1 KALMAR LIFTING AND DUMPING 5th WHEELS MORE WORK IN LESS TIME
2 Trailer Lifting Kalmar Lifting 5th Wheels Improve Productivity by 2.5 Times The Kalmar Lifting 5th Wheel is designed to make trailer spotting much more efficient by saving time, labor and improving safety. The cranking of the landing gear is eliminated so the Kalmar Lifting 5th Wheel can do more work in less time and reduce operator fatigue. By serving as a trailer spotter and over the road delivery vehicle, It speeds up trailer movement operations by making handling more efficient and flexible. It can also serve as a transport vehicle to various plant locations. Three of our Lifting 5th wheel models permit converted tractors to do double duty by spotting trailers and hauling over the road. After reviewing this brochure, please fill out the selection guide summary included. Then, your knowledgeable representative will analyze your operation to see which Kalmar product is right for you. Kalmar has over 45 years of designing and manufacturing Lifting 5th Wheels, so we truly are dedicated to making things easier for you.
3 The Kalmar Lifting 5th Wheel provides a simple, cost effective way to convert standard road tractors into hard working yard tractors with on-road capabilities. It can provide improved safety and less operator fatigue to move many trailers from one location to another as with just-in-time manufacturing. Lifting maximum height horizontal position of lift with full oscillation available to clear ramps Full down position
4 Selection Guide Lifting 5th Wheels for Trailer Spotting The selection of a lifting 5th wheel for trailer spotting is based on six main factors: 1. Type of application: For example yard spotting, marine dock spotting, JIT transport, off road, public road use, or trailer dumping. 2. Gross weight: This includes the weight of the trailer plus load. As shown in the tables, Kalmar lifting 5th wheels are available for handling loads (gross capacity, meaning trailer and contents) from 60,000 lbs. to 120,000 lbs. It can transport, locate and dump trailers and containers. 3. Lifting height: Landing gear in a normally extended position must be lifted high enough to clear any anticipated obstructions. Most applications require a 13 to 14-inch lift. This will clear obstructions in most normal spotting areas. For use on ramps, Kalmar offers the M95 or W Installed down height: This is the height (from ground) of the 5th wheel plate in down position when installed on a tractor. It determines whether an installed 5th wheel will be low enough to couple with your lowest trailers and your tallest legal height trailers and still be under First, determine whether a Kalmar 5th wheel will be low enough to fit your lowest kingpin height. Determine installed height as follows: a. Refer to Table l, item l on table and drawings. This is the down height of the 5th wheel itself before installation. b. Determine installed down height by adding 5th wheel down height dimension l to the height of your tractor frame (top of frame to ground); measure tractor frame without a load. c. Determine the uncoupled height of your trailer king pin plate (measure from bottom of plate to ground on your lowest trailer). Keep in mind the legal height limit of Choose a lifting 5th wheel that will have a down height closest to your trailer king pin plate height. The 5th wheel installed down height should not exceed 3 inches above the trailer king pin plate height. In any case, proper pick-up ramps must be installed. Keep in mind that 5th wheel height also determines legal road height of the tractor/trailer 5. Trailer king pin setting: This is the distance from trailer king pin to trailer front (including refrigeration unit). This, and tractor C.A., determines whether there is adequate clearance from the back of the cab to the front of the trailer. As with any 5th wheel, adequate space is necessary for clearing trailer corners when turning. Regardless of 5th wheel model, base your selection on the trailer having the longest king pin setting (and refrigeration unit). Kalmar Lifting 5th Wheels can improve your trailer spotting productivity by 2.5 times 6. Tractor C.A. dimension and capacity: Be sure you select a tractor with the proper gross weight capacity and C.A. dimension. C.A. refers to the area on top of the tractor frame measuring from the last above-frame obstructions (i.e. transmission mount) behind the cab to the center of the single or tandem axles an area that must be clear for mounting the 5th wheel. The C.A. must also provide adequate clearance between the back of the cab and the front of the trailer. See No. 5, trailer king pin setting.
5 When you choose a Kalmar Lifting 5th Wheel our global expertise goes to work for you. We want to make things easier for you, so here are the specifications to help you determine which Kalmar Lifting 5th wheel best meets your needs. These models are suitable for most applications. All of these models are mounted on top of the truck frame. Please read the footnotes before ordering. B B B C D A A C D A C D E E E F G F G F G K H K H K H Q P I J N Q P I J P I N N Q L M R L M R L M R M62, M63, M92 Twin Cylinder M85, M60, M61, Single Cylinder M95, Single Cylinder J Models and Specifications M85 M92 M95 M60HD-14 M61HD-14T M62HD-14T M63HD-14T U.S. METRIC U.S. METRIC U.S. METRIC U.S. METRIC U.S. METRIC U.S. METRIC U.S. METRIC Gross Weight Capacity 2 (Lbs., Kg.) 60,000 27,216 90,000 41,000 60,000 27,216 60,000 27,216 70,000 31, ,000 45, ,000 54,432 Minimum Tractor C.A. Dim. 3 (inches, mm) Lifting Height 4 (inches, mm) Down Height 5 (inches, mm) Dimensions (inches, mm) A. Width B. Length C. Cyl. Bore Diameter D. Cyl. O.D E. Cyl. Center to Frame F. Frame Front to King Pin, Down Pos G. Travel Back, Up Pos H. Lifting Height I. Down Height J. Frame Height K. Cyl. Front Below Frame L. Cyl. to Frame Front M. Cyl. Barrel Length N. Cyl. Port Block Length P. Cyl. Rear Below Frame Q. Port Block Below Frame R. King Pin to Cyl. Barrel Dry Weight (Lbs., Kg.) Footnotes 1. Top-Frame Mounted models fit most tractors. 2. Gross weight refers to trailer and contents. 3. C.A. refers to distance from last above-frame obstruction (i.e. transmission mount) behind tractor cab to center of single or tandem axles. C.A. figures based on 36-inch king pin setting. Most models fit single and tandem tractors. 4. Lifting height refers to distance from down height to maximum raised height. 5. Down height refers to distance from top of tractor frame to top of 5th Wheel plate when unit is in the down position. 6. Shaft extension adds 1/4 inch to each side. Road Kit: Standard on most models. King Pin Release: Pneumatic with cab control valve. For public road use, Road Kit is required. Hydraulic Cylinders: 7 or 8 bore, depending on model. Fluid Type: Anti-wear hydraulic oil with pourpoint rated according to operating temperatures and conditions. (Not included with unit). Extra Heavy Duty: Optional models are available for more severe applications. Pump: Hydraulic gear pump with integral valve. Output at 1500 rpm: 20 gpm, 2000psi maximum pressure. Restrictor valve installed to limit descent speed. Air shift for the valve comes standard. Hydraulic System fittings and tubing are supplied for installation. System is power-up, gravity down with cylinder barrel rod end for the hydraulic reservoir. PTO Ratio: Recommended: Twin cylinder fifth wheel models %: Single cylinder fifth wheel models 80-90%. Air Shift Kit: An air shifting kit for the air shift functions is available as an extra cost option. Kit consists of air controls for PTO, hydraulic valve and jaw release that are mounted in a console for cab installation.
6 Trailer Dumping Kalmar Dumping 5th Wheel More work in less time Kalmar s Dumping 5th Wheels will easily turn your trucks into versatile trailer dumpers. You can save time, labor and money by easily dumping the load where you want it using lifting heights up to an additional six feet. Kalmar s Dumping 5th Wheel is the best way to cut the cost of unloading bulk material from trailers. Your truck can also perform multiple duties as a yard tractor, by spotting trailers, picking up and delivering materials as well as performing dumping tasks. Dumping pits or ramps can be used to increase the dump angle, along with vibrators, to break up the material bridging. Kalmar Dumping 5th Wheels are more stable than self-dumping trailers and high-lift 5th wheels, which makes things easier and safer for you.
7 Kalmar s lifting 5th wheels have been improving trailer moving productivity for more than 50 years. They are the best solution for converting a truck into a productive multitasking vehicle. Combined with the best parts and service support and the most extensive nationwide distributor network in the business, the Kalmar Lifting 5th Wheel is the ideal choice. Full Up Position Full Down Position
8 Selection Guide Kalmar Lifting 5th Wheels for Trailer Dumping Operations The Kalmar Dumping 5th wheel is designed for unloading products that do not require a high dumping angle such as: Food Products Citrus Fruit Apples Building Products Manufactured Home Sections Lumber To increase the dumping angle dumping pits or ramps can be used, vibrators can be added to dislodge the product. The selection of a 5th wheel for trailer dumping is based on the dumping angle required to release your product or material from the trailers you intend to use. The dumping angle required is based upon: Kalmar offers unsurpassed service and product support 1. Material to be unloaded. Considerations are aggregate size and shape, bulk and weight. 2. Condition of material. High moisture content and/or freezing temperatures tend to reduce material release. 3. Length of trailer (A) on trailer angle drawing and axle location (B). Trailer length and axle setting determine the maximum dumping angle available with a given 5th wheel model. 4. Gross load weight trailer and contents. Each lifting 5th wheel is designed to handle a specific gross weight as shown on specification tables. 5. Construction of trailer bed and sides. This greatly influences material slide-out. Trailer beds and sides made of steel, aluminum or other smooth surfaces permit material to slide our readily. Wood surfaces and interior posts inhibit material movement. Models and Specifications M59HD-72T Footnotes 1. Gross weight refers to trailer and contents. 2. Single or tandem required. Tilt or standard cab. 3. C.A. refers to distance from last above-frame obstruction (i.e. transmission mount) behind tractor cab to center of single or tandem axles. 4. Lifting height refers to distance from down height to maximum raised height. 5. Down height refers to distance from top of tractor frame to top of 5th Wheel plate when unit is in the down position. 6. Shaft extension adds 1/4 inch to each side. U.S. METRIC Gross Weight Capacity 1 (Lbs., Kg.) 50,000 22,680 Min. Tractor 2 C.A. Dim. 3 (inches, mm) Lifting Height 4 A (inches, mm) Down Height 5 G (inches, mm) Dimensions (inches, mm) Table C A. Lift Height B. Travel Forward - Down to Up Pos C. Shaft Diameter D. Cyl. Bore E. Down Height F. Port Block Below Frame NA7 NA7 G. Cyl. Rear Below Frame H. Cross Member Behind Cylinder I. Cross Member Below Frame J. Width K L M. Cyl. Center to Lift Arm N. Cyl. O.D P Q Dry Weight (Lbs., Kg.) Installation Time (Est. Hours) 47
9 Kalmar s Dumping 5th Wheel gives you the stability and control to make dumping easier and safer. Road Lock Kit: Included with Unit. Pneumatic Air Control Kit: For use on all tilt cabs or where standard control levers may be impractical. Kit consists of air control for pump, PTO and jaw release. Required with all tilt cabs and for other applications where air control is desired. Kingpin Release: Pneumatic with cab control valve. Manual Safety lock is included. Hydraulic Cylinders: Single-acting type with 8 bore. Fluid Type: Anti-wear hydraulic oil with pourpoint rated according to operating temperatures and conditions. (Not included with unit). Pump: Hydraulic gear pump with integral valve. Output at 1000 rpm: 20 gpm at 2000psi. PTO Ratio: Recommended: 80%-100%. Frame Elevating Sections and Lift Plate A ssembly. All hand fabricated. Pick-up Ramps: To meet varying tractor requirements, ramps are to be fabricated and fitted by installer. Instructions included with unit. Complete Units: Units shipped complete except for power take-off, hydraulic fluid and flat stock steel for installation. (Fluid, flat stock and PTO supplied by distributor). Installation: Units are installed at the factory, or by an authorized and qualified distributor. Selection Steps The following procedure for the selection of a lifting Kalmar 5th Wheel for trailer dumping operations is intended as a general guide. Before making a final decision, we strongly recommend that you discuss your requirements with a Kalmar factory representative or an authorized distributor. M59HD-72T 72", 12º M59HD-57T 57", 9º M59HD-48T 48", 8º A B 1. Determine Dumping Angle Required Note: The following figures are to be used only as a general guide. Type of trailer, weather conditions and condition of the material or product all may alter the angle required. Use your own experience and consult with your distributor or the Kalmar factory. a. Generally, angles required to dump typical materials are as follows: Animal by-products* o + Loose hay o + Apples** o + Lumber* 8-20 o + Baled hay o + Manufactured home sections 8-20 o + Citrus fruit** o + Sand, dry o + Crushed rock o + Scrap metal* o + Dirt, loose o + Scrap paper o + Fruit, Vegetables** o + Solid waste 30 o + Glass cullet* o + Sugar cane o + Grain o + Sugar beets o + Logs o + Wood chips ***55 o + *Depending on type and size, **Depending on ripeness, ***Depending on moisture b. Evaluate weather and climate conditions that may influence dumping efficiency. Moisture content of material, water and freezing may reduce material release, often requiring an increased dumping angle and/or thawing. c. Evaluate construction of your trailer. Generally, if bed and sides are made of steel, aluminum or fiberglass, the dumping angles required will be less than when bed and sides are wood, or if sides contain interior posts. 2. Determine Lifting 5th Wheel Model Trailer length, location of the rear axle and the lifting height of the 5th wheel determine the dumping angle available. The dumping angle tables show dumping angles available by trailer length and by 5th wheel model. Table A* Mid-Lifting 5th Wheel Dumping Angles for Tandem Axle Trailers Trailer Length Center of Tandem 2 M59HD-72T at 72 Max. Lift o (Dumping Degrees) o (Dumping Degrees) o (Dumping Degrees) o (Dumping Degrees) o (Dumping Degrees) 1. Approximate Maximum. Dumping angle based on 36 pin setting and axle setting shown if kingpin setting is more than 36 inches, angle is greater. If kingpin setting is less, angle is less. 2. From center of tandem to rear of trailer. Table B** Mid-Lifting 5th Wheel Dumping Angles for Single Axle Trailers Trailer Length Center of Tandem 2 M59HD-72T at 72 Max. Lift o (Dumping Degrees) o (Dumping Degrees) o (Dumping Degrees) o (Dumping Degrees) 1. Approximate Maximum. Dumping angle based on 36 pin setting and axle setting shown if kingpin setting is more than 36 inches, angle is greater. If kingpin setting is less, angle is less. 2. From center of tandem to rear of trailer. Note: For dumping angles available with other trailer lengths, contact the factory. Lower dumping angles: Tables A and B, Mid-Lifting models On the appropriate dumping angle table, in the trailer length column, locate the length of the trailer you plan to use, along with the applicable tandem axle setting. From your trailer length figure in the first column, move to the columns at the right until you locate the approximate dumping angle you require. The 5th wheel model shown at the head of that column will provide the dumping angles listed. Note: Bumper Clearance. In some cases, the bumper may not clear when raising certain trailers. This can be corrected on trailers with sliding tandem axles by moving the axles to the rear. On trailers with tandem axles set far forward, it may be necessary to modify the rear bumper to permit maximum lift height. Please contact the factory for further details. 3. Determine Tractor Required Table C provides the basic specifications needed to select a tractor with the right capacity and C.A. dimensions for each of the 5th wheel models. C.A. refers to the area on top of the tractor frame measuring from the last above-frame obstruction (i.e. transmission mount) behind the cab to the center of the single or tandem axles. This area must be clear of any obstruction to allow space for mounting the 5th wheel assembly. Tractor frame may be extended, or the axle(s) relocated, if necessary. Pick-up height required. Most any standard tractor with a properly installed lifting 5th wheel and properly designed pick-up ramps will couple with any average trailer made. Check to be sure 5th wheel and tractor you plan to use are low enough to couple with the trailers you intend to unload. This depends on how the height of your tractor frame plus the down height of the mounted 5th wheel plate compares to the height of your trailer kingpin plate from ground. Pick-up ramps provide a lower reach than the 5th wheel plate. They are used to bring the trailer kingpin plate up to the plate of the 5th wheel for coupling. Pick-up ramps are fabricated and fitted by the 5th wheel installer, since they must be matched to tractor/trailer dimensions. Instructions are included with the 5th wheel unit. Other Tractor Requirements Springs and tires must be in good condition to provide adequate load-handling stability. Power steering is strongly recommended. Mid-Lifting Models If you are considering one of the Mid-Lifting 5th wheels: a. Any of the three Mid-Lifting models may be used on single or tandem axle tractors having the proper gross weight capacity and C.A. dimension. b. The tractor must have a minimum C.A. dimension of 84 inches, depending on the 5th wheel model. c. The C.A. tractor used for Mid-Lifting 5th wheels, is important not only for adequate mounting space, but for another important reason: Mid-Lifting models travel forward as they rise, drawing the trailer toward the cab (see Table I, item B). A trailer with an exceptionally long kingpin setting may require a tractor with a longer C.A. dimension. The kingpin setting is the distance from the center of the kingpin to the front of the trailer. As with any 5th wheel, adequate clearance between rear of cab and front of trailer must be provided. In addition, the forward movement of the rising 5th wheel may require a greater C.A. dimension for clearance. d. Refer to Table C and drawings, dimensions F, G, H and I. As shown, a portion of each cylinder extends below the 5th wheel frame. A frame member (H and I) also extends down into the truck frame area, across from side to side. Space for these extensions must be clear for mounting. B C F G H I Mid-lifting 5th Wheel in Maximum Lift Position J K L Top View M D P N A E Q
10 How to Order Application: Determine your application. For most common applications and for most tractors, you will be selecting one of the top frame mounted 5th wheel models on Table 1. For public road use, M85, M92 and M95 are recommended. Gross Weight: Determine the gross weight of your maximum load-trailer plus contents. Note the 5th wheel models on the table offering your required capacity, and select the proper model. Lift Height and Down Height: Determine whether the 5th wheel model you have selected offers the lifting height and down height required by your trailer, your tractor and the terrain on which you will be spotting your trailers. Tractor: Make sure the tractor you are considering has the proper gross weight capacity and C.A. dimension as noted on Table 1. Make sure it will provide adequate clearance between cab and trailer (trailer king pin setting). Note whether it has single or tandem axles, torque bars and an air brake system. Also, note the transmission make and model. Check the following: a. Clearance along the top of the tractor frame (C.A. dimension). C.A. refers to the area on top of the tractor frame, measuring from the last above-frame obstruction (i.e. transmission mount) behind the tractor cab to the center of the single or tandem axles. This area must be clear for 5th wheel mounting. b. Clearance within tractor frame. On all Top-Frame models, the bottom of the cylinders, and the connecting hydraulic hoses, extend below the 5th wheel frame. Refer to Table 1 and dimensional drawings. Clearance for this must be provided within the tractor frame. In some cases, it may be necessary to slightly modify frame cross-members in the affected area. c. Tandem tractors with torque bars. Tractors with torque bars may require a twin cylinder fifth wheel if clearance below the hydraulic cylinders is limited. (Twin cylinder models: M62HD-14T, M63HD-14T, M92). Please consult your local distributor or the Kalmar factory if you have questions on any of the above items. Other tractor considerations: a. Tractor may be tilt cab or conventional. If a tilt cab is to be used, an air shifting kit is required for the hydraulic valve. You will also need an air shifting Power Take Off. b. PTO: Select Power Take Off type and ratio according to transmission make and model, and 5th wheel model. Recommended for best results: 80-90% ratio for single cylinder 5th wheel models; % ratio for twin cylinder models. c. Public road use: Determine whether your application includes hauling trailers on any public roads. If so, a Road Kit is mandatory. A Road Kit may be ordered with your 5th wheel, or may be ordered and installed later. Road Kit is standard on models M85, M92 and M95. d. Pick-up ramps: These are fabricated and fitted by the installer. Design, material and installation depend on individual tractor dimensions and 5th wheel model. Instructions are included with 5th wheel units. Other Options: Hydraulic Power Up and Down: A different pump and valve is used to supply both cylinder ends. A 10 gallon hydraulic tank is optional. Proximity Switch Installation: A heavy duty proximity switch is used to detect cylinder (rod) position and to detect the 5th wheel down height.
11 Lifting 5th Wheel Selection Guide Summary When discussing the selection of a Lifting 5th Wheel with a Kalmar representative or with your distributor, it will be helpful to have the following information readily available. Please refer to contents of this brochure for details relating to the following factors. 1. Applications (truck or marine terminal, piggyback, etc.). Will unit be used on public roads? 2. Approximate lifting height required. Most applications require a 13 to 14 inch lift. 3. Maximum gross weight anticipated (trailer and contents). 4. 5th wheel down height required. 5. Trailer kingpin setting. 6. Tractor C.A. dimension and gross weight capacity. 7. Tilt (C.O.E.) or conventional cab trailer. Kalmar Industries Corp. Kalmar Lifting 5th Wheels 415 Dundee Street Ottawa, KS USA Phone: (800) Fax: (785) Tandem or single axle tractor. 9. Transmission make and model, and preferred P.T.O. location. 10. Rear suspension type. Bulletin No. 103 E; Specifications subject to change without notice. Printed in the U.S.A. Dumping 5th Wheel Selection Guide Summary When discussing the selection of a Dumping 5th Wheel with a Kalmar representative or with your distributor, it will be helpful to have the following information readily available. Please refer to contents of this brochure for details relating to the following factors. 1. Number of unloadings per day anticipated. 2. Type of product(s) to be unloaded. Size and Shape. Weight (maximum trailer and contents). Moisture content. 3. Climatic conditions (temperature range, humidity, precipitation). 4. Unloading surface (concrete, earth stable, flat, uneven, etc.). 5. Trailer(s) available (your trailers and/or those of other firms). Longest anticipated. Weight capacity. Single or tandem axle, setting max., min. (adjustable?). Bumper dimensions (height, overhang). Type (closed van, open top, flat bed, etc). Floor and sides (metal, wood or other lining; interior posts). Kalmar Industries Corp. Kalmar Lifting 5th Wheels 415 Dundee Street Ottawa, KS USA Phone: (800) Fax: (785) Tractor(s) available. Make, size, capacity (high-lifting models require tandem). Cab type (must have air brake system: high-lifting models require conventional cab). C.A. dimension. 7. Where used (yard only, or yard and public road). Bulletin No. 104 C; Specifications subject to change without notice. Printed in the U.S.A.
12 Kalmar Industries Corp. Kalmar Lifting Devices 415 Dundee Street Ottawa, KS USA Phone: (800) Fax: (785)