Holland FW0070, FW1226, FW0100, FW1560, FW1900 Installation, Operation And Maintenance Manual

...

XL-FW482 Rev C

FW0070, FW0100, FW0165, FW1226, FW1560, FW1900, FW2000, FW2500, FW2555, FW2570, FW2870, FW7040, FW7090 Fifth Wheel



Installation, Operation, and

Maintenance Procedures

Owners Manual

English

XL-FW482 Rev C · 2016-07-05 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,

and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Contents

Contents Page

Introduction ................................................... 2

Notes, Cautions, and Warnings ....................... 2

Section 1 – General Safety ............................. 3

Section 2 – Installation ..................................4

Section 3 – Stationary Fifth

Wheel Installation ........................6

Section 4 – Sliding Fifth Wheel Installation ..... 9

Section 5 – Inspection and Lubrication

Prior to Use ...............................14

Section 6 – Operating Instructions ...............14

Section 7 – Coupling Procedures ..................14

Section 8 – Uncoupling Procedures ..............16

Contents .................................................. Page

Section 9 – Sliding Procedure For a

Sliding Fifth Wheel .....................17

Section 10 – Maintenance Procedures ..........18

Section 11 – As Needed Lubrication .............18

Section 12 – Periodic Inspection

and Adjustment .......................18

Section 13 – Fifth wheel Locking Mechanism

Inspection and Adjustment ....... 18

Section 14 – Re-Lubricate After Inspection

and Adjustment .......................19

Section 15 – Sliding Mechanism Inspection

and Adjustment .......................20

Introduction

This manual provides you information necessary for the proper installation of HOLLAND® Fifth Wheels.

NOTE: For technical support and genuine

HOLLAND® ﬁfth wheel replacement components contact SAF-HOLLAND® Customer Service at:



1.888.396.6501



+86.592.6388.891

Notes, Cautions, and Warnings

Throughout this manual, you will notice the terms “NOTE,” “IMPORTANT,” “CAUTION,” and “WARNING” followed by useful product information. So that you may better understand the manual, those terms are deﬁned as follows:

NOTE: Includes additional information

to enable accurate and easy performance of procedures.

IMPORTANT: Includes additional

information that if not followed could lead to hindered product performance.

Used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, could result in property damage.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or both.

XL-FW482 Rev C · 2016-07-05 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF, and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

General Safety

1. General Safety

It is important to read, understand, and follow the important information contained in these installation instructions. Failure to do say may result in a hazardous condition or cause a hazardous condition to develop.

All welding should be performed by an AWS certified welder using a low hydrogen process and AWS E70XX filler metal. Failure to weld correctly may cause distortion, damage, and/or result in insufficient strength and subsequent joint failure which, if not avoided, could result in death or serious injury.

Prior to welding take precaution to ensure that the tractor electrical system is not damaged due to the welding process.

1. Keep work area clean. cluttered areas and benches invite accidents.

2. Keep fingers away from all potential pinch points in the fifth wheel.

3. All ﬁfth wheel maintenance MUST be performed by a qualiﬁed service technician using proper tools and safety procedures.

4. Use SAF-HOLLAND® Parts only.

5. Use safety goggles. Glasses or goggles not in compliance with ANSI or CSA can cause serious injury when damaged or broken.

6. Wear proper apparel. DO NOT wear loose clothing, gloves, neckties, jewelry (rings, watches, etc.) that can get caught in moving parts. Non-Slip footwear is recommended.

Fifth Wheel Design and Intended Use:

1. For pulling trailers with standard SAE kingpins which are in good condition and securely mounted or locked in position in the trailer.

2. For on-highway hauling applications.

3. Within the capacities stated in SAFHOLLAND® Literature.

4. As Recommended in SAF-HOLLAND® Literature (available from SAF-HOLLAND® or SAF-HOLLAND® distributors).

HOLLAND® Fifth Wheels are NOT Designed or Intended For:

1. Use with non-SAE kingpins, such as kingpins which are bent, improper size or dimensions, not secured to maintain SAE configuration, or which are installed in warped trailer bolster plates.

2. Tow-away operations which may damage or interfere with the proper operation of the fifth wheel.

3. The attachment of lifting devices.

4. The transport of loads in excess of rated capacity.

5. Off-highway applications and use.

6. Applications other than recommended.

XL-FW482 Rev C · 2016-07-05 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,

and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Installation Procedures

2. Installation

2.1 General Recommendations

1. Every user and installer using HOLLAND® products either recommended or not recommended by HOLLAND®, MUST thoroughly satisfy him/herself that the installation procedure used is appropriate for the vehicle, product and application.

2. Consult the HOLLAND® literature for fifth wheel capacities and applications.

3. Consult the tractor manufacturer's body builder's book and the latest SAE and D.O.T. Standards for additional installation methods. HOLLAND® recommends the

T.M.C. Recommended Maintenance Practice 603B for installation

procedures.

4. Determine the proper ﬁfth wheel position, or, in the case of a sliding ﬁfth wheel, the range of proper positions. Proper positioning of a ﬁfth wheel is important for weight distribution, swing clearance and handling characteristics. Refer to SAE J701a for proper placement, as well as the tractor manufacturer's body builder's book.

5. Use Grade 8, 5/8" minimum diameter bolts and Grade “C” locknuts for mounting.

6. Bolt holes can be 1/32" larger in diameter than the bolt fastener. Bolts MUST be adequately tightened using torque ranges in foot-pounds for the recommended Grade 8, 5/8" diameter bolts. Larger diameter Grade 8 bolts and coated fasteners may be used.

7. The bolts attaching the fifth wheel mounting angles to the truck frame require hardened steel washers under both the bolt and under the locknut, unless flanged head bolts or flanged head locknuts are employed.

8. A minimum of 5 bolts are required to attach each mounting angle to the frame rail, and the distance between bolts MUST NOT exceed 8", except when cutouts are required in the mounting angles.

9. Whenever a cutout is made on the mounting angle, such as required to by pass spring hangers, a 1" minimum radius should be used and bolts should be placed within 1 1/2", but not closer than 1" of the cut, fore and aft.

10. The mounting angle should have a minimum thickness as shown in Table 1 and should be steel speciﬁcation ASTM A 36

11. When initially positioning the ﬁfth wheel for frame holes, the full length of the ﬁfth wheel or slider mounting angles should seat ﬂush on the top and side surface of the truck-tractor frame rails where channel-type rails are employed. There should NOT be a gap over the top of the truck frame rails. The base of the ﬁfth wheel assembly and of the mounting angle members should seat ﬂush on the top of the frame rail to prevent ﬂexing and to give uniform weight distribution. It is also recommended to chamfer or smooth sharp edges and corners of mounting materials wherever contact is made with the tractor frame.

12. If the fifth wheel is to be mounted using a mounting plate (bracket with mounting base), refer to TABLE 1 for minimum plate thickness recommendations.

DO NOT use U-bolts in ﬁfth wheel installations. Use only new Grade 8 bolts and new Grade C lock nuts, sized 5/8" minimum diameter. Failure to do so may result in structural failure of the installation with a potential loss of the ﬁfth wheel assembly, mounting structure, and/or trailer and may result in death or serious injury.

Installation Procedures

Fifth Wheel

Vertical Capacity

Minimum Mounting

Angle Thickness

Minimum Mounting

Plate Thickness

12,000 lbs.

1/4" 1/4"

20,000 lbs.

5/16" 1/4"

40,000/45,000 lbs.

5/16" 5/16"

50,000/55,000 lbs.

3/8" 3/8"

62,500/70,000 lbs.

1/2" 1/2"

100,000 lbs.

3/4" 3/4"

165,000 lbs. 3/4" 1"

Table 1

13. Trailer pick-up ramps are recommended at the rear of the truck-tractor frame.

14. When mounting to aluminum frames, follow the tractor manufacturer's recommendations. HOLLAND® has available a stationary mounting angle intended for use with aluminum frames. Contact SAF-HOLLAND® and SAF-HOLLAND® distributors for availability.

15. Review, in addition the specific information on the following pages for each type of fifth wheel mounting, as well as “Inspection and Lubrication Prior to Use” on page 13 of this publication.

XL-FW482 Rev C · 2016-07-05 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF,

and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Figure 1

Installation Procedures

3. Stationary Fifth Wheel Installation

Prior to proceeding with the installation of the stationary fifth wheel assembly, carefully review the “General Safety Information” Section on page 3.

3.1 Bracket with Mounting Angle

1. HOLLAND® brackets with mounting angle are provided with the bracket welded in the center of the 36" long angle with a 4" minimum horizontal and 3 1/2" minimum vertical leg size, and to a specific tractor frame width. Verify that the bracket and tractor frame width are the same.

2. In addition to the information given in "Installation: General Recommendations" on page 4, follow the recommendations in Figure 1, 2, and 3.

IMPORTANT: The full length of the fifth

wheel mounting angle should seat flush on the truck frame when mounting to prevent flexing of the mounting angle and to give uniform weight distribution along the truck frame rail (Figure 1).

IMPORTANT: Use 5/8" Grade 8 bolts and

Hardened steel washers or ﬂanged locknuts (Figure 1). Torque according to bolt manufacturer charts.

3.2 Bracket for Angle Mounting

1. HOLLAND® brackets for angle mounting are intended to be welded to mounting angles at the time of installation.

Figure 2

HARDENED STEEL WASHERS

REFER TO TABLE 1 FOR

MOUNTING ANGLE THICKNESS

5/8" GRADE 8 BOLTS

TRUCK FRAME RAIL

5/8" GRADE C LOCKNUTS

36.00" MIN (914.4 mm)

2.00" MIN (50.8 mm)

18.00" MIN (457.2 mm)

8.00" MAX TYP. (203.2 mm)

BOTH SIDES

1" MIN

(24 mm)

1/4" 1/2"

DOUBLE

PASS MIN.

BOTH ENDS

Installation Procedures

2. Refer to "Installation: General Recommendations" on page 4, for angle thickness and material (use 4" minimum horizontal and 3-1/2" minimum vertical leg size). The recommended length of each mounting angle is 36". it is recommended that each angle extend at minimum length of 18" forward of the fifth wheel pivot point, and not less than 12' to the rear (Figure 2). If angles shorter than 36" are required, the special recommendations of the tractor manufacturer should be obtained.

3. In addition to the information given in "Installation: General Recommendations," follow the recommendations given in Figures 1, 2, and 3. The following sequence is suggested for both fabricated and cast brackets:

a. Securely position the mounting angle

to the tractor frame.

b. Bolt the angles to the tractor as

illustrated (Figure 1 and 2).

c. Position the brackets on the angles

and verify the correct spacing to mount the fifth wheel.

d. For fabricated brackets (welded

assembly), weld the bracket to the mounting angle with 1/4" fillet welds on both sides, and 1/2" groove welds on both ends, as illustrated (Figure 1 and 2). The welds should be continuous around the bracket and joined at the corners.

e. For cast brackets (single piece), weld

with 5/16" fillet weld as illustrated (Figure 3). The welds MUST be continuous around the bracket ends.

Figure 3

BOTH SIDES CENTER OF BRACKET

GAP 1/4" - 1/2" IN FOUR (4) PLACES

WELDING DETAILS

(CAST BRACKETS ONLY)

BOTH ENDS CONTINUOUS

5/16"

and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Installation Procedures

3.3 Bracket with Mounting Base

1. HOLLAND® brackets with mounting base are intended for installation on either corrugated or flat mounting plates.

2. In addition to the information given in "Installation: General Recommendations" on Page 4, follow the recommendations in Figures 4, 5, and 6.

IMPORTANT: Attach the outboard angle to

tractor frame with hardware listed in Figure 1. Attach mounting plate to angle with the same number of bolts (in addition to attachment to ﬁfth wheel support bracket) (Figure 4 and 5).

IMPORTANT: Attach bracket and mounting

plate as illustrated (Figure

6). Use center bolt of sufficient length to bolt through bracket, mounting plate and mounting angle.

3. Refer to "Installation: General Recommendations," on page 4, for angle thickness and material. The mounting angle should be 1" longer than the mounting plate, and be 36" minimum length. Use 3" minimum horizontal and 3-1/2" minimum vertical leg size. Longer horizontal legs may be required with narrow frame widths.

Figure 5

Figure 6

Figure 4

FIFTH WHEEL SUPPORT BRACKET

FLAT MOUNTING PLATE REFER TO TABLE 1 FOR MINIMUM THICKNESS

CORRUGATED MOUNTING PLATE REFER TO TABLE 1 FOR MINIMUM THICKNESS

SPACER

TRACTOR FRAME

CENTER BOLT

INBOARD ANGLE

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Holland FW0070, FW1226, FW0100, FW1560, FW1900 Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual