Warren FW-30 User manual

Warren Elevating 5th Wheels
Operation and Maintenance Manual
FW-30, FW-45, & FW-25HL6

Warren Elevating 5th Wheel
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TABLE OF CONTENTS
Safety Notice................................................................................................................... 4
Preface................................................................................................................................. 4
Please Note Cautions ...................................................................................................... 5
Determine Tractor Compatibility.................................................................................... 5
General Information........................................................................................................ 6
Pre-Installation Instructions................................................................................................ 7
Check Tractor C.A.......................................................................................................... 7
Check for Power Take Off Capability and Location ...................................................... 7
Check 5th Wheel Capacity............................................................................................... 8
Check Parts and Assemblies........................................................................................... 8
Operating Controls.......................................................................................................... 8
Check Parts and Materials Obtained Locally.................................................................. 8
Check Tools and Supplies Required............................................................................... 9
Installation Introduction.................................................................................................... 10
Two Methods Available................................................................................................ 10
Method 1................................................................................................................... 10
Method 2................................................................................................................... 12
Introduction to Operating Controls................................................................................... 12
Power Take-Off ................................................................................................................ 12
Power Take Off Installation.......................................................................................... 12
Installation......................................................................................................................... 14
Air Control System....................................................................................................... 14
Installation of the 5th 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 Figure 4b) .................................... 17
All Models —Mark Interfering Cross Members ......................................................... 18
Check for Actual Contact.............................................................................................. 19
To Mark a cross Member for Alteration....................................................................... 20
Make Tractor Frame Alterations................................................................................... 20
Alter Cross members................................................................................................. 20
Installing Steel Angles.................................................................................................. 21
When To Use One Angle Per Side (Fig. 1) .............................................................. 21
When To Use Two Angles Per Side (Fig. 2)............................................................ 22
How to Install Steel Angles ...................................................................................... 22
If One Angle Per Side (Fig. 1).................................................................................. 23
If Two Angles Per Side (Fig. 2)................................................................................ 23
Drill Bolt Holes......................................................................................................... 23
Mounting 5th Wheel Assembly on Tractor .............................................................. 24
On Installations Using Two Steel Angles Per Side .................................................. 26
On Installations Using One Angle Per Side.............................................................. 26
Lower 5th Wheel Plate to Collapsed (Down) Position................................................. 26
Install Pickup Ramps .................................................................................................... 27
Prepare Tractor Frame .............................................................................................. 27

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Install Ramps ............................................................................................................ 28
Severe Duty Applications......................................................................................... 28
Connect Hydraulic Hoses, Pump.................................................................................. 28
Prepare Tractor For Service.............................................................................................. 29
Fill Tank and Cylinder(s).............................................................................................. 29
Final Installation Steps.................................................................................................. 30
Check Out Installation .................................................................................................. 30
Check Out Performance................................................................................................ 30
Coupling and Locking................................................................................................... 31
Operator Instructions ................................................................................................ 31
Final 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
Repairs .......................................................................................................................... 36
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.................................................................................................... 40
Warranty ........................................................................................................................... 41

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CAUTION: Before operating or before performing any service or maintenance on this
Warren Product, all appropriate OSHA regulations must be observed.
Safety Notice
Proper service and repair are important to the safe, reliable, operation of Warren’s
products. Operation and servicing procedure recommended by Warren are in this manual
and are effective for proper use of this product. Some of these operations may require the
use of tools or blocking devices specifically designed for the purpose. Special tools
should be used when and as recommended. It is important to note that warnings against
the use of specific operations or methods that can damage the product or render it unsafe
are stated in this manual. It is also important to understand these warnings are not
exhaustive. Warren could not possibly know, evaluate, and advise the service trade of all
conceivable ways in which operation or service might be done or of the possible
hazardous consequences of each way. Accordingly, anyone who uses operational
procedure, service procedures, or tools whether recommended by Warren or not, must
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 assist in the correct operation and
maintenance of the Warren Elevating 5th wheels by providing information for installation,
operation, service, and maintenance. Please read this manual thoroughly before
proceeding to use the equipment.
The economic life of any piece of equipment is directly related to the care and
maintenance it receives. 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.
If additional information is required or should you desire to have a qualified service
facility work on this unit, contact your local Warren Distributor.
Name __________________________________________
Address ________________________________________
_______________________________________________
Phone __________________________________________
Fax ____________________________________________
Warren reserves the right to make changes in our units at anytime without incurring any
obligation whatsoever to change units already in the field.

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Please Note Cautions
Special attention should be paid to all the caution notes and directions to help make your
installation as safe and efficient as possible.
Determine Tractor 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
installation procedures. 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.

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General Information
1. All Warren 5th wheels come with an air shift direct drive pump. Ensure your PTO,
transmission, and pump are compatible. The Warren supplied pump is counter
clockwise (CCW) rotating.
2. Install PTO. Run engine to check PTO installation.
3. Install hydraulic pump.
4. Install controls in cab for pump and PTO.
5. Prepare tractor frame and install steel angles on tractor frame.
6. Fit and install 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 and test unit under loaded trailer.
11. If you decide to repaint 5th wheel and/or pick up ramps, ensure warning labels and
operating decals are clearly visible.
12. Follow maintenance and service instructions.
5th Wheel Frame
Top Plate
Cylinder
King Pin Jaws
King Pin Jaw Air
Camber
King Pin Jaw
Locking Cylinder
Rear Elevator
Front Elevator
Front Cross Shaft
Rear Cross Shaft
Roller Shaft and
Wheels
Elevator Shafts
Pick-up Ramps

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Pre-Installation Instructions
Important: Before starting the installation carefully complete all the pre-installation installation
steps.
Check Tractor C.A.
Refer to the Table 1 to ensure you will be operating the elevating 5th wheel within its operating
parameters.
C.A. refers to the distance from the last above-frame obstruction (i.e. transmission mount,
muffler, etc.) behind tractor cab to center of single or tandem axles. This area must be kept clear
for mounting the 5th wheel assembly. If there is no above frame obstruction, the CA. is the
distance from the back of the cab to the center of the single or tandem axles.
Make sure the tractor you are planning to use has the proper C.A. and gross weight capacity to
match the lifting 5th wheel model you have received.
Table 1: 5th Wheel C.A.1Requirements and Gross Weight2Capacity
5th Wheel
Model
Minimum Recommended Tractor
C.A. Dimension Trailer King Pin
Setting3Ins., (mm.)
36(914) 42(1067)
Gross Weight
Capacity
Lbs. (Kg.)2
FW-30
72 inch (1829 mm ) 78 inch (1982 mm)
60,000 (27,218)
FW-45
72 inch (1829 mm ) 78 inch (1982 mm)
90,000 (40,909)
FW-25HL6
84 inch (2134 mm ) 90 inch (2286 mm)
50,000 (22680)
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 in. king pin setting. Add dimension for refrigeration unit.
2. Gross Weight Capacity refers to total weight —trailer and contents.
3. 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.
Most standard trailers have 36 or 42 inch king pin setting. Your trailers may differ. Be sure to
add extra clearance for refrigeration unit or other equipment which may extend beyond trailer
front.
Check for Power Take Off Capability and Location
The installation of a Warren 5th 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. Order the PTO based on which opening has easier access.
Check to make sure that your tractor has a PTO drive gear installed. Some Mack©transmissions
do not have a PTO drive gear installed. It can be installed by a truck transmission shop or Mack©

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dealer. Allison transmissions require special PTO’s. Consult Warren or your PTO supplier for
information on these PTO’s.
All Warren 5th Wheels are equipped with air shift direct mount pumps with counter clockwise
(CCW) rotation unless otherwise specified. If this is not compatible with the truck, contact your
Warren dealer to see if Warren can accommodate your truck’s requirements. Ensure the pump
(CCW) and PTO rotation and connection are compatible.
You can order your 5th wheel without a pump and use your own. There are several ways that your
pump may be connected. Please contact Warren or your distributor if you have questions about
the correct way to hook up a non-standard pump. In all cases, you should use a 10 micron filter in
the system.
Check 5th Wheel Capacity (Refer to Table 1.)
Make sure the 5th wheel you have received is the proper model, and that it has the proper gross
weight capacity for you application. Gross weight refers to total lifting weight —including trailer
and contents.
Check Parts and Assemblies
Though we take great effort to ensure your order is packed carefully, ensure all required parts and
assemblies have 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
provides the most reliable and trouble-free operation. If you have special ordered other controls
or have special requirements, please contact your Warren dealer for special instructions.
Check Parts and Materials Obtained Locally
You will need the following items which are not included with your 5th wheel shipment.
1. Power Take Off: See information above. Warren recommends a single speed, dual gear
heavy duty, direct mount, air shift PTO. On direct mount pumps, be sure that the PTO
and pump rotations will work together properly. 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.
3. Flat stock steel and steel angles, for pick-up ramps, brackets, reinforcing plates and other
requirements. You will need about 175 inches of steel angle for a bolt-on installation. The
steel angles should be either 3/8 by 3 1/2 by 4 inches, or 1/4 by 3 1/2 by 4 inches.
4. Hydraulic oil. Oil should meet or exceed the following criteria.
Type
Mineral Oil, Paraffin Base, Solvent
Extracted
Viscosity index @ 100ºF
90 or higher
Viscosity SUS @ 100ºF
150-300 (32-65 CST)

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Aniline Point
165 min.
Anti-foam additives
Yes
Anti-oxidant additives
Yes
Note: This oil is recommended for normal climatic conditions within the continental United
States. Where sustained temperatures are 0 degrees F. and lower or in excess of 90+ degrees F.,
this oil should be removed and replaced with one of a viscosity rating suitable to the ambient
temperature of your region. For a suitable replacement, consult your local oil 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 hoist 2-ton min., and
chain with hooks.
•Two steel saw horses
•Acetylene torch
•Heavy duty arc welder 300 amp.
Min.
•Welding rods or wire
•Power drill with various bits
•Power hand grinder
•Sledge hammer
•Pipe wrenches
•Open-end wrenches (U.S. sizes)
•Various Allen wrenches.
•Six large C clamps - 8 to 10 in. min.
•Center punch
•Chalk
•Tape measure
•Straight edge
•Grease gun with suitable grease
•Selection of fasteners including
Grade 8 bolts, 5/8 in. lock nuts and
washers
•Black paint

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CAUTION: Safety Precautions
Before you begin any step in installation, be sure you understand the following notes
carefully.
Keep hands and any other part of the body away from the elevating sections when the
unit is in raised position.
After elevating the 5th wheel plate to raised position, always leave the hoist in supporting
(hold) position.
Whenever the 5th wheel plate is in elevated or raised position, it must be securely
propped or blocked so it cannot fall on anyone while making repairs or adjustments. Do
not depend on the hoist alone. Blocking 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 wheel. On gasoline powered tractors, you must
also remove fuel tanks, drain fuel lines and plug fuel lines before doing any welding,
grinding or burning on or near the tractor.
Installation Introduction
Two Methods Available
Note for FW-25HL6
Method 1 is the only method for FW-25HL6!
Method 1
Lay the angle with the long leg (4”) on the top of the frame, and the short leg (3 1/2’) down the
side of the frame. 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