SAF XL-FW488 User Manual

FIFTH WHEEL

OWNER’S
MANUAL

FW2800 and FW2900 Series
Hydraulic Elevating
Fifth Wheel

Installation, Operation,
Maintenance Procedures and
Comprehensive Warranty

TECHNOLOGY

XL-FW488 Rev A

Questions or Comments?
Call

www.thehollandgroupinc.com

FIFTH WHEELS

1-888-396-6501

INSTALLATION INSTRUCTIONS

When welding, use a procedure which assures a sound, good quality

cause distortion and damage, and underwelding may not develop sufficient strangth. A
low hydrogen process and AWS E70XX filler metal are recommended. Take precautions
to ensure that the tractor electrical system is not damaged by the welding.

weld and which protects the operator and others. Overwelding may

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. Within the capacities stated in Holland literature.

3. As recommended in Holland literature (available from Holland or 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

dimension, not secured to maintain SAE configuration, or which are installed in
warped trailer bolster plates.

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

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

4. Applications other than recommended.

Installation

General Recommendations

1. Every user and installer using Holland products either recommended or not
recommended by Holland, must ensure 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. Determine the range of proper fifth wheel positions. Proper positioning of the fifth
wheel is important for weight distribution, swing clearance and handling characteristics.

The center of the kingpin locks must always be positioned on or
ahead of the tractor rear axle or bogie centerline. Failure to do so
can result in loss of vehicle control.

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

5. Bolt holes can be 1/32˝ larger in diameter than the bolt fastener. Bolts must be
adequately tightened using charted 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.

Figure 1

1˝ min. from
hole to the end
of the angle.

Holes drilled for
5/8˝ mounting
bolts.

Angle cut out for tractor
frame interference. 1˝
minimum for radius.

Lift wheel
mounting base.

1

⁄2˝ mounting required

8˝

Maximum

hole spacing

2

1˝ – 1
between 1˝ and 11⁄2˝ of
angle cut out.

XL-FW488 Rev A

INSTALLATION INSTRUCTIONS

APPROX. 1˝ APPROX. 1˝

FIFTH WHEEL MOUNTING FRAME

MOUNTING ANGLE MARK ANGLES HERE

PIVOT LOCATION

continued

6. 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.

7. A minimum of 5 bolts should be applied to attach each mounting angle to the
tractor frame rail, and the distance between bolts should not exceed 8˝, except
when cutouts are required in the mounting angles (see Figure 1).

8. Whenever a cutout is made on the mounting angle, such as required to bypass
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 (see Figure 1).

9. When initially positioning the fifth wheel for frame holes, the full length of the fifth
wheel mounting angles should seat flush on the top and side surfaces of the truck­tractor 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 any sharp edges and corners of mounting materials wherever
contact is made with the tractor frame.

10. Review “System Check” found on page 8.

Detailed Information

1. Remove the shipping lugs
from the bottom of the unit.

2. Determine the proper fifth
wheel position on the tractor:

A. Verify that the tractor has

sufficient “Cab to Axle”
(C.A.) clearance for the
elevating fifth wheel
model selected, as listed

Chart 1 and Figure 2.

in

B. Locate the pivot point of

the fifth wheel (when it’s
in the down position) on
the given mounting
angles by positioning the
angles approximately 1˝
beyond each end of the
fifth wheel assembly
frame. Once this has been
completed, mark the pivot
point of the fifth wheel on
both angles (see Figure 3).

Chart 1

Cab to Axle Requirements and Mounting Location

MODEL CAB TO AXLE* LOCATION (A)

MINIMUM MOUNTING

FW2800-X 72˝ 10˝
FW2800-5X 77˝ 10˝
FW2900-X 60˝ 6˝
FW2900-5X 65˝ 7˝

* Based on a 102˝ wide, square corner trailer, with a 36˝

kingpin setting. More or less cab to axle clearance may be
required for other nose configurations, kingpin settings,
refrigeration units, etc.

Figure 2

(A)

FIFTH WHEEL

MOUNTING

LOCATION

CAB TO AXLE

CLEARANCE

CENTERLINE
OF THE REAR
AXLE/BOGIE

Figure 3

XL-FW488 Rev A

3

INSTALLATION INSTRUCTIONS

5˝x 5˝
ANGLE

SPACER

FRAME RAILS

FIFTH WHEEL MOUNTING FRAME

TRUCK
FRAME
RAIL

3/8˝
(9.53mm)
MINIMUM
ANGLE

HARDENED
STEEL WASHERS

The full length of the fifth wheel mounting angle should
seat flush on the truck frame when mounting to prevent
flexing of mounting angle and to give uniform weight
distribution along truck frame rail.

.63” diameter Grade 8 bolts
minimum size.
Tightening torque to bolt
manufacturer charts.
Hardened steel washers or
flanged locknuts. .63”
diameter Grade “C” locknuts.

3/8˝ 3/8˝

FIFTH WHEEL MOUNTING FRAME

MOUNTING ANGLE

continued

C. Take the marked angles and position them on the tractor frame.

NOTE: The marked angles will no longer be symmetrical. It is critical
to make certain that the angles are notaccidentally reversed.

D. Line up the marks of both angles with the imaginary centerline of the rear

axle/bogie. Use the dimension listed under “Mounting Location (A)” in Chart 1
for the elevating fifth wheel model selected, and offset the angle forward (toward
the cab) by that distance.

NOTE: The offsetting of the angles is necessary to allow for the horizontal (forward)
movement of the wheel when elevating. When the wheel is in its maximum vertical
condition, the pivot point of the wheel will be in line with the imaginary centerline
of the rear axle/bogie and the centerline markings made on the angles in Step 2B,
above (see Figure 2).

3. Once the proper position of the angles is known, mark the angles in all areas of
interference between the angles and the tractor frame. For example, mark the areas
of the angle needed to be cut out to clear bolts, rivets, spring hangers, etc.

NOTE: A spacer may be
required to obtain

Figure 4

clearance between the
hydraulic cylinder (and
hoses) and the
transmission or cross
members. If a riser is
needed, it may be
necessary to use 5˝x 5˝
angles.

4. Remove the angles from the tractor frame and machine any interference areas in
accordance with the “

Installation: General Recommendations” found on the page 2.

5. Clamp the mounting angles tightly to the tractor frame. Be certain to check
clearances of cutouts. Drill holes in accordance with the “Installation: General
Recommendations” found on the page 2.

6. Remove the clamps and fasten the angles, in accordance with the “General
Information”. In addition, see Figure 5.

7. Position the fifth wheel

Figure 5

on the mounting angles
with the top plate pivot
on the marked location.
Verify that there are no
interferences and that
the fifth wheel frame
seats flush on the
mounting angles. Tack
weld the fifth wheel to
the mounting angles.

8. Weld the ends of the
fifth wheel assembly
frame to the top of the
mounting angles with
two 3/8˝ groove welds,
as shown in Figure 6.

4

Figure 6

XL-FW488 Rev A

INSTALLATION INSTRUCTIONS

5/16˝

3-8

1

/2˝

3/8˝

3-8

1

/2˝

FIFTH WHEEL
MOUNTING FRAME

MOUNTING ANGLE

continued

9. Remove the rear pivot shaft (see corresponding fifth wheel’s parts list — pages 11
through 12 — in combination with Chart 2 — to find the rear pivot shaft):

Chart 2

Rear Pivot Shaft Identification

FIFTH WHEEL REAR PIVOT SHAFT REAR PIVOT SHAFT

PART NUMBER PART NUMBER DETAIL NUMBER

FW2800-X XA-2895 Detail #7
FW2900-X XA-2895 Detail #7
FW2800-5X XA-2895 Detail #37
FW2900-5X XA-2895 Detail #37

10. Using a lifting device, pick up the rear support assembly (see corresponding fifth
wheel parts list in combination with Chart 3 to find the rear support assembly). For
safety, block out the assembly after it is lifted.

Chart 3

Rear Support Assembly Identification

FIFTH WHEEL ASSEMBLY ASSEMBLY

PART NUMBER PART NUMBER DETAIL NUMBER

FW2800-X XA-2808-B Detail #2
FW2900-X XA-2908-B Detail #2
FW2800-5X XA-2808-B Detail #32
FW2900-5X XA-2908-B Detail #32

11. Use air pressure to extend the cylinder rod(s) approximately 12˝. Be sure to cover
the cylinder rod(s) to protect from weld splatter.

12. Weld the fifth wheel frame to the mounting angles per
skip welds inside the frame, and 3/8˝ groove skip welds on the outside. Make the
skip welds 3˝ long on approximately 8-1/2˝ centers (i.e. weld 3˝ bead, skip 5-1/2˝).
Make inside skip welds opposite to the outside welds.

REAR SUPPORT REAR SUPPORT

Figure 7. Make 5/16˝ fillet

Figure 7

13. Reassemble the rear pivot shaft removed in Step 9.

XL-FW488 Rev A

5

POWER TAKE OFF (PTO) AND
HYDRAULIC PUMP INSTALLATION

General Information

1. Hydraulic fifth wheels require certain hydraulic components for operation. These
components should have the following characteristics:

A. Pump – Single cylinder, 17 gallon/minute @ 1300 r.p.m.
B. Power Take Off – Compatible with transmission and pump, and with an

output as close as possible to engine speed (i.e. 1-to-1 ratio).

C. Hose and Fittings – Should be of good quality and selected to handle the

maximum pump output at 2,000 p.s.i.
Hydraulic Oil – Selection of the proper oil is a prime requirement for

D.

satisfactory system performance and life.

Detailed Information

1. Install the PTO in accordance with the PTO manufacturer’s instructions. In the
absence of instructions, proceed as follows:

A. Start the tractor and listen to the transmission. After installation, the

transmission should sound similar.
B. Shut off the tractor and drain the transmission fluid.
C. Remove the transmission cover plate from the PTO installation point.
D. Check the PTO and transmission gears for proper width, diameter, and

location.
E. Install studs in the transmission.
F. Install gaskets and sufficient shims on the transmission.
G. Install the PTO. Draw the nuts evenly while checking the gear backlash. When

fully tightened, the backlash should be .008˝– .012˝. If the backlash is

incorrect, remove the PTO and add or remove the required shims.
H. Check for free shifting. If free, refill the transmission to the proper level.
I. Install the PTO shift controls.
J. Start the tractor. Engage the PTO and listen to the transmission. If any

unusual noises occur, inspect and correct using the shimming procedure

outlined above in Step F.

2. Install the hydraulic pump per the manufacturer’s recommendations.

Hydraulic Component Installation

1. Install the oil tank and brackets. The tank should be located as close to the pump
as possible, with the bottom of the tank higher than the inlet port on the pump.

2. Install the hydraulic control valve.
A. Manual – Locate the valve in the cab at a convenient operation location.

Then, route the hydraulic hoses through the cab to the pump, tank, and
manifold.

B. Air Operated – If your unit was purchased with the optional air operated

control valve kit (RK-2800-50), install as follows (refer to FIGURE 8 for the
following steps):

1. Mount the control valve/air cylinder assembly in a convenient location,
between the manifold and air valve.

2. Mount the lift control valve in the cab in a location were it will not be
accidentally activated.

3. With hoses, connect the air supply from a location recommended by the
chassis manufacturer.

6

XL-FW488 Rev A