Summary of Contents for Warren FW-30
- Page 1 Warren Elevating 5 Wheels Operation and Maintenance Manual FW-30, FW-45, & FW-25HL6...
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Page 2: Table Of Contents
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 Figure 4b) ........17 All Models — Mark Interfering Cross Members ............18 Check for Actual Contact.................... - Page 3 If the locking jaws need repair .................. 36 Replacement of other components ................36 Correct Locking Procedure ..................36 WARREN Locking Assembly Repair and Adjustment Instructions ........ 37 Tools Required For Repair..................37 Locking Assembly Inspection................... 38 Locking Assembly Repair..................38 Final Locking Test ....................
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Page 4: Safety Notice
Use this manual as a reference in seeing that this unit receives proper care and is correctly operated. The use of genuine Warren parts is recommended for best equipment service as well as insuring that our warranty policy is not voided. -
Page 5: Please Note Cautions
If you have problems or questions applying the installation procedures to your tractor, please contact your local Warren Distributor before attempting to install the unit on the tractor. -
Page 6: General Information
General Information 1. All Warren 5 wheels come with an air shift direct drive pump. Ensure your PTO, counter transmission, and pump are compatible. The Warren supplied pump is clockwise (CCW) rotating. 2. Install PTO. Run engine to check PTO installation. -
Page 7: Pre-Installation Instructions
Check for Power Take Off Capability and Location The installation of a Warren 5 wheel requires the addition of a PTO to the tractor. Check the tractor transmission to see which opening you will use for the PTO. Most transmissions have two PTO openings. -
Page 8: Check 5 Th Wheel Capacity
The Warren supplied pump is counter clockwise (CCW) rotating. 2. PTO ratios. Single cylinder 5th wheel models (FW-30): 80-90 % of engine speed. Twin cylinder models (FW-45): 90- 110 % of engine speed. -
Page 9: Check Tools And Supplies Required
Power drill with various bits Selection of fasteners including • Power hand grinder Grade 8 bolts, 5/8 in. lock nuts and • washers Sledge hammer • • Pipe wrenches Black paint • Open-end wrenches (U.S. sizes) Warren Elevating 5 Wheel... -
Page 10: Installation Introduction
This steel angle will increase the down height of the 5th wheel by its thickness. The 5th wheel will be installed on the tractor frame using steel angles. The angles will be bolted Warren Elevating 5 Wheel... - Page 11 (long leg) Wheel Frame Steel Angle (short leg) Weld 5/8 Inch SAE Grade 8 Bolts Steel Angle (long leg) Tractor Frame Steel Angle (short leg) Figure 2 Installation method 2 using two pieces of angle steel Warren Elevating 5 Wheel...
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Page 12: Method 2
Jaw Control Pump Valve PTO Valve Image 1 Console Power Take-Off Power Take Off Installation Install and adjust PTO according to the manufacturer’s instructions. Warren Elevating 5 Wheel... - Page 13 NOTE: The Warren supplied pump is counter clockwise rotating (CCW). NOTE: PTO shaft rotation direction on direct mount type pumps. Opposite engine rotation PTO’s require counter clockwise pumps. Engine rotation PTO’s require clockwise pumps. If in doubt, consult your PTO supplier.
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Page 14: Installation
5 wheel assembly. There is a restrictor valve included with each Warren air shift pump. DO NOT REMOVE THIS VAVLE. Pressure Port of... -
Page 15: Installation Of The 5 Th Wheel On Tractor
Before installing the steel angles, temporarily place the 5th wheel assembly 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) - Page 16 B. Front of E. Rear of 5 ahead of 5 C. King Pin wheel wheel frame wheel frame Jaws center frame D. Axle in down Center position Figure 4a. FW-30 & FW-45 5 wheel in down position Warren Elevating 5 Wheel...
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Page 17: Position 5Th Wheel Assembly For Fw-25Hl6 (See Figure 4B)
D. Axle Center CAUTION: King Pin Jaw Center (C) must be ahead of the axle in the up position. Figure 5a. FW-30 & FW-45 5 wheel in up position Position 5th Wheel Assembly for FW-25HL6 (see Figure 4b) Using an overhead hoist and a suitable safety chain, lift the entire 5 wheel assembly and lower it carefully onto the tractor frame. -
Page 18: All Models - Mark Interfering Cross Members
Figure 4b. FW-25HL6 5 wheel in down position All Models — Mark Interfering Cross Members Here, you will be checking for proper clearance between cylinder(s) and cross members. You will be marking cross members for any necessary alterations. Warren Elevating 5 Wheel... -
Page 19: Check For Actual Contact
NOTE: If the 5 wheel frame fits flush on the tractor frame rails. Check any gap between the two frames may be caused by a cylinder resting on a cross member. Check each cross member Warren Elevating 5 Wheel... -
Page 20: To Mark A Cross Member For Alteration
On any tractor, disconnect battery cables and wrap cable ends to insulate. Using a torch, cut out crescent-shaped section (A) as previously marked. The, reinforce the cut-out area by welding a strip properly shaped (B) to fit. Warren Elevating 5 Wheel... -
Page 21: Installing Steel Angles
Steel Angle (short leg) Figure 2 Installation method 2 using s angle pieces of angle steel You will now decide angles on each side When To Use One Angle Per Side (Fig. 1) FW-25HL6 requires this method! Warren Elevating 5 Wheel... -
Page 22: When To Use Two Angles Per Side (Fig. 2)
The angles should be long enough to extend from about 3 inches ahead of the 5 wheel frame, to the rear of the tractor frame. Holes Truck Frame Angle Figure 7a Fitting steel angle to tractor frame and hole locations for FW-30 & FW-45. Warren Elevating 5 Wheel... -
Page 23: If One Angle Per Side (Fig. 1)
With the angles properly positioned and clamped, mark the angles for at least 8 bolt holes along the side for the FW-30 & FW-45, 12 bolts for the FW-25HL6. First mark, then drill a pilot hole, and then an 11/16 inch hole at the locations indicated in Figure 7. Also drill any additional holes where you feel additional bolts may be needed. -
Page 24: Mounting 5Th Wheel Assembly On Tractor
Angle Ahead of Roller Wheel Figure 8. Proper clamping and blocking of the FW-30 & FW-45 Figure 8b. Proper clamping and blocking of the FW-25HL6 You are now ready to place the 5 wheel assembly on the steel angles you have installed on the tractor frame. - Page 25 FW-30 & FW-45 the center of king ping should in front of the center of the axle(s) 6 inches when in the down position. For the FW-25HL6, the center of king ping should line up with the center of the axle(s) when in the down position.
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Page 26: On Installations Using Two Steel Angles Per Side
Lower 5th Wheel Plate to Collapsed (Down) Position To lower the 5 wheel plate safely, remove the filler plug and vent from the top of the cylinder(s). Remove the pipe plug from the other end of the cylinder. Warren Elevating 5 Wheel... -
Page 27: Install Pickup Ramps
NOTE: You may not want to cut the tractor frame to install pick-up ramps. To avoid cutting, make the pickup ramps slope to the top of the tractor frame. The more gradual the slope, the better. Warren Elevating 5 Wheel... -
Page 28: Install Ramps
Severe Duty Applications If your 5 Wheel will be used in severe duty, it may require additional bracing. Please contact your installer or Warren Truck and Trailer for more information. Connect Hydraulic Hoses, Pump Figure 11. Hydraulic layout for FW-30... -
Page 29: Prepare Tractor For Service
“lower” position. If you do not have a trailer nearby, have the driver put the pump into the “lower” position while a mechanic uses the pry bar to help lower the fifth wheel. Check oil level in tank and add if necessary. Warren Elevating 5 Wheel... -
Page 30: Final Installation Steps
Grease the top of the fifth wheel plate. Warren suggests the use of a safety step deck plate (not supplied) to the area on top of the frame where the driver will stand when hooking up trailer air lines and electrical lines. -
Page 31: Coupling And Locking
11. If the jaws still do not lock, refer to “Repairs” section later in this manual. Warren Elevating 5 Wheel... - Page 32 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. See picture below for actual photo of fully engaged jaw fork Warren Elevating 5 Wheel...
- Page 33 The pictures below are actual images of this condition. Note that you could hear the “snap” of the jaw around the king pin (see below), but this unit was not securely locked! Warren Elevating 5 Wheel...
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Page 34: Final Locking Test
Monthly: Check all of the hoses and fittings for leaks, cracks or deterioration. Replace as needed. Yearly: Drain all oil from system. Remove oil filter. Replace filter with a new filter element, then refill tank and cylinder(s) with new oil. Warren Elevating 5 Wheel... -
Page 35: Mechanical Maintenance
Check to be sure that this valve is present. This valve makes the fifth wheel come down slowly. If you have supplied your own pump, make sure that a flow restrictor is installed. Check for any hydraulic leaks that might be drawing in air. Warren Elevating 5 Wheel... -
Page 36: Repairs
You must be sure that any repairs be done properly. Your Warren distributor has the parts and knowledge required to repair your Warren 5 wheel. We recommend that you call your distributor or Warren if you have any questions on the best ways to check your 5 wheel. -
Page 37: Warren Locking Assembly Repair And Adjustment Instructions
IMPORTANT: The locking assembly must be carefully adjusted to insure safety. Failure to properly repair and adjust these parts will result in accidents! USE ONLY AUTHORIZED WARREN REPLACEMENT PARTS. DO NOT USE A STANDARD TYPE 9 BRAKE CHAMBER TO REPLACE THE WARREN AIR CHAMBER. -
Page 38: Locking Assembly Inspection
Notice the linkage connecting the jaw fork to the Warren Air Chamber. First, remove linkage components: flat washer, bushings and linkage bar. Remove the long air cylinder that extends from the front of the 5 wheel plate. - Page 39 Repeat the entire locking procedure. If the fork does not go in all the way, hit the fork rod, remove the fork and grind the fork where it is binding. DO NOT GRIND THE JAWS, only the fork. Warren Elevating 5 Wheel...
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Page 40: Final Locking Test
When the 5 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 15768 U.S. Hwy 271 North... -
Page 41: Warranty
(2) any unit which shall have been subject to misuse, negligence, alteration or accident or which shall have been repaired by anyone other than Warren or its authorized service distributor in any way so as in the judgment of Warren to affect adversely its performance or reliability, or (3) normal maintenance services.