SAF XL-FW10028OM User Manual

Owner’s Manual

31 NoLube® and 33 Low Lube Series Fifth Wheels

Operation, Maintenance and Troubleshooting Procedures; Warranty Information

FW31 Assembly Series XA-311 Top Plate Series FW33 Assembly Series XA-331 Top Plate Series

XL-FW10028OM-en-US Rev A

2

Contents

Introduction

Notes, Cautions, and Warnings

NOTE:

IMPORTANT:

Introduction ………………..…….................. 2

Notes, Cautions, and Warnings…………….. 2 Section 1—Model Identification……………. 3 Section 2—General Safety Instructions….. 4 Section 3—Fifth Wheel Intended Use…….. 5 Section 4—Fifth Wheel NON-Intended Use 5 Section 5—Coupling Preparation………….. 5 Section 6—Coupling Procedures…………... 8 Section 7—Uncoupling Procedures……….. 10 Section 8—Positioning Sliding Fifth Wheels……………………………..

This manual provides you information necessary for the proper operation and maintenance of Holland 31 and 33 series fifth wheels.

components contact SAF-HOLLAND Customer Service: 1-888-396-6501.

For Holland replacement

Page

Section 9—Top Plate Removal ………….. 14 Section 10– Lube Plate Inspection…….. 14 Section 11—Fifth Wheel Lubrication…… 15 Section 12—Fifth Wheel Adjustment…… 16 Section 13—Slide Base Adjustment…… 19 Section 14—Pocket Insert Inspection…. 20 Section 15—Top Plate Installation……… 20 Troubleshooting .……………………………. 21 Rebuild and Replacement Kits………….. 24 Warranty and Performance Guarantee. . 25

12

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

Includes additional information to enable accurate and easy performance of procedures.

Page

You must read and understand all of the procedures presented in this manual before operating or starting work on any Holland 31 or 33 series fifth wheel.

location for future reference.

Proper tools must be used to perform the maintenance and repair procedures described in this manual.

safety requirements are defined by federal and/or state Occupational Safety and Health Acts. Equivalent laws may exist in other countries. This manual is written based on the assumption that OSHA or other applicable employee safety regulations are followed by the location where the work is performed.

Keep this manual in a safe

In the United States, work shop

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

potentially hazardous situation which, if not avoided, may result in property damage.

if not avoided, may result in minor or moderate injury.

if not avoided, could result in death or serious injury.

Includes additional

Used without the safety alert symbol, indicates a

Indicates a potentially hazardous situation which,

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

3

Model Identification

1. Model Identification

Figure 1

Figure 2

Figure 1

Figure 2

Fifth wheel serial tags are located on the left side of the fifth wheel top plate above the fifth wheel bracket pin, or on the pickup ramps as shown (

The part number and serial number are listed on the tag as shown (

).

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

4

General Safety Instructions

2. General Safety Instructions

IMPORTANT

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.

All fifth wheel installation and maintenance must be performed by a trained technician using proper tools and safe procedures.

fifth wheel you must be thoroughly satisfied that the fifth wheel has been appropriately installed

on the vehicle.

tractor trailer separation which, if not avoided, could result in death or serious injury.

Refer to SAF-HOLLAND Installation Manual XL-FW10008IM-en-US (available on the Internet at www.safholland.us) for proper installation procedures.

: Prior to operation of the

Failure to properly install the fifth wheel may result in

Failure to follow all the

operating procedures contained in these instructions may result in a hazardous condition which, if not avoided, could result in death or serious injury.

These instructions apply to the proper operation of your fifth wheel only. There are other important checks, inspections, and procedures listed in the Owner’s Manuals for your tractor and trailer that are necessary, prudent, and/or required by law.

Only SAF-HOLLAND Original Parts should be used.

A list of SAF-HOLLAND technical support locations to supply SAF-HOLLAND Original Parts can be found on the Internet at www.safholland.us or contact our Customer Service group at 1-888-396-6501.

Updates to this manual will be published as necessary on the Internet at www.safholland.us.

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

5

Operation Instructions

3. Fifth Wheel Intended Use

4. Fifth Wheel NON-Intended Use

IMPORTANT

5. Coupling Preparation

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

position in the trailer.

2. To transport loads that are within the maximum fifth wheel rated capacities: 55,000 lbs. Maximum Vertical Load

150,000 lbs. Maximum Drawbar Pull.

3. In on-road applications.

of off-road refers to terrain on which a tractor-trailer operates which is unpaved and rough, or ungraded. Any terrain not considered part of the public highway system falls under this heading.

: SAF-HOLLAND definition

Failure to couple with a

proper kingpin may result in improper coupling, allowing tractor and trailer separation, which if not avoided, could result in death or serious injury.

3. The attachment of lifting devices.

4. The transport of loads in excess

of rated capacity.

5. In off-road applications.

6. Applications other than

recommended in SAF-HOLLAND literature available on the

Internet at www.safholland.us.

4. As recommended in SAF-HOLLAND literature available at

www.safholland.us.

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, or upper coupler and fifth wheel lube plates that do not maintain the SAE kingpin dimensions. Refer to SAF-HOLLAND Service Bulletin XL-SB004-01(available on the Internet at www.safholland.us) for more information on fifth wheel lube

plates.

1. Prior to coupling you must inspect the fifth wheel and

mounting.

• Confirm that lube plates are in

place and firmly fastened.

• Tighten loose fasteners.

• Replace missing fasteners.

• Repair/replace missing,

cracked or otherwise damaged components.

•FW33-Inspect fifth wheel

mechanism. Lubricate dry or rusty components

• If you have a sliding fifth

wheel, make sure both plungers are fully engaged.

• Inspect air line connections.

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

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

6

Operation Instructions

Figure 3

Figure 5

Figure 4

Figure 6

Figure 5

not

Figure 3

Figure 4

Figure 5

Figure 6

• Make sure fifth wheel is in appropriate position for

weight distribution on the tractor. For proper positioning of the fifth wheel refer to SAF-HOLLAND publication

XL-FW10008IM-en-US available on the Internet

at www.safholland.us.

2. Make sure coupling area is flat, level and clear of persons and obstacles.

3. Tilt ramps of fifth wheel downward (

4. Make sure locks are open (

).

If locks are closed (if equipped with a manual secondary lock, first pull secondary release handle and hook on casting ( handle all the way out (

), pull release

air release equipped, set tractor brakes and actuate fifth wheel control

valve to open locks.

5. If locks are not completely open as shown (

), check the

following:

TILT DOWNWARD

).

). If

a. Nut and washer at front of fifth wheel are n

snug against the

wheel.

b. Release handle is in extended “open” position.

If both of these conditions exist, you can still successfully couple the fifth wheel even though the lock jaws appear closed. The movement of the kingpin into the fifth wheel jaws will

allow a successful couple.

If either of the above conditions do

not exist, repeat Step 4.

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

LOCKS ARE

OPEN

LOCKS ARE

CLOSED

7

Operation Instructions

Figure 7

Figure 8

Figure 9

Figure 7

Figure 8

Figure 9

6. Inspect leading edge of trailer bolster/skid plate. It must be free of any

square or sharp edges (

).

7. Make sure there are no bolts or nuts extending below bolster/skid plate within 152 mm (6.0”) of the fifth

wheel travel path while coupling.

8. The area supported by the fifth wheel should be free of any large holes or

gouges (

9. Any access holes that the fifth wheel passes beneath should have cham-

).

fered or radius edges.

10. Check that any splits from the skid plate to bolster plate are welded adequately, and that there are no sharp edges or abrupt changes in

elevation (

).

11. The upper coupler should extend adequately rearward to maintain full contact with the fifth wheel during tight turning. If it does not, at a minimum, the rear edges should be

chamfered or radius edges.

CHAMFERED (Preferred) OR LARGE RADIUSED LEADING EDGE

20º

2” MIN.

KEEP PATH OF FIFTH WHEEL FREE OF LARGE HOLES & GOUGES

6” MIN.

40”

KEEP BOLTS AND NUTS CLEAR OF THIS AREA

ACCESS HOLE

12. Make sure that any upper coupler residual grease is free of heavy course

MAKE SURE THERE ARE NO SHARP EDGES

grit.

13. Ensure that the upper coupler fifth wheel contact surface is free of rust and is not painted. The area should be conditioned with a rust inhibitor

NO ABRUPT TRANSITIONS IN ELEVATION

such as a light oil.

14. Verify that kingpin is not obstructed by a kingpin lock or other security

device.

Failure to remove kingpin

lock prior to coupling may result in improper coupling which, if not avoided, could result in death or serious

injury.

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

8

Operation Instructions

6. Coupling Procedures

Figure 10

Figure 11

Figure 10

IMPORTANT:

IMPORTANT

15. Inspect kingpin for excessive wear and damage (use Holland Kingpin Gage tool TF-0110 ) along with bolster bow (See SAF-HOLLAND Service Bulletins XL-SB020 and XL-

SB033).

procedures for FW31 NoLube and FW33 Low Lube fifth wheels is extremely important.

these coupling instructions may result in damage to the

lube plates.

: Following proper coupling

Failure to follow all of the procedures contained in

TRAILER

(TOP)

KINGPIN

EXHAUST SUSPENSION AIR BEFORE BACKING UP

1. Position the tractor so that the center

between fifth wheel and trailer or damage to lube plates may occur.

2. Back tractor close to the trailer and

3. Chock trailer wheels.

4. Connect brake lines and light cord.

5. Support slack in lines to prevent

6. Set trailer brakes.

7. Completely exhaust air from tractor

of the fifth wheel is aligned with kingpin and back up straight

(

).

DO NOT make contact

STOP before making contact with trailer (

).

interference.

suspension, ensuring that the fifth wheel is below the contact surface of

trailer (

).

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

9

Operation Instructions

Figure 12

Figure 13

Figure 14

Figure 15

Figure 12

Figure 13

IMPORTANT:

Figure 15

Figure 14

8. Slowly back tractor just past the

Kingpin should not be engaged at this step.

9. Adjust tractor suspension to ride

may result in improper coupling, allowing tractor and trailer separation, which if not avoided, could result in death or serious

injury.

leading edge of the trailer so that fifth wheel is under trailer (

).

DO NOT attempt to couple.

height. Fifth wheel plate face must make contact with bolster plate

(

).

Failure to couple with the trailer at the proper height

10. Slowly back into trailer, engaging kingpin in fifth wheel.

11. Perform a pull test as an INITIAL CHECK by locking trailer brakes and pulling forward with tractor to make sure tractor trailer separation does

not occur (

).

12. Get out of tractor and visually inspect the following to be sure lock is closed and tractor and trailer are properly

coupled (

).

a. Nut and washer must be snug against the fifth wheel casting.

b. No gap is permissible between trailer bolster plate and fifth

wheel.

c. Fifth wheel locks must be closed around the trailer kingpin with 1/4” or less gap visible between

the lock jaws.

LOCK TRAILER BRAKES AND

PULL FORWARD WITH TRAILER

NUT AND WASHER SNUG AGAINST FIFTH WHEEL

NO GAP!

1/4” OR LESS GAP

LOCKS COMPLETELY CLOSED AROUND KINGPIN

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

10

Operation Instructions

Figure 16

7. Uncoupling Procedures

Figure 16

IMPORTANT:

NOTE:

IMPORTANT

13. If you do not achieve a proper couple,

Failure to properly couple the tractor and trailer may result in tractor trailer separation while in use which, if not avoided, could result in death or

serious injury.

that fails to operate properly.

Failure to repair a malfunctioning fifth wheel before use may result in a tractor trailer separation which, if not avoided, could result in death or

serious injury.

14. Fully retract the landing gear legs off

repeat the coupling procedure.

Do not use any fifth wheel

the ground and secure the crank handle (

).

SECURE CRANK

Follow instructions published by landing gear manufacturer for proper operation of landing gear.

15. Verify brake lines and light cords are

connected.

16. Remove wheel chocks, continue with

pre-trip inspection.

procedures for FW31 NoLube and FW33 Low Lube fifth wheels is extremely important.

these uncoupling instructions may result in

damage to the lube plates.

: Following uncoupling

Failure to follow all of the procedures contained in

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

11

Operation Instructions

Figure 17

Figure

18

Figure 19

Figure 20

Figure 17

Figure 18

NOTE:

IMPORTANT:

Figure 19

Figure 20

1. Position tractor and trailer on firm, level ground clear of obstacles and

persons.

2. Set trailer brakes.

3. Slowly back tractor tightly against trailer to relieve pressure on the fifth

wheel locks.

4. Set tractor brakes.

5. Chock trailer wheels.

6. Lower landing gear until pads just touch the ground (

).

Follow instructions published by manufacturer for proper operation of landing gear and ability to transfer trailer weight off fifth wheel. Do not raise trailer off the fifth wheel.

LOWER LANDING GEAR

7. Disconnect brake lines and light cord.

8. If equipped, pull secondary release

9. Pull release handle all the way out

10. Release tractor brakes and slowly pull

of the trailer.

handle and hook on casting (

).

(

). If air release equipped,

actuate fifth wheel control valve to open locks.

forward 12” (306 mm) to disengage kingpin from fifth wheel. Fifth wheel should be between the front edge of trailer and kingpin (

).

Do not drive the tractor free

SLOWLY PULL FORWARD AND STOP

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

12

Operation Instructions

Figure 21

)

Figure 22

8. Positioning Sliding Fifth Wheels

Figure 23

Figure 24

NOTE:

Figure 21

Figure 24

Figure 22

Figure 23

11. Completely exhaust air from tractor suspension, ensuring that fifth wheel is below the contact surface of trailer

(

.

12. Slowly pull away from trailer.

13. Air-up tractor air suspension to ride height (

1. Position tractor and trailer in a straight line on level ground.

2. Lock trailer brakes.

Failure to stop and

properly lock the trailer brakes may cause uncontrolled sliding of fifth wheel which, if not avoided, may result in component damage to

tractor or trailer.

3. Release slide locking plungers by

moving cab switch to unlock position ( equipped, pull release lever.) If plungers do not come out, lower the landing gear to relieve pressure on the fifth wheel. This will allow fifth

wheel to slide easier.

). (If manual slide release

EXHAUST SUSPENSION AIR BEFORE PULLING FORWARD

).

AIR-UP TRACTOR SUSPENSION

AIR OPERATED

MOVE CAB SWITCH

TO UNLOCK POSITION

Cab switch style may differ by OEM

design.

4. Slowly drive the tractor forward or

backward to position fifth wheel and stop tractor at desired position.

5. Re-engage slide locking plungers by

moving cab switch to the lock position (

). (If manual slide release

equipped, trip release arm to allow plungers to retract.).

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

AIR OPERATED

MOVE CAB SWITCH

TO LOCK POSITION

13

NOTE:

IMPORTANT:

Figure 25

FIFTH WHEEL MAINTENANCE

IMPORTANT:

Maintenance Procedures

NOTE:

6. Retract landing gear legs if lowered.

landing gear manufacturer for proper operation of landing gear.

7. Verify that slide locking plungers have

if the plungers are not fully engaged (locked).

may cause loss of vehicle control which, if not avoided, could result in

death or serious injury.

Follow instructions published by

been re-engaged by performing a pull test. Lock trailer brakes and pull forward with tractor to make sure fifth wheel does not slide (

).

Do not operate the vehicle

Failure to properly engage plungers into slide base

LOCK TRAILER BRAKES AND

PULL FORWARD WITH TRAILER

performed by a trained technician using proper tools

and safe procedures.

performed while the tractor is uncoupled from the trailer.

in tractor trailer separation which, if not avoided, could result in death or serious injury.

is not required for maintenance but may be required when performing repairs.

Removal of the fifth wheel top plate

All maintenance must be

Failure to properly maintain your fifth wheel could result

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

14

Maintenance Procedures

9. Top Plate Removal

Figure 26)

Figure 26

10. Lube Plate Inspection

Figure 27

Figure 26

IMPORTANT:

Figure 27

NOTE:

replaceable pocket inserts installed between the fifth wheel top plate and mounting base. Take care when removing fifth wheel top plate not to lose pocket inserts.

the top plate could cause a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury.

1. Remove bracket pin retention nuts

and bolts from both sides of fifth wheel top plate (

Fifth wheel assembly has

Failure to prevent pocket inserts from falling out of

.

RETENTION BOLT

TOP

PLATE

BRACKET PIN

RETENTION NUT

LOOK FOR STRAIGHT EDGE CONTACT HERE

2. Using a pry bar, pull bracket pins out

of fifth wheel top plate (

Using a lifting device capable of

3.

lifting 500 lbs., remove the top plate from the mounting base. Place fifth

wheel on a flat, clean working area.

Follow instructions published by lifting device manufacturer for proper operation of lifting device.

Thoroughly steam clean top surface of fifth wheel for visual inspection. Replace lube

plates if:

One or both lube plates is missing.

A straight edge laid across the lube plate contacts any metal portion of the fifth wheel surrounding the lube

plates (

).

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

15

Maintenance Procedures

Lube plates are severely chipped,

11. Fifth Wheel Lubrication

IMPORTANT:

worn, cracked, gouged or bent

20% (40 sq. in.) or more of lube plate coating is missing from one or both

plates due to normal wear or damage.

FW31 and FW33 fifth wheels are both equipped with NoLube plate inserts that eliminate the need to lubricate the fifth wheel-to-trailer contact sur-

faces.

Thoroughly clean the locking mechanism every 6 months or

60,000 miles.

is necessary to get the maximum service life from your FW33 fifth wheel. Perform the following procedures at the intervals shown.

FW31 fifth wheels are equipped with NoLube lock coating technology. The lock components are protected with a low-friction coating which provides long wear life and corrosion protection, eliminating the need for lubrication. The locking mechanism of a new FW31 fifth wheel assembly has a thin layer of grease applied by SAF-HOLLAND to aid the components for an initial “break-in” period. Grease will not adversely affect an FW31 NoLube fifth wheel.

Fifth wheel lubrication

The FW33 locking mechanism does require periodic lubrication.

Lubricate FW33 locking mechanism every 3 months or 30,000 miles.

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

16

Figure 28

Maintenance Procedures

11. A. Proper Lubrication Method

Figure 28

11.B. As-Needed Lubrication

12. Fifth Wheel Adjustment

IMPORTANT:

snowy or icy winter conditions, lubrication should be performed every spring in addition to routine lubrication (as noted on the previous page), to ensure optimum operation.

If your fifth wheel operates in

1. Using water-resistant lithium-based

Item 1

Item 3

).

grease, lubricate ( where contact is made with the locks and casting, ( (

Items5

in and out of the fifth wheel casting, (

Item 6

is made with the cam plate, ( release handle, and ( contact is made with the kingpin

(

) yoke shaft in area that slides

) secondary lock where contact

) yoke tips

) cam profile,

Item7

Item 8

) where

)

2

1

3

4

5

6

7

8

2. Using a light oil, lubricate ( cam pivot point (

Item 2

3. Lubricate ( Seez® only if necessary (

) lock pin with Never-

Clean and lubricate locking mechanism if operational difficulties arise during the service life of your

i.e.

fifth wheel ( coupling, uncoupling, or pulling the

release handle).

problems with

Fifth wheel adjustment should be performed at a minimum of every 60,000 miles or if excessive movement between kingpin and fifth wheel is noticed when

driving the vehicle.

Item 4

).

)

).

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

17

Figure 31

Figure 32

Figure 29

Maintenance Procedures

Figure 29

Figure 30

Figure 31

Figure 32

IMPORTANT:

NOTE:

Figure 30

between the tractor and trailer can effect vehicle

handling.

could result in loss of vehicle control which, if not avoided, could result in

death or serious injury.

adjustment SAF-HOLLAND recommends use of Holland lock tester Part No. TF-TLN-5001, available from your local Holland

distributor.

1. If fifth wheel is locked, pull release

Excessive movement

Failure to maintain proper fifth wheel adjustment

To obtain proper fifth wheel

handle all the way out to unlock fifth wheel (

) (if equipped with a manual secondary lock, first pull secondary release handle and hook on casting). If air release equipped, actuate fifth wheel control valve to

open lock .

2. Set lock tester on fifth wheel top plate (

).

3. To lock fifth wheel, rotate handle on lock tester clockwise (

).

4. With locks closed around lock tester, position adjustment nut on yoke shaft so that it is slightly compressing rubber washer making it difficult to

turn by hand (

).

5. Turn adjustment nut one additional full turn clockwise to further compress

rubber washer (

XL-FW10028OM-en-US Rev A 09-10 Amendments and Errors Reserved. © SAF-HOLLAND, Inc.

).

RUBBER WASHER

ROTATE CLOCKWISE 1 ADDITIONAL TURN

ADJUSTMENT NUT

18

Maintenance Procedures

Figure 33

Figure 34

Figure 35

Figure 33

Figure 34

IMPORTANT:

Figure 35

washer with additional turns will take the fifth wheel out of proper adjustment and degrade the performance of

the fifth wheel.

6. To unlock fifth wheel, push down and

7. Pull release handle to unlock fifth

8. To unlock fifth wheel, rotate handle

Over compressing the rubber

rotate “J” hook so that it locks under front skirt of fifth wheel casting as

shown (

).

wheel (if equipped with a manual secondary lock, first pull secondary release handle and hook on casting). If air release equipped, actuate fifth

wheel control valve to open lock.

on lock tester counter-clockwise (

).

9. Repeat coupling and uncoupling process with lock tester at least twice to help “seat” the yoke. Then recheck

adjustment of the fifth wheel.

10. With fifth wheel unlocked, unhook “J” hook from under front skirt of fifth wheel casting (

) and

remove lock tester from fifth wheel.

19

Maintenance Procedures

13. Slide Base Adjustment

Figure 36

Figures

37 and 38

If plungers do not release fully to allow fifth wheel to slide:

Figure 39

Figure 38

Figure 37

NOTE:

Figure 39

Figure 36

Some Holland slide bases are equipped with adjustable locking plungers. Adjustment should be performed at a minimum of every 60,000 miles or if excessive movement is noticed when driving the vehicle. (ILS slider plungers do not require adjustment.) To obtain proper adjustment, perform the following

procedures.

1. Loosen lock nut and turn adjustment bolt out (counterclockwise)

(

2. Disengage and engage locking plungers. Verify that plungers have engaged properly, as shown (

3. Tighten adjustment bolt until it contacts the rack.

).

LOCKED

(ENGAGED

RACK

LOCK NUT

PLUNGER

ADJUSTMENT BOLT

PLUNGER

4. Turn adjustment bolt clockwise an additional 1/2 turn, then tighten lock

nut securely.

a. Check the air cylinder for proper

operation. Replace if necessary.

b. Check plunger adjustment as

explained above.

c. If a plunger is binding in the plunger

pocket, remove the plunger using a Holland F-TLN-2500 spring compressor. Grind the top edges of the plunger 1/16”, as shown (

). Re-install and adjust

the plungers as explained above.

If problems persist, contact SAF-HOLLAND Customer Service at: 1-888-396-6501.

UNLOCKED

(RELEASED)

RACK

PLUNGER

CHECK FOR POSSIBLE

INTERFERENCE

1/16”

20

Maintenance Procedures

14. Pocket Insert Inspection

Figure 40

15. Top Plate Installation

Figure 41

Figure 42

Figure 40

Figure 42

Figure 41

NOTE:

Replace pocket inserts if:

The pocket insert thickness is 1/16” or less.

The free vertical movement of top plate on the bracket is 1/2” or greater, without compressing rubber

bushings. (

).

The pocket inserts are severely chipped, cracked or gouged.

1. If pocket inserts are dislodged from fifth wheel casting, clean pocket area of casting and apply a strip of doubleface tape in bottom of pockets. Install pocket inserts by pressing down into

pockets. (

).

1/2” MAX. (MEASURED AT EAR)

PUSH DOWN

DOUBLE-FACE TAPE

REPLACE

IF 1/16” OR LESS

POCKET INSERT

POCKET AREA

2. Using a lifting device capable of lifting 500 lbs., install the fifth wheel

top plate onto its mounting base.

Follow instructions published by lifting device manufacturer for proper operation of lifting device.

3. Install bracket pins through fifth

wheel casting and mounting base and secure by installing the bracket pin retention bolts and nuts ( Torque retention bolts not to exceed

60 ft-lbs.

TOP PLATE

RETENTION BOLT

RETENTION NUT

BRACKET PIN

).

21

Troubleshooting

Difficult to Couple to Trailer:

MUST

POSSIBLE CAUSE REMEDY

3

Attempting to couple too fast.

The trailer may be too high; the kingpin is not entering the lock properly.

Locks are closed.

Couple in accordance with the procedure in this Owner’s Manual.

Lower the trailer in accordance with manufacturer’s instructions.

If equipped with manual secondary lock, pull secondary release handle and hook on casting. Pull release handle all the way out. If air release equipped, set tractor brakes and actuate fifth

wheel control valve to open locks.

Locks may be open even if they still appear closed. Check to make sure nut and washer at front of fifth wheel are not snug against fifth wheel and that release handle is in extended “open” position. If both of these conditions exist, you can still successfully couple the fifth wheel even though the lock jaws appear closed. The movement of kingpin into fifth wheel jaws will allow a

successfully couple.

Accumulated rust or grime interfering with the lock operation.

The lock is adjusted too tightly.

The lock may be damaged.

Damaged, bent release handle.

Damaged, bent yoke shaft from improper coupling.

Bent kingpin, damaged upper coupler, or improper use of “lube plate” may be

interfering with lock movement.

Thoroughly clean the fifth wheel and relubricate in accordance with the procedure in this Owner’s

Manual.

Check lock adjustments in accordance with the procedure in this Owner’s Manual.

The fifth wheel M appropriate SAF-HOLLAND service kit.

Replace release handle using the appropriate SAF-HOLLAND service kit.

The fifth wheel M appropriate SAF-HOLLAND service kit.

Check the kingpin and upper coupler as detailed in Holland Service Bulletin XL-SB020. Repair/ replace as required. Remove any improperly installed or improperly specified lube plates. Refer to Holland Service Bulletin XL-SB004-01 for

lube plate warnings.

be rebuilt using the

22

Troubleshooting

Difficult to Uncouple from Trailer :

manual secondary

automatic secondary

MUST

POSSIBLE CAUSE REMEDY

3

The tractor may be putting pressure against locks.

Tractor too low. Raise tractor suspension to proper ride height.

The secondary lock is not released.

Accumulated rust or grime interfering with the lock operation.

The locks are adjusted too tightly.

Lock the trailer brakes and back the tractor tightly against the kingpin to relieve the pressure on the fifth wheel lock, set the brakes, then pull the release handle.

If up and lock open by hooking the handle on the top plate casting. If a for missing or broken parts and repair or replace

as required using the appropriate service kit.

Thoroughly clean the fifth wheel and relubricate in accordance with the procedure in this Owner’s

Manual.

Check lock adjustments in accordance with the procedure in this Owner’s Manual.

: pull release handle out and

: inspect

The release handle will not stay out or must be held out when unlocking.

Missing or damaged release system parts.

Casting bent/damaged at throat area, restricting movement.

Bent kingpin, damaged upper coupler, or improper use of “lube plate” may be

interfering with lock movement.

Replace the cam and release handle spring using the appropriate SAF-HOLLAND service kit.

The fifth wheel M appropriate SAF-HOLLAND service kit.

The entire fifth wheel top plate M

Check the kingpin and upper coupler as detailed in Holland Service Bulletin XL-SB020. Repair/ replace as required. Remove any improperly installed or improperly specified lube plates. Refer to Holland Service Bulletin XL-SB004-01 for

lube plate warnings.

be rebuilt using the

be replaced.

23

Troubleshooting

Excessive Movement between Fifth Wheel and Kingpin:

MUST

Hard Steering or Binding:

FW33)

FW31

Lock Pins Raising:

POSSIBLE CAUSE REMEDY

3

Fifth wheel lock requires adjustment.

Fifth wheel cannot be adjusted further.

Kingpin is loose. Repair trailer.

Kingpin is worn.

POSSIBLE CAUSE REMEDY

3

Warped trailer upper coupler plate.

Follow the procedures contained in this Owner’s Manual.

The fifth wheel M appropriate SAF-HOLLAND service kit.

Check kingpin for acceptable wear with Holland TF-0110. Replace kingpin, if necessary.

Check upper coupler for flatness and replace, if necessary. Refer to Holland Service Bulletin

XL-SB020.

be rebuilt using the

3

POSSIBLE CAUSE REMEDY

Kingpin too short or improperly installed “lube plates”.

Locks are too tight around kingpin.

Kingpin is worn.

Kingpin/Locks not lubricated well enough.

Lock pins not lubricated well enough. Lubricate lock pins with Never-Seez®.

If issues persist:

Check the kingpin and upper coupler as detailed in Holland Service Bulletin XL-SB020. Repair/ replace as required. Remove any improperly installed or improperly specified lube plates. Refer to Holland Service Bulletin XL-SB004-01 for lube plate warnings. Check if there is evidence on bottom of locks of kingpin making contact and

“lifting” the locks.

Check lock adjustments in accordance with the procedure in this Owner’s Manual.

Check kingpin for acceptable wear with the Holland part TF-0110. Replace the kingpin if

necessary.

Relubricate in accordance with the procedures in this Owner’s Manual.

Order lock pin repair kit with retaining rings and shims, RK-07292-82 (F

(F

).

or RK-07292-2

24

Rebuild and Replacement Kits

Rebuild and Replacement Kits FW31 FW33

Rebuild Kit-Standard Left Hand Release RK-311-A-L RK-351-A-L

Rebuild Kit-Standard Right Hand Release RK-311-A RK-351-A Rebuild Kit-Left Hand Release

with Manual Secondary Lock Rebuild Kit-Right Hand Release

with Manual Secondary Lock

Rebuild Kit-Air Release RK-311-A-80-L RK-351-A-80-L

Lock Replacement Kit RK-311-LK RK-351-07296

Lock Yoke Replacement Kit RK-311-10257 RK-351-07295

Cam Plate Pivot Bolt Hardware Replacement Kit RK-311-2083 RK-351-2083

Cam Plate Roller Bolt Hardware Replacement Kit RK-311-10343 RK-351-1507

Lock Pins Replacement Kit RK-07292-2 RK-07292-82

Release Handle Replacement Kit-Left or Right Hand RK-311-10344 RK-08415-1

RK-311-A-02-L RK-351-A-02-L

RK-311-A-02 RK-351-A-02

Air Release Replacement Kit RK-10506-1 RK-09649

Lock Adjustment Tag Replacement Kit RK-351-02312

Lube Plate Inserts-Pair RK-331-1

Pocket Inserts-Pair RK-PKT-2

25

26

Notes

27

Notes

SAF XL-FW10028OM User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual