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Страница 1: ...Service Manual Trucks Group 922 502 Fifth Wheel VN VHD PV776 TSP194811 ...

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Страница 3: ...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 de...

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Страница 5: ...th Wheel 13 Fifth Wheel Kingpin Air Release Switch Operation 14 Fifth Wheel Coupling Procedures 17 Fifth Wheel Uncoupling Procedures 21 Operating the Slider 25 Saddle Plate Assembly 27 Troubleshooting 29 29 Fifth Wheel Troubleshooting 29 Service Procedures 31 Fifth Wheel Checking 31 Fifth Wheel Jaw to Kingpin Clearance Adjustment 42 System check 45 Fifth Wheel Cleaning 45 Fifth Wheel Lubrication 4...

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Страница 7: ...ons 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 ...

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Страница 9: ...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 Torque...

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Страница 11: ...ools 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 ...

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Страница 13: ...justed 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 t...

Страница 14: ...pling 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 aroun...

Страница 15: ...te 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 wh...

Страница 16: ...ts 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 for additional serv...

Страница 17: ...ng 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 wi...

Страница 18: ...ailer 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 an...

Страница 19: ...ck 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 W...

Страница 20: ...ng 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...

Страница 21: ...sely followed Using the following procedures inspect the equipment before coupling to a trailer Make sure the fifth wheel is properly lubricated and the jaw is in the open position W9000516 WARNING If the jaw is not in the open position use a pry bar to rotate the jaw to the open position The lock is spring loaded Keep hands away to avoid injury If necessary use a pry bar to open the fifth wheel j...

Страница 22: ...is tight and in good condition Ensure that the fifth wheel mounting angles are parallel to the top flange of the frame rails If using a sliding fifth wheel make sure the slide locking plungers are fully engaged W9000205 Place the transmission in neutral and chock the trailer wheels W9000263 18 ...

Страница 23: ...the trailer kingpin centered in the throat of the fifth wheel back firmly into the kingpin Then pull forward slightly to test the completeness of the coupling as an initial check CAUTION A direct visual check is required to assure proper coupling Several types of improper coupling will pass the initial pull test Sound is not reliable Do not take for granted that you are properly coupled Get out of...

Страница 24: ...rance by moving the tractor backward and forward with the trailer brakes set If the clearance is more than 3 mm 1 8 in or if the jaw does not lock the fifth wheel should be inspected by a qualified technician before proceeding See Jaw to Kingpin Clearance Checking page 34 Wind up the trailer landing gear trailer support to its fully retracted position Fold down or remove the crank handle and place...

Страница 25: ...pply knob Place the transmission in neutral and chock the trailer wheels W9000263 Wind down the landing gear until it touches the ground and then give it a few extra turns in low gear Do not raise the trailer off the fifth wheel It may be necessary to provide a base for the landing gear in poor ground conditions Fold down or remove the crank handle and place it in the crank handle holder Disconnec...

Страница 26: ...or the air springs to deflate W9000238 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 After the suspension lowers pull clear of the trailer and immediately select the Ride switch to restore the vehicle to proper operating height Note The fifth wheel kingpin lock will only relock by completing the...

Страница 27: ...nd can cause serious injury or death to anyone under the vehicle Set the system park brake on the tractor Set the trailer brakes by pulling out the trailer air supply knob Place the transmission in neutral and chock the trailer wheels W9000263 Wind down the landing gear until it touches the ground and then give it a few extra turns in low gear Do not raise the trailer off the fifth wheel It may be...

Страница 28: ...entering the brake lines Unlock the fifth wheel Note If the operating rod is too difficult to pull back tractor slightly to relieve any kingpin load against the fifth wheel jaw Release the tractor park brakes and slowly drive the tractor out from under the trailer Let the trailer slide down the fifth wheel and pickup ramps W9000239 24 ...

Страница 29: ...ine on level ground Lock the trailer brakes CAUTION The trailer must be stopped and the trailer brakes locked or damage to the tractor and or trailer may result from uncontrolled sliding of the fifth wheel Release the slide locking plungers by moving the switch to the UNLOCK position W8001459 25 ...

Страница 30: ...heel to the desired position engage the slide locking plungers by moving the cab switch to the LOCK position CAUTION Do not operate the vehicle if the plungers are not fully engaged and the trailer landing gear is not fully retracted Doing so may cause damage to the tractor trailer and landing gear Visually check to see that the slide plungers are fully engaged Leaving the trailer brakes locked an...

Страница 31: ...ddle Plate Assembly W9000254 1 Saddle plate 2 Lock pins 2 3 Springs 2 4 Linkage operating levers 5 Washer 6 Clinch pin 7 Linkage operating rods 2 8 Washer air cylinder 9 Cotter pin air cylinder 10 Air cylinder 11 Pin 12 Cotter pin 27 ...

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Страница 33: ...lace Inspect operating rod Bent cover plate that is interfering with movement Inspect replace if bent Accumulated grime restricts lock operation Check operation Clean and add light lubrication to moving parts Fifth wheel hard to uncouple from trailer Possible cause Repair Procedure Kingpin applying pressure to jaw Back tractor into trailer to relieve pressure Jaw adjusted too tight Back tractor in...

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Страница 35: ...re adequately spread for proper lock Clinch pins and cotter pins should be installed with the short leg in the upward direction 3 All mounting bolts should be torqued for 5 8 to 270 25 Nm 200 20 ft lb and M16 to 320 50 Nm 236 37 ft lb 270 25 Nm 200 20 ft lb 320 50 Nm 236 37 ft lb 4 WARNING Eye injury hazard Wear eye protection when welding or grinding any part of the truck trailer or fifth wheel F...

Страница 36: ...fety latch swings freely over the operating rod with the fifth wheel locked and the operating rod fully retracted 6 Check the lever bar and the operating rod for proper alignment If the lever bar or operating rod is bent or out of alignment it must be replaced 32 ...

Страница 37: ...and jaw If it exceeds 3 mm 1 8 in the jaw should be adjusted Refer to Jaw to Kingpin Clearance Checking page 34 8 W9000183 W9000185 Check to be sure the DANGER placards are in place and secure One is located on the left side of the fifth wheel plate The other is located on the left side of the slider plate 33 ...

Страница 38: ...gauge or a new kingpin into the open jaw to achieve a coupled and locked condition The safety latch must swing freely over the operating rod and the operating rod must be fully retracted 2 Measure maximum longitudinal movement between the jaw and kingpin If using a gauge the plate must be flat on the fifth wheel 3 If the jaw to kingpin clearance exceeds 3 mm 1 8 in the clearance must be adjusted u...

Страница 39: ... the fifth wheel fifth wheel plate mounting plate etc 1 W9000239 With a trailer properly hooked up to the tractor apply the trailer brakes and move the tractor forward 2 W8001458 Scribe a line on the fifth wheel plate above the pin hole 3 Scribe another line on the underside of the trailer bed plate even with the line on the fifth wheel 4 With the trailer brake still applied move the tractor rearw...

Страница 40: ... the horizontal movement between the upper half and the lower half trailer and the fifth wheel Horizontal movement must not exceed 12 7 mm 0 5 in Horizontal Movement Between Pivot Bracket Pin and Bracket Checking 1 With a trailer properly hooked up to the tractor apply the trailer brakes and move the tractor forward 2 W8001456 Scribe a line on the side of the saddle plate bracket below the pin hol...

Страница 41: ...t even with the line on the fifth wheel plate 5 Measure the distance between the two scribed lines on the saddle plate bracket The measurement between the two scribed lines is the movement between the pivot bracket pin and the bracket Horizontal movement must not exceed 9 5 mm 0 375 in If the movement exceeds 9 5 mm 0 375 in replace the saddle plate 37 ...

Страница 42: ...re and aft 2 Measure distance X from a point on the mounting plate to the top of the fifth wheel plate 3 Pry top plate upward at center of bracket pin 4 While fifth wheel top plate is in the raised position measure distance Y similar to how distance X was measured 5 The difference between measurements X and Y is the vertical movement 6 This measurement on a new fifth wheel is 1 5 mm 1 16 in nomina...

Страница 43: ...pening and the addition of a new lock pin will reduce the longitudinal slack to a like new condition 1 W9000246 With the lock pins in the rail segments in a locked position use a pry bar to move the saddle plate forward at both sides 2 Scribe lines on the base plates adjacent to the saddle plate edges 3 Then move the saddle plate rearward 4 W9000572 A Longitudinal Slack B Scribe here Measure the d...

Страница 44: ...n pry the saddle plate from the opposite side until the saddle plate contacts the inside of the rail and measures the distance Y 3 If the difference between these two measurements exceeds 9 5 mm 3 8 in repairs should be made Slider Vertical Slack Checking 1 Clean the area in between the saddle plate rail bracket and the base plate rail 2 W9000570 A Saddle plate bracket B Saddle plate C Base plate ...

Страница 45: ... this condition exists 9 5 mm 0 38 in maximum lateral slack and 6 5 mm 0 25 in maximum vertical slack repairs should be made To measure lateral and vertical slack see the following procedure 1 For lateral slack checking see Slider Lateral Slack Checking page 40 2 For vertical slack checking see Slider Vertical Slack Checking page 40 41 ...

Страница 46: ...r and rotate the jaw to the locked position This removes pressure on the jaw pin 2 W9000189 Remove the jaw pin clinch pin or cotter pin from under the fifth wheel 3 W9000520 Lift the jaw pin sufficiently to clear the indexing head and rotate the pin to the next higher number position or refer to table below to determine how many positions to rotate the jaw pin Position Cumulative Incremental 1 1 5...

Страница 47: ... 5 until the clearance allows approximately 1 5 mm 1 16 in of kingpin movement WARNING Do not over adjust or the fifth wheel will not lock to a new king pin Failure to follow these instructions can result in separation of the trailer from the tractor causing personal injury or death 7 After final adjustment insert and spread a new cotter pin or reinstall the clinch pin Note Do not rotate the jaw p...

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Страница 49: ... should always be relubricated after steam cleaning Otherwise lubricate at least every 24 000 km 15 000 miles Chassis or multipurpose grease is recommended on the fifth wheel and slider assemblies A heavy coating of grease should be maintained on the fifth wheel plate by using the grease fittings on the underside of the fifth wheel top plate or by direct application to the top of the plate The Vol...

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Страница 52: ...th America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 5600A Cancross Court Mississauga Ontario L5R 3E9 http www volvotrucks volvo com PV776 TSP194811 08 2003 Volvo Trucks North America Inc 2003 ...

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