Volvo Trucks VN User manual

Service Manual
Trucks
Group 922–502
Fifth Wheel
VN, VHD
PV776-TSP194811


Foreword
The descriptions and service procedures contained in this manual are based on designs
and methods studies carried out up to August 2003.
The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplementary
service bulletins will be issued to cover the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a
reference to an V.S.T. (Volvo Standard Times).
Service procedures which do not include an operation number in the title are for general
information and no reference is made to an V.S.T.
The following levels of observations, cautions and warnings are used in this Service
Documentation:
Note: Indicates a situation, handling or circumstance which should be observed.
Caution: Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury or damage to property.
Warning: Indicates a potentially hazardous situation which, if not avoided, could result
in death, serious injury or major damage to property.
Danger: Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
Volvo Trucks North America, Inc.
Greensboro, NC USA
Order number: PV776-TSP194811
© 2003 Volvo Trucks North America, Inc., Greensboro, NC USA
All rights reserved. No part of this publication may be reproduced, stored in
retrieval system, or transmitted in any forms by any means, electronic,
mechanical, photocopying, recording or otherwise, without the prior written
permission of Volvo Trucks North America, Inc.. USA14052


Contents
General....................................................................................................3
FifthWheel.............................................................................................3
Specifications.........................................................................................5
FifthWheel.............................................................................................5
Tools........................................................................................................7
SAEKingpinGauge...............................................................................7
DesignandFunction.............................................................................9
FifthWheel...............................................................................................9
...............................................................................................................9
FifthWheelBracketTrunnion...............................................................11
FifthWheelSlider................................................................................12
UnlockingtheFifthWheel....................................................................13
FifthWheelKingpinAirReleaseSwitch,Operation.............................14
FifthWheelCouplingProcedures........................................................17
FifthWheelUncouplingProcedures....................................................21
OperatingtheSlider.............................................................................25
SaddlePlateAssembly........................................................................27
Troubleshooting...................................................................................29
...............................................................................................................29
FifthWheelTroubleshooting................................................................29
ServiceProcedures.............................................................................31
FifthWheel,Checking..........................................................................31
FifthWheelJawtoKingpinClearance,Adjustment.............................42
Systemcheck.......................................................................................45
FifthWheel,Cleaning..........................................................................45
FifthWheel,Lubrication.......................................................................45
1

2

Group 92 General
General
Fifth Wheel
W9000516
This information covers Volvo fifth wheel specifications,
tools, design and function, troubleshooting, service
procedures, and maintenance. Information pertaining to
the fifth wheel slider service procedures and maintenance
are also included.
Note: For further information on fifth wheels available on
Volvo vehicles refer to the appropriate vendor literature.
3

4

Group 92 Specifications
Specifications
Fifth Wheel
See also “Fifth Wheel” page 3.
General
Specification Minimum Maximum
Fifth wheel static vertical load
capacity 18,144 kg (40,000 lb) 31,751 kg (70,000 lb)
Trailing load capacity 68,039 kg (150,000 lb) 90,718 kg (200,000 lb)
Slider Specifications
Slider Widths Available 845 to 865 mm (33 1/4 to 34 in.)
Slider Travel Available 305 mm (12 in.) ( Standard)
405 mm (16 in.) (Optional)
610 mm (24 in.) (Standard)
915 mm (36 in.) (Optional)
1220 mm (48 in.) (Optional)
Maximum Allowable Wear Tolerances
Component Movement Maximum
Plate casting Vertical lift (upward lift) 7.9 mm (5/16 in.)
Fifth wheel jaw Longitudinal (front to back) 3.2 mm (1/8 in.)
Slide plate Lateral (side to side) 9.5 mm (3/8 in.)
Slide plate Longitudinal (front to back) 9.5 mm (3/8 in.)
Slide plate Vertical (upward) 6.4 mm (1/4 in.)
Slide plate Combined vertical and lateral 9.5 to 6.4 mm
(3/8 to 1/4 in.)
Torques
Mounting Bolts 5/8 in. 270 ± 27 Nm (200 ± 20 ft-lb)
Mounting Bolts M14 271 ± 41 Nm (200 ± 30 ft-lb)
Mounting Bolts M16 320 ± 50 Nm (236 ± 37 ft-lb)
Removable Front Stops 75 Nm (55 ft-lb)
Fifth Wheel Height
Fifth Wheel Height
170 mm (6.69 in.)
175 mm (6.88 in.)
195 mm (7.67 in.)
220 mm (8.66 in.)
5

6

Group 92 Tools
Tools
SAE Kingpin Gauge
The SAE kingpin gauge is recommended for work with the
Volvo fifth wheel. The tool is available from Volvo through
the ASF ship direct program number 095.
W9000230
Fig. 1: ASF40-2-00171
7

8

Group 92 Design and Function
Design and Function
Fifth Wheel
See also “Fifth Wheel” page 3.
The Volvo fifth wheel can be identified by the Volvo name
which is cast into the top plate. The top plate has a large
grease pattern reservoir and can be lubricated with the
trailer hooked up.
W9000516
The fifth wheel locking mechanism has only 12 parts, 5
of which are moving. The jaw can be adjusted in a few
minutes using a pair of pliers. The jaw is mounted with
an eccentric jaw pin and can be adjusted 3 times. This
process can be accomplished by a 7-step process of
lifting the jaw pin and rotating it to a new position to create
a tighter fit.
W9000207
There are several operational features of the fifth wheel.
It has a built in safety latch (1- Fig. 2: Volvo Fifth Wheel
page 9) that must be rotated toward the rear of the fifth
wheel before the operating rod (2- Fig. 2: Volvo Fifth
Wheel page 9), used to unlock the fifth wheel, is pulled.
This safety latch allows the driver to confirm that the fifth
wheel is locked or unlocked. The operating rod used to
unlock the fifth wheel is also designed to require less
effort to pull.
W9000243
Fig. 2: Volvo Fifth Wheel
1 Safety latch
2 Operating rod
9

Group 92 Design and Function
There are three operating positions for the fifth wheel
locking mechanism:
Locked—This is the position that the fifth wheel is in with
a trailer hooked up. In the locked position the operating
rod is retracted and the safety latch will swing back and
forth freely.
W9000180
Lockset—This is the position the fifth wheel is in when
uncoupling the trailer. To achieve the lockset position, the
operating rod is pulled out with a slight upward motion.
The operating rod shoulder will catch on the plate casting.
The safety latch is rotated toward the rear of the fifth
wheel.
W9000242
Open—This is the position the fifth wheel is in after the
trailer is uncoupled. The jaw is open and the operating
rod is now dropped down and can be moved around
freely. The safety latch is rotated toward the rear of the
fifth wheel. This is the position the fifth wheel must be in
when being coupled to a trailer.
W9000203
10

Group 92 Design and Function
Fifth Wheel Bracket Trunnion
The fifth wheel plate is attached to the slider or stationary
mounting bracket by use of a trunnion arrangement.
The fifth wheel plate sits directly on top of the fifth wheel
bracket trunnions. By using this mounting arrangement,
the bracket pins bear no vertical load from the trailer.
W9000567
ABracket trunnion
BBracket
The fifth wheel plate to bracket connection is designed to
minimize wear between the plate and the brackets. To
ensure that excessive wear does not occur, the fifth wheel
plate to bracket connection was designed so that the load
applied to the fifth wheel is transferred to the bracket
trunnions. The bracket trunnions provide the maximum
bearing area which reduces wear between the fifth wheel
plate and the bracket. It is secured to the bracket by a
bracket pin on each side of the fifth wheel.
W9000568
AFifth wheel
BBracket pin
CBracket
To eliminate bracket pin loading, the fifth wheel plate
bracket pin hole is oblong in shape. This clearance
assures that the vertical load will be transferred to the
bracket trunnions and not the bracket pins.
W9000227
11

Group 92 Design and Function
Fifth Wheel Slider
The fifth wheel comes standard with an air operational
slider. This feature allows the driver to distribute the load
easily on the axles to remain within legal weight limits.
The air operated slider takes the work out of adjusting the
tractor for various trailer loads. The fifth wheel portion is
easily adjusted even with a fully loaded trailer connected.
Movement between the adjustable saddle plate and the
stationary base plate rail can result in wear, causing
longitudinal, latitudinal and vertical slack. Field repairs
can be made to reduce this slack foradditional service life.
W9000205
12

Group 92 Design and Function
Unlocking the Fifth Wheel
Rotate the safety latch toward the rear of the fifth wheel.
W9000180
Using a slight upward motion, pull the operating rod out
until the operating rod shoulder is outside the fifth wheel
operating slot.
W9000202
When the shoulder of the operating rod is outside of
the operating slot, raise the operating rod handle to its
maximum upward position.
W9000242
Release the operating rod. The upper shoulder of the
operating rod should now be in contact with the plate
casting above the operating slot. The fifth wheel is now in
the lockset position.
The fifth wheel may now be uncoupled from the trailer.
After the trailer is uncoupled, the fifth wheel will be in the
open position. The operating rod will drop and can be
moved around freely.
W9000203
13

Group 92 Design and Function
Fifth Wheel Kingpin Air Release Switch, Operation
DANGER
Check that the transmission is in neutral, the wheels
to the trailer are chocked and that the parking brake is
applied. Failure to do so can result in unintended trailer
movement, serious injury or death.
DANGER
Stay clear when suspension air is released. Chassis
may drop quickly and can cause serious injury or death
to anyone under the vehicle.
Park the vehicle and apply the parking brake for both the
tractor and trailer.
W5000921
Place the transmission in neutral and chock the trailer
wheels.
W9000263
Lower the trailer landing gear until it touches the ground
and then lower it a few extra turns in low gear.
14

Group 92 Design and Function
Disconnect the trailer electrical and air supply lines from
the trailer.
To release the fifth wheel kingpin lock, engage the fifth
wheel air release switch, by pushing upward to release
the locking mechanism.
W9000494
1 Fifth Wheel Air Release Switch
2 Fifth Wheel Air Release Danger Label
DANGER
Activation of the kingpin lock release switch only
unlocks the kingpin latch mechanism. To relock the
latch mechanism, you must pull forward and then back
up to reengage the kingpin lock mechanism. Failure to
follow these instructions can result in separation of the
trailer from the tractor causing personal injury or death.
Release the tractor parking brake and drive the tractor
away from the kingpin approximately 300 mm (12 in.). W9000239
To deflate the air springs, press the suspension control
switch, by pushing down the latch and pressing the
bottom part of the switch.
W3001341
15

Group 92 Design and Function
Wait 30 seconds for the air springs to deflate.
W9000238
After the suspension lowers, pull clear of the trailer and
immediately select the Ride switch to restore the vehicle
to proper operating height.
CAUTION
The vehicle must never be driven with the air springs
deflated. Damage to air suspension parts will occur if
springs are not inflated properly.
Note: The fifth wheel kingpin lock will only relock by
completing the recoupling procedure as described in
the fifth wheel general Information section of your
operator’s manual. For further information refer to
“Fifth Wheel Coupling Procedures” page 17.
W8001459
16
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