SAF XL-FW504 User Manual

FIFTH WHEEL

OWNER’S
MANUAL

FW35-S09623 Series
Fifth Wheel

Installation, Operation, Inspection,
Maintenance Procedures and
Comprehensive Warranty

TECHNOLOGY

XL-FW504 Rev A

Questions or Comments?
Call

www.thehollandgroupinc.com

FIFTH WHEELS

1-888-396-6501

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,

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 genuine Holland parts.
Use Safety Goggles. Glasses or goggles not in compliance with ANSI or CSA can

5.
cause serious injury when damaged or broken.

Wear Proper Apparel. Do not wear loose clothing, gloves, neckties, jewelry (rings,

6.
wristwatches, etc.) that can get caught in moving parts. Non-slip footwear is
recommended.

may result in property damage.

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 Holland literature.

4. 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

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-FW504 Rev A

INSTALLATION INSTRUCTIONS

continued

Installation

General Recommendations

1. Every user and installer using Holland products either recommended or not recommended by
Holland, must thoroughly satisfy himself that the installation procedure used is appropriate

or the vehicle, product and application.

f

2. Consult the Holland literature for fifth wheel capacities and applications.

. Consult the tractor manufacturer’s body builder’s book and the latest SAE and D.O.T.

3

standards for additional installation methods. Holland recommends the

aintenance Practice 603Bfor installation procedures.

M

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

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.

13. Trailer pick-up ramps ar

14. When mounting to aluminum frames, follow the tractor manufactur

15. Review, in addition, the specific information on the following pages for each type of fifth

CHART 1 for minimum plate thickness recommendations.

refer to

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

ecommended at the r

e r

Holland has available a stationary mounting angle intended for use with aluminum frames.
Contact Holland or Holland distributors for availability.

wheel mounting, as well as “
publication.

Inspection and Lubrication Prior to Use” on page 8 of this

Fifth Wheel Mounting Angle Mounting Plate

Vertical Capacity Thickness 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˝

ear of the tr

CHART 1

Minimum Minimum

uck-tractor frame.

T.M.C. Recommended

Chart 1 and should be

ecommendations.

s r

er’

XL-FW504 Rev A

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
c

harts.
Hardened steel washers or flanged lock
nuts (5/8˝ diameter Grade “C” lock nuts).

HDN. STEEL WASHERS

T

RUCK FRAME RAIL

See Chart 1
for minimum
mounting
angle
t

hickness

18.00˝ MIN.

3

6.00˝ MIN.

1

.00˝ MIN.

D

OUBLE PASS MIN.

BOTH ENDS

8.00˝ MAX. TYP.

(50.8mm)

2.00˝

(203.2mm)

1

/4˝

BOTH SIDES

8.00

˝

(

203.2mm)

(

203.2mm)

8

.00

˝

(

203.2mm)

8.00˝

(

914.4mm)

2.00˝

(

50.8mm)

1/2˝

(457.2 mm)

3

5

/1

6

GAP

1

/4˝-1/2˝ in 4 places

5

/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
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 ar

4

FIGURE 1C

(Cast Brackets Only)
WELDING DETAILS

“Installation: General Recommendations,”

FIGURE 1A (End View)

FIGURE 1B (Side View)

ound the bracket ends.

XL-FW504 Rev A

INSTALLATION INSTRUCTIONS

FIFTH WHEEL
SUPPORT BRACKET

FLAT MOUNTING PLATE
See Chart 1 for
minimum thickness

INBOARD ANGLE

T

RACTOR 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).

Attach the outboard angle to
tractor frame with hardware
l

isted in Figure 1A. Attach
mounting plate to angle with
same number of bolts (in
a

ddition to attachment to

fifth wheel support bracket).

CORRUGATED
M

OUNTING 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

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 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.

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

FIGURE 2B

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 2C

Sliding Fifth Wheel Installation

Prior to proceeding with the installation of the sliding fifth wheel assembly,
carefully review the

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.

“General Safety Information” section on page 2.

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 fr
base plate for ease of handling.

XL-FW504 Rev A

om the

FIGURE 4 (End View)

5

INSTALLATION INSTRUCTIONS

1.00˝
(25.4 mm) MIN.

CENTER LINE OF
TRACTOR REAR
A

XLE(S) OR

BOGIE

P

LATE LENGTH PLUS 2.00˝ MIN. (50.8 mm)

4.00˝

(101.6 mm)

m

ax.

1˝ min. 6 bolts equally spaced

FORWARD TRAVEL

T

RUCK FRAME RAIL

T

he 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 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.

4. Weld as shown in FIGURE 3. Make

F

5/16˝fillet welds inside and 3/8˝

IGURE 4 (Side View)

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

The plate to the top of the

WELD:

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.

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
on page 2, 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 tr

B. Locate the slide base and center left to right and fr

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

6

FIGURE 6). Use all mounting holes on the fifth wheel.

“Installation: General Recommendations,”

uck frame.

ear on the mounting

ont to r

XL-FW504 Rev A

FIGURE 5

FIGURE 6