Warren Elevating 5
th
Wheels
Operation and Maintenance Manual
FW-30, FW-45, & FW-25HL6
Page 1: ...Warren Elevating 5th Wheels Operation and Maintenance Manual FW 30 FW 45 FW 25HL6...
Page 2: ...Wheel on Tractor 15 Prepare Tractor Frame 15 Prepare for Bolt On installation 15 Position 5th Wheel Assembly for FW 30 FW 45 see Figures 4a and 5a 15 Position 5th Wheel Assembly for FW 25HL6 see Figur...
Page 3: ...inal Locking Test 34 Check Raising and Lowering 34 Final Systems Test 34 Maintenance 34 Lubrication Maintenance 34 Hydraulic Maintenance 34 Mechanical Maintenance 35 Service Conditions and Problems 35...
Page 4: ...t first satisfy himself thoroughly that neither his safety nor the product safety will be compromised or jeopardized by the selected procedure Preface This Operation and Maintenance Manual is to assis...
Page 5: ...ctor Compatibility Many tractors are compatible with Warren Elevating 5th Wheels however your tractor may have different design and dimensional characteristics that affect its compatibility or install...
Page 6: ...stall 5th wheel on tractor attach 5th wheel frame to steel angles installed in Step 5 7 Make pick up ramps 8 Connect air and hydraulic lines to 5th wheel 9 Put oil in cylinder s and tank 10 Inspect an...
Page 7: ...2680 Footnotes 1 CA refers to the distance tram last above frame obstruction i e transmission mount muffler etc behind tractor cab to center of single or tandem axles Most trailers have a 36 in or 42...
Page 8: ...e been included in the shipment Refer to the packing list enclosed with the shipment Operating Controls Unless special ordered all Warren 5th wheels have full air controls We have determined this prov...
Page 9: ...distributor or dealer CAUTION NEVER USE A DETERGENT OIL OR USED OIL IN THE HYDRAULIC SYSTEM Check Tools and Supplies Required Make sure you have the following tools on hand for installation Overhead h...
Page 10: ...ng recommendation Use a C clamp in front of each roller Refer to Fig 9 On all tractors you must disconnect all battery cables and tape the cable ends before doing any welding on the tractor or fifth w...
Page 11: ...method 1 using 1 piece of angle steel Figure 2 Installation method 2 using two pieces of angle steel 5th Wheel Frame Tractor Frame 5 8 Inch SAE Grade 8 Bolts Steel Angle short leg Steel Angle long leg...
Page 12: ...her Introduction to Operating Controls As a standard your 5th wheel has been provided with an air shifting hydraulic pump The control valve air lines and fittings are also included Also standard is an...
Page 13: ...pumps Opposite engine rotation PTO s require counter clockwise pumps Engine rotation PTO s require clockwise pumps If in doubt consult your PTO supplier NOTE For direct mount pumps fabricate a support...
Page 14: ...ant to have this installed on or close to the air tank If you are supplying your own air shift pump you MUST install a restrictor valve to limit 5th wheel decent speed Allowing the 5th wheel to lower...
Page 15: ...mbly on the tractor frame to make measurement marks on the tractor frame Position 5th Wheel Assembly for FW 30 FW 45 see Figures 4a and 5a Using an overhead hoist and a suitable safety chain lift the...
Page 16: ...orward mark A to the very rear of the tractor frame This is the length of the steel angle s you will need on each side Table 2a Minimum forward position of 5th wheel Jaws center D In relation to axle...
Page 17: ...trailer when it is pulling a trailer having a long king pin setting If the 5th wheel frame does not fit completely flush on the tractor frame do not be concerned You will fix this in a later step When...
Page 18: ...axle s center D ins mm FW 25HL6 C and D aligned 0 Figure 4b FW 25HL6 5th wheel in down position All Models Mark Interfering Cross Members Here you will be checking for proper clearance between cylinde...
Page 19: ...parts later Check for Actual Contact When the 5th wheel is in the exact position where you want to install it check for interference from any cross members or other components Remember that the suspen...
Page 20: ...s a center draw an arc C running from each side of the second mark to the top of the cross member This crescent shaped section will be removed in later steps Check for clearance regardless of actual c...
Page 21: ...You will now decide angles on each side When To Use One Angle Per Side Fig 1 FW 25HL6 requires this method 5th Wheel Frame Steel Angle long leg Tractor Frame 5 8 Inch SAE Grade 8 Bolts Steel Angle sho...
Page 22: ...ide the lowest 5th wheel down height because it permits the 5th wheel frame to fit directly against the tractor frame How to Install Steel Angles Whether you are installing one angle per side or two a...
Page 23: ...pointing away from the tractor frame and the 3 1 2 inch leg is pointing down Clamp the lower angle in place aligned with the top edge of the tractor frame Cut out the angles to fit around any obstruct...
Page 24: ...lly pick up the 5th wheel and lift it above the tractor frame Be sure any hoses are clear and then lower the 5th wheel onto the tractor Adjust the position of the 5th wheel For Truck Frame Angle C CLA...
Page 25: ...arts of your body away from elevating sections While raising the 5th wheel carefully observe the moving parts under the 5th wheel Make sure the cylinder s hoses and front elevator have adequate 1 4 in...
Page 26: ...de of the tractor frame Make these marks on the other side of the tractor frame Drill 11 16 holes through both angles on each side of the tractor frame Secure the angles together using 5 8 SAE Grade 8...
Page 27: ...t Install Pickup Ramps WARNING Do not attempt to put the tractor into service without adding pick up ramps as directed Figure 10 Installation of Pickup Ramps Prepare Tractor Frame Make a mark at the e...
Page 28: ...d of the tractor frame to E Weld from point A to E Cut off excess stock if any If there are any gaps between the pickup ramp and truck frame cut 3 8 inch stock to make a brace centered under the picku...
Page 29: ...and replace batteries and battery cables Fill Tank and Cylinder s We recommend using hydraulic oil with minimum specifications stated earlier in this manual and suited to your operating conditions and...
Page 30: ...5th wheel installation should be thoroughly checked out before the unit is coupled with a trailer Then it should be checked out while handling a loaded trailer Check components and Operation PICK UP R...
Page 31: ...beyond the front of the plate b If the jaws are unlocked the rod will extend more than 1 inch beyond the front of the plate 8 If you will be traveling on the road engage the Road Lock by pulling up o...
Page 32: ...mage 1 Bottom View of 5th Wheel Locking Jaws With The Jaw Fork Fully Engaged Note that you ARE able to engage the road lock in this view The jaw fork is fully engaged in the back of the king pin jaws...
Page 33: ...n Notice that the rod on the jaw fork extends past the square bar on the road lock In this case it is possible for the jaw fork to be forcibly pushed out of the locked position with excessive pull or...
Page 34: ...he unit is new CAUTION Failure to provide an adequate supply of grease will result in premature wear and damage This is especially true on the cross shafts that carry heavy loads A lack of lubrication...
Page 35: ...system Relief valve is opening due to very heavy load or relief valve damage If unit will not stay in a raised position Cylinder may be damaged Piston may be cracked or barrel might be severely scored...
Page 36: ...like elevators shafts and roller wheels are included when you purchase these parts These repairs must only be done mechanics that are familiar with vehicle repair Correct Locking Procedure Back the t...
Page 37: ...e to any trailer 4 Do not push the king pin Jaw control valve until you want to release the trailer As soon as you push down this valve the trailer will drop 5 Before traveling on public roads put the...
Page 38: ...r Bring the tractor into the shop Repair procedure Raise the 5th wheel to maximum height In the case of high lifting 5th wheels raise to a convenient working height NOT TO EXCEED 45 DEGREES ABOVE HORI...
Page 39: ...any marks are present Make sure that the fork will slide easily into the locked position A new fork will normally need some grinding to fit properly Install in this order fork flat washer steel bushin...
Page 40: ...the trailer at a 35 to 45 degree angle When the 5th wheel can lock at any angle it is ready to be put back in service Please call us if we can be of any help Warren Truck and Trailer LLC P O Box 425 1...
Page 41: ...e to repair or replace at its option any warranted unit or part as described above which shall be returned to Warren s factory or authorized service distributor and which examination shall disclose to...
