SAF XL-FW503 User Manual

OWNER’S MANUAL

FleetMaster LowLube Series Fifth Wheels with Manual Sliding Secondary Lock

XA-201-S10217, XA-201-S10579 & XA-231-S10217

Installation, Operation, Maintenance Procedures and Comprehensive Warranty

FIFTH WHEEL

TECHNOLOGY

XL-FW503 Rev B

Questions or Comments? Call

1-888-396-6501

www.safholland.us

LOWLUBE

INSTALLATION INSTRUCTIONS

General Safety Information

It is important to read, understand, and follow the important information contained in these installation instructions. Failure to do so 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 precautions to ensure that the tractor electrical system is not damaged due to the welding process.

Safety Signal Words

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

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

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

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

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 safe procedures.

4. Use only SAF-HOLLAND original parts.

5. Use Safety Goggles. Glasses or goggles not in compliance with ANSI or CSA can cause serious injur

6. Wear Proper Apparel. Do not wear loose clothing, gloves, neckties, jewelry (rings, wristwatches, etc.) that can get caught in moving parts. Non-slip footwear is recommended.

y when damaged or broken.

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 SAF-HOLLAND literature.

4. As recommended in SAF-HOLLAND literature (available from www.safholland.us).

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 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.

2 XL-FW503 Rev B

INSTALLATION INSTRUCTIONS

continued

Installation

General Recommendations

1. Every user and installer using SAF-HOLLAND products either recommended or not

recommended by procedure used is appropriate for the vehicle, product and application.

2. Consult the

3. Consult the tractor manufacturer’s body builder’s book and the latest SAE and D.O.T. standards for additional installation methods. Recommended Maintenance Practice 603B for installation procedures.

Determine the proper fifth wheel position, or, in the case of a sliding fifth wheel, the range of

4. proper positions. Proper positioning of the fifth wheel is important for weight distribution, swing clearance and handling characteristics. See 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 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.

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 a 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 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.

10. The mounting angle should have a minimum thickness as shown in Chart 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 sur 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 CHART 1 for minimum plate thickness recommendations.

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 injur

13. Trailer pick-up ramps are recommended at the rear of the truck-tractor frame. When mounting to aluminum frames, follow the tractor manufacturer’s recommendations.

14.

SAF-HOLLAND has available a stationary mounting angle intended for use with aluminum

frames. Contact

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 8 of this publication.

SAF-HOLLAND, must thoroughly satisfy himself that the installation

SAF-HOLLAND literature for fifth wheel capacities and applications.

SAF-HOLLAND recommends the T.M.C.

face of the truck-tractor

CHART 1

Fifth Wheel Mounting Angle Mounting Plate

Vertical Capacity Thickness Thickness

12,000 lbs. 1/4˝ 1/4˝

20,000 lbs. 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˝

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

SAF-HOLLAND or distributors of Holland brand products for availability.

Minimum Minimum

5/16˝ 1/4˝

XL-FW503 Rev B 3

INSTALLATION INSTRUCTIONS

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.

5/8˝ diameter Grade 8 bolts minimum size, tightening torque to bolt manufacturer charts. Hardened steel washers or flanged lock nuts (5/8˝ diameter Grade “C” lock nuts).

HDN. STEEL WASHERS

TRUCK FRAME RAIL

See Chart 1 for minimum mounting angle thickness

18.00˝ MIN.

36.00˝ MIN.

1.00˝ MIN.

DOUBLE PASS MIN.

BOTH ENDS

8.00˝ MAX. TYP.

(50.8mm)

2.00˝

(203.2mm)

1/4˝

BOTH SIDES

8.00

(203.2mm)

8.00

(203.2mm)

8.00˝

(914.4mm)

2.00˝

(50.8mm)

1/2˝

(457.2 mm)

/16

GAP

/4˝-1/2˝ in 4 places

/16

Both ends continuous

Both sides center of bracket

continued

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 2.

Bracket with Mounting Angle (see Figure 1A, 1B, and 1C):

1. Holland brackets with mounting angle are provided with the bracket welded in the center of a 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 3, follow the recommendations in FIGURE 1.

Bracket for Angle Mounting (see Figure 1A, 1B, and 1C):

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

2. See “Installation: General Recommen- dations” on page 3, 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 a minimum length of 18˝ forward of the fifth wheel pivot point, and not less than 12˝ to the rear. 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 1A, 1B, and 1C. 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 shown in FIGURES 1A and 1B. C. Position the brackets on the angles and verify the correct spacing to mount

the fifth wheel.

D. For fabricated brackets (a welded asssembly), weld the bracket to the mounting

angle with 1/4˝ fillet welds on both sides, and 1/2˝ groove welds on both ends, as shown in FIGURES 1A and 1B. 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 shown in

FIGURE 1C. The welds must be continuous around the bracket ends.

4 XL-FW503 Rev B

FIGURE 1C

(Cast Brackets Only) WELDING DETAILS

FIGURE 1A (End View)

FIGURE 1B (Side View)

INSTALLATION INSTRUCTIONS

FIFTH WHEEL SUPPORT BRACKET

FLAT MOUNTING PLATE See Chart 1 for minimum thickness

INBOARD ANGLE

TRACTOR FRAME

SPACER

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

CORRUGATED MOUNTING PLATE

See Chart 1 for minimum thickness

TRACTOR FRAME

FIFTH WHEEL SUPPORT BRACKET

CENTER

BOLT

Attach bracket and mounting plate as shown. Use center bolt of sufficient length to bolt through bracket, mounting plate and mounting angle.

3/8˝ 3 - 8.50˝

5/16˝

3 - 8.50˝

INSIDE WELD

OUTSIDE WELD

See Chart 1 for min.

mounting angle

thickness

HARDENED STEEL

WASHERS

5/8” diameter Grade 8 bolts minimum size. Tightening torque to bolt manufacturer charts. Hardened steel washers or flanged locknuts. 5/8” diameter Grade “C” locknuts.

TRUCK FRAME RAIL

Stationary Fifth Wheel Installation continued

Bracket with Mounting Base (See Figures 2A, 2B, and 2C):

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

continued

2. In addition to the information given in “Installation: General

FIGURE 2A

Recommendations,” on page 3, follow the recommendations in FIGURES 2A, 2B, and 2C.

See “Installation: General Recommendations” on page 3 for angle thickness and material. The mounting angle should be 1˝ longer than the mounting plate, and be 36˝ minimum length.

FIGURE 2B

Use 3˝ minimum horizontal and 3 -1/2˝ minimum vertical leg size. Longer horizontal legs may be required with narrow frame widths.

FIGURE 2C

Sliding Fifth Wheel Installation

Prior to proceeding with the installation of the sliding fifth wheel assembly, carefully review the “General Safety Information” section on page 2.

Inboard Angle Mounting (See Figures 3 and 4):

1. Angles must be installed on the sliding fifth wheel base plate to facilitate mounting. See “Installation: General Recommendations,” on page 3, for angle thickness and material.

FIGURE 3

2. Use a mounting angle which is at least 2˝ longer than the slide base plate and 36˝ minimum length. Use 4˝ minimum horizontal and 3-1/2˝ minimum vertical leg size. The fifth wheel top plate and support bracket may be removed from the base plate for ease of handling.

XL-FW503 Rev B 5

FIGURE 4 (End View)

INSTALLATION INSTRUCTIONS

1.00˝ (25.4 mm) MIN.

CENTER LINE OF TRACTOR REAR AXLE(S) OR BOGIE

PLATE LENGTH PLUS 2.00˝ MIN. (50.8 mm)

4.00˝

(101.6 mm)

max.

1˝ min. 6 bolts equally spaced

FORWARD TRAVEL

TRUCK FRAME RAIL

5/8˝ diameter Grade 8 bolts minimum size, tightening torque to bolt manufacturer charts. Hardened steel washers or flanged locknuts. 5/8˝ diameter Grade “C” locknuts.

HARDENED STEEL

WASHERS

continued

Sliding Fifth Wheel Installation continued

Inboard Angle Mounting continued

3. Position the angles on the slide plate for the required frame width. Be sure to keep the plate centered left to right, and front to rear on the mounting angles.

Weld as shown in FIGURE 3. Make 5/16˝fillet welds inside and 3/8˝ groove welds on the outside with skip welds 3˝ long on approximately 8-1/2˝ centers (weld 3˝, skip 5-1/2˝). Weld inside opposite skips on the outside. ALSO WELD: The plate to the top of the angle at the ends of the plate.

5. Attach the slider plate and mounting angles to the tractor using recommendations in

“General Recommendations”

and in FIGURE 4.

6. Reassemble the fifth wheel top plate and bracket sub-assembly to the slider base plate if they were removed previously.

FIGURE 4 (Side View)

FIGURE 5

Outboard Angle Mounting (See Figures 5 and 6):

1. If angles are not installed, see “Installation: General Recommendations,” on page 3, for thickness and material. Use 3˝ minimum horizontal and 3-1/2˝ minimum vertical leg size. Longer horizontal legs may be required with narrow frame widths. The recommended length of each mounting plate is the same length as the slide base mounting plate.

2. In addition to the information given in “Installation: General Recommendations,” on page 3, follow the recommendations in FIGURE 5 and FIGURE 6. The following sequence is suggested:

A. Securely position the mounting angles to the tractor frame and attach as shown

in FIGURE 5. Follow the bolting recommendations as shown in FIGURE 4. Angles must be flush with the top of the truck frame.

B. Locate the slide base and center left to right and front to rear on the mounting

6 XL-FW503 Rev B

angles. Clamp in place and drill 21/32˝ diameter holes using the mounting plate as a template if holes are not provided in the angle.

C. Align holes in the slide plate with outboard angle mounting holes and bolt

using Grade 8 fasteners, hardened steel washers and Grade C locknuts, properly tightened, (see FIGURE 6). Use all mounting holes on the fifth wheel.

FIGURE 6

PLUNGER ADJ. BOLT

POCKET

PLUNGER

RACK

BRACKET CAP

1/8”

1/4”-1/2”

Locate and weld the rear slide stops per steps 2 through 5 above. Weld the forward side in the center only to avoid interference with the bracket.

TYP.

5/16˝

Dimensions apply after welding.

TYP.

5/16˝

SLIDE STOP

INSTALLATION INSTRUCTIONS

Sliding Fifth Wheel Installation continued

Adjustment of Sliding Bracket Locking Plungers

The slide locking plungers are given a preliminary adjustment during factory assembly. However, due to variations introduced during mounting (such as frame and material tolerances) a final adjustment must be made at the time of installation.

Adjust the locking plungers at installation, after one month of service,

and at recommended maintainence intervals. by use of the adjusting bolts provided on both sides. Failure to do so may result in accelerated wear of components, lower service life, improper load transfer, or improper load distribution.

To adjust locking plungers:

1. Loosen lock nut and turn adjusting bolt

out (counterclockwise). See FIGURE 7.

2. Disengage and engage the locking

plungers. Check that the plungers are securely seated without binding.

3. Turn the adjusting bolt in (clockwise)

until it contacts the rack. Turn the bolt an additional 1/2 turn then tighten the locking nut securely.

Prior to proceeding with the installation of the sliding fifth wheel assembly, carefully review the “General Safety Information” section on page 2.

Installation of Slide Stops

1. It is the responsibility of the installer

to insure that slide stops are installed properly at all four corners of the slider plate.

2. Slide the bracket to the full rear

position and engage the plungers in the rack.

3. Locate rear stops under the curled

edge allowing some clearance to the bracket (approximately 1/8˝). Clamp in place. This should position the stops approximately 1/4˝ to 1/2˝ from the edge of the rear of the plate, see FIGURES 8A and 8B.

4. Slide bracket ahead out of the way

and weld the stops in place as shown in FIGURES 8A and 8B. The welds should be 5/16˝ fillet.

5. Slide the bracket to the full rear

position and check for clearance. Make sure the plungers on the sliding bracket seat properly into the rack with all teeth engaged.

6. Repaint as required.

XL-FW503 Rev B 7

FIGURE 8A

FIGURE 8B (Rear End View)

continued

FIGURE 7

(Outside View)

INSTALLATION INSTRUCTIONS

continued

Attachment of Air-Activated Slide Release – If Required

1. Mount the cab control valve in accordance with the instructions provided. It should be readily accessible to the driver, but protected to prevent accidental activation.

2. Attach an air line, using appropriate fittings to the “air” or “in” port of the valve. Use an air source recommended by the tractor manufacturer. Use fittings and lines of suitable pressure rating.

3. Connect an air line between the “cyl” or “out” port of the valve and the active side of the air cylinder. A bulkhead fitting may be placed at the front of the slide base plate, if desired. Use fittings and lines of suitable pressure rating and be sure line is run so as not to interfere with any other operation or component.

4. Check operation of the valve and cylinder.

Inspection and Lubrication Prior to Use

1. Review the installation. Be sure all nuts and bolts are in place and properly

tightened. Be sure all necessary steps were properly followed and that all components removed to facilitate installation are reinstalled.

2. Check the fifth wheel locking mechanism with a Holland TF-TLN-5001 (2˝) or TF-TLN-1500 (3-1/2˝) Lock Tester. Examine for proper locking as described in the “Operating Instructions” of this manual. This must be done to assure that the mechanism has not been damaged by shipment, handling, or storage.

Failure to properly install, operate, or maintain this fifth wheel could result in tractor and trailer separation causing death or serious injury to others.

3. Apply grease to the bearing surface of the support bracket through the grease fittings on the side or front of the fifth wheel pockets. The top plate must be lifted up slightly to ensure proper application of grease. (NOTE: This is not required on Holland LowLube and NoLube top plates.)

4. Apply a generous coating of grease to the top of the fifth wheel plate, where it will contact the trailer plate. (NOTE: This is not required on Holland LowLube and NoLube top plates.)

5. Apply a generous coating of grease to the front lock and lock jaws.

8 XL-FW503 Rev B

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SAF XL-FW503 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual