
1) Unscrew the two screws (3) and remove
the pin (13);
13
Warning! Limb injury hazards!

2) Lift the fifth wheel plate (8) using appropriate lifting devices for 150 kg
weights;
Make sure that the fifth wheel plate (8) is
safely anchored and secure for extraction of
the meniscus (14). Dispose as specified in 8
section 9 DISPOSAL page 34/36;
3) Position in the new meniscus (14);

4) Remove the rubber bearing (16) and

the support bushing and replace them;

5) Position in the fifth wheel plate 14

(8) being very careful to insert
the pedestals (15) into their
lodgings underneath the fifth
wheel plate (8); 3
15
6) Insert the pin (13) and
block it with two screws
(3) and the relative safety
washers. 16
Torque wrench setting 25 Nm. 13

N Each time the pivot bearings are replaced, all

O the screws (3) and the safety washers must be
T replaced as well. Dispose as specified in section 9
E
- DISPOSAL - page 34/36.
 PAG.
FIFTH WHEEL Rp10 30/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONSCHAP. 7

REV. 00

7.2 REPLACEMENT OF THE JAW LOCK MECHANISM

This chapter refers to the figures on pages 30-32/36.

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.

19c
2b 2c 2a

7
2a

11b

1) Remove the two contrast ring screws (2a) to release the contrast ring
(2c);
2)
Remove the worn contrast ring (2c). Dispose as specified in section 9 -

3) Turn out the screw (2a) to remove the pin (2b);

4) Position the fifth wheel plate (8) as shown in the illustration on page
31/36 then proceed with the operations necessary for fifth wheel plate
(8) release from its supports, as per directions given at section 7.1 -
FIFTH WHEEL BEARINGS REPLACEMENT - page 27/36;
 PAG.
FIFTH WHEEL Rp10 31/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS CHAP.

REV. 00
7

Care with turning the fifth wheel upside down is

recommended! Make sure
that the new position will provide ready access to the coupling
point for subsequent removal of the jaw (7).

5) Remove the traction spring (18);

18
6) Pull out the operating handle (19c)
fully; 3
7) Remove the spring (6) and slip 1
the jaw out (7). Dispose as
specified
19c
in section 9 DISPOSAL

8) Release the jaw (7) from the

lubrication pipe (4);

9) Insert the new jaw (7) and block it

with the contrast ring pin (2b);

10) Position in the contrast ring (2c) and lock it on with the two screws (2a)
using some loctite 243 thread-locking compound;

Torque wrench setting for screws (2a)

And (2b): 100-120 Nm. 19a 18 4

11) Anchor the spring (6) onto

the jaw (7) and also insert
lubrication pipe (4); 11c
12
12) Unscrew nuts (11c) and (19a) and 6
slide out the release lever (12);
7
11b
13) Remove the wedge (11b) and the
Relative wedge screw (11a). Dispose as
Specified in section 9 - DISPOSAL page 34/36 and
replace accordingly.

14) Reposition the wedge (11b) and the release lever (12) into the fifth
wheel plate (8);
 PAG.
FIFTH WHEEL Rp10 32/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS CHAP.

REV. 00
7

15) Screw in nuts (11c) and (19a) pack-tight with relative screws (11a) and
(19b),

16) Unscrew the adjustment screw counter nut (1b) and the adjustment
screw (1a) for at least 10 turns;

17) Close the fifth wheel and assemble on the traction spring (18);

18) Reassemble the fifth wheel back onto its pedestals, as per directions at
steps 6 and 8 in section 7.1.1 FIFTH WHEEL WITH RUBBER BEARINGS on

19a 18
19b

11c
1b

1a
11a

19) Proceed with steps 7, 8, 9, and 10 in section 5.1 CLEARANCE

20) Load mechanism lock and couple up the semi-trailer as per directions
in section 3.1 - COUPLING UP at page 14/36.
 PAG.
FIFTH WHEEL Rp10 33/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS CHAP.

REV. 00
8

8 CLEANING
Fifth wheels featuring standard plates must be kept clean, oiled
and a layer of grease spread on the semi-trailer counter plate.
Consult section 2.4 SETTING UP FOR OPERATION at page 13/36.

Avoid the accumulation of foreign matter onto the fifth wheel

surface, the same goes for the jaw lock mechanism.

Clean after each journey or trip, possibly 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 .

19c

8 Fifth wheel standard plate.

N
O Use of high pressure water jet machines is allowed only on the
T coupling up area.
E
 PAG.
FIFTH WHEEL Rp10 34/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS CHAP.

REV. 00
9

9 DISPOSAL

Read the following instructions carefully:

No part of the drawbar eye shall be disposed of in the enviroment

Every part,

The appropriate actions and measures adopted must regularly comply with
the local regulations and laws in force at the time of disposal.
 PAG.
FIFTH WHEEL Rp10 35/36

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS CHAP.

REV. 00
10

10 STRIPPING

This chapter refers to the figure on page 24/36.

CAUTION: before proceeding with any operation, check that the

wedge (11b) and the jaw (7) are clearly visible and the operating
handle (19c) is regularly back into position.

Disassemble the fifth wheel from the tractor unit frame. Consult
section 2.1 INSTALLATION WITH CARRIER PLATE at page 10/36,
section 2.2 - DIRECT INSTALLATION at page 11/36 or section 2.3 -
INSTALLATION WITH WELD-ON PEDESTALS at page12/36.

Warning! Limb injury hazards!

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.
NOTES