FedEx Ground Parts Book.docx

With Jam Eye Shank already installed in the shock housing, slide the pushrod, threaded end first, over the top of the eye and into the tubular shank.

Make sure the jaw is closed. If not, it can be closed by pushing the trip block (9) forward with a rod or bar. The jaw should be all the way across the center casting (the handle will be in). Caution: Keep your hands clear of the jaw, it is spring-loaded.

Install new pull handle

Remove pull handle (24)

Pull the lever into the uncoupling position. This is where the lever is pulled out and held up by the “Catch Point” indicated in view A-A. If the lever won’t stay up, the adjuster nuts on the adjuster at the back end of the lever are probably screwed in too far. Back them off until lever will stay on the catch point.

PUSHROD, AIR JAM EYE, ¾”

With vehicle at rest in a relaxed condition

Tighten bolt until lever is secure against Jaw assembly.

Make sure jaw is locked open and trailer is at

JAW W/HUCKED PUSHROD

Using a pair of vise grips, clamp the trip lock rod in front of the guide hole on 5th wheel center casting (16) so as to prevent it from moving aft when jaw is removed.

While holding bolt secure from turning, tighten jam nut.

Pull dolly slowly out from under the trailer.

Back dolly slowly under trailer until jaw locks

FRONT PULL HANDLE

Install the shoe by placing it into the eye with the contact surface facing to one side, rotate the shoe 90 º so its contact surface faces forward and the hole for the pushrod is to the rear. Check to insure the shoe will slide fore and aft along the inside of the eye.

Remove the 3/8 bolt, 3/8 lock nut and the two 3/8 washers

Test the 5th wheel for proper coupling with a test kingpin. Test with the lever in the uncoupling position. If it doesn’t release from the “catch point”, then the adjuster nuts probably need to be screwed in further.

Install the pushrod into the shoe, making sure to line up the holes. Drive the roll pin into the shoe and through the pushrod.

If the handle will not pull outward when the vehicle

With the jaw closed or in the coupled position, pick the lever up and out of the locked position. Hold the lever just shy of falling back into the locked position. Release the lever to ensure that it passes freely into the locked position.

When removing the guide bolt (25), applying an anti-seizing compound to the exposed threads often makes the removal process easier.

Remove the trip block (16) and the trip block spring through the

JAW ASSY, HUCKED PUSHROD, LH

Install the new trip block and / or trip block spring in the throat of the

Remove the jaw spring (22) by pulling it through the push rod guide nut.

When 5th Wheel functions properly, tighten the lever adjuster locknut securely.

LEVER, JAW, 5TH WHEEL, FRONT PULL

Consult wheel maintenance instructions. Check wheel nut torque. Recheck at every dismount.

Slip the threaded end of the pushrod through the cap on the shank nut and install a jam nut and coupling nut. Thread both nuts on as far as possible to draw the shoe to the rearmost position in the eye.

Pull the fifth wheel handle (19) all the way out.

Push the trip block (16) as far forward as possible, with a rod or bar

Install a service air chamber with a s 2" pushrod length with a jam nut threaded onto its pushrod. Torque air chamber mounting nuts to 100 ft/lbs.

Check axle maintenance instructions. Check axle for oil levels and leaks.

GUIDE, PUSHROD

With anti-seize applied to the 3/8 bolt, reinstall the bolt, two washers

Disconnect the fifth wheel handle (19) from the lever (19) and the lever from the jaw/pushrod assy (16).

Tighten the fifth wheel/leaf spring U-bolts to 375 lbs/ft torque.

Torque: 375 lbs/ft

LEVER ADJUSTER KIT

With a 5/8" open-end wrench pry against the jam nut on the air chamber pushrod to pull the pushrod out 3/16" to 1/4". Thread the coupling nut part way onto the air chamber pushrod to couple ti with the pushrod and shoe.

Tighten the axle seat bolts to 420 lbs./ft. torque.

Remove the jaw/pushrod assy (18) from the 5th wheel table.

Loosen the jam nut against the cap of the shank nut to allow the pushrod and shoe to travel forward when air pressure is applied.

Lubricate and install the replacement jaw/pushrod assy (18) in the table making sure the pointed tine on the jaw is to aft end of the dolly

Place a 2" diameter rod into the eye and apply air to the service chamber. DO NOT PLACE FINGERS IN THE AREA OF THE EYE AND SHOE OR AREA OF COUPLING NUT WHEN APPLYING AIR TO THE SERVICE CHAMBER.

Inspect springs for broken leaves and missing or broken spring keepers or keeper bolts.

Inspect drawbar eye assembly and tighten shank nut (Item 14) as required. NOTE: Tighten shank nut until shock absorber bushings bulge almost to outer edge of shock housing. Be sure to reconnect the shank nut safety wire after tightening shank nut.

Slide jaw/pushrod assy in place without spring. Align hole in jaw with mating hole in lever.

With the shoe contacting the 2" diameter rod, adjust the jam nut on the pushrod until it contacts the cap on the shank nut. Tighten the coupling nut and the two jam nuts, jamming them together.

Apply loctite 242 medium strength thread adhesive or equivalent to cleaned threads of capscrew (23) and jam nut.

Release the air pressure and reapply to recheck the adjustment.

Tighten all other fasteners as required. Replace any worn, stripped or missing fasteners with appropriate grade and strength.

Thread capscrew (23) into jaw/pushrod assy (18) with two washers (20) between the capscrew head & the lever. Torque the jaw bolt to approximately 70 ft-lbs. The lever should have minimum clearance to allow free rotation against the jaw without binding through its full travel.

Torque: 70 ft-lbs

Inspect all air lines and electrical cables for chafing, kinking, leakage or damage.

Inspect fifth wheel table assembly for bent, worn, cracked or excessively loose parts. Replace any cracked parts and worn or missing fasteners, readjust or tighten fasteners as necessary.

Tighten the jam nut (1/6-1/4) turn – after contacting the jaw while ensuring the capscrew does not turn.

Slide pushrod spring (22) on push rod of the jaw

While holding lever back far enough so the jaw pushrod protrudes

Remove the vise grips from the trip block rod.