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XL-FW10009UM-en-US Rev F

Owner’s Manual

FW35 Series Fifth Wheel

Operation, Maintenance and
Troubleshooting Procedures

Summary of Contents for FW35 Series

Page 1: ...XL FW10009UM en US Rev F Owner s Manual FW35 Series Fifth Wheel Operation Maintenance and Troubleshooting Procedures ...

Page 2: ...t 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 I...

Page 3: ...d alert messages The alerts provide information that can help prevent serious personal injury damage to components or both Failure to follow the instructions and safety precautions in this manual could result in improper servicing or operation leading to component failure which if not avoided could result in death or serious injury All fifth wheel installation and maintenance MUST be performed by ...

Page 4: ... fifth wheel Tuerca y arandela ajustadas contra la quinta rueda Écrou et rondelle serrés contre la sellette 3 Locks completely closed around kingpin Seguros completamente cerrados alrededor del perno rey Mâchoires complètement fermées sur le pivot SIEMPRE inspeccione la quinta rueda después de acoplar el tractocamión al remolque Si no acopla adecuadamente el tractocamión y el remolque podría ocasi...

Page 5: ...cations IMPORTANT SAF HOLLAND definition 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 4 Approved applications Van Trailers Tanker Dry Bulk Trailers Vacuum Tankers Flatbed Stretch Pole Trailers End Dump Framed Trailers End Dump Frameless Trailers Bottom D...

Page 6: ...peration of the fifth wheel 4 The attachment of lifting devices 5 The transport of loads in excess of rated capacity 6 Applications other than those recommended in the SAF HOLLAND Fifth Wheel Catalog Specification Guide Document No XL FW10066SG en US available on the internet at www safholland us Use of fifth wheel in non intended applications could result in tractor trailer separation which if no...

Page 7: ... fifth wheel release valve until the locking mechanism opens and locks into place Release the pull valve Release the tractor parking brake 5 Visually inspect the fifth wheel throat to ensure that the locks are completely open and ready to accept the kingpin Figure 7 6 If the locks are NOT completely open Figure 7 check the following a Nut and washer at the front of the fifth wheel are NOT snug aga...

Page 8: ...ure that the fifth wheel is below the upper coupler plate Verify proper fifth wheel height If the trailer is too low use the landing gear to raise the trailer height NOTE For proper operation of landing gear follow the instructions published by the landing gear manufacturer 7 Slowly back up using the lowest gear possible Stop when the fifth wheel is under the leading edge of the trailer Figure 10 ...

Page 9: ...r engaging the kingpin into the fifth wheel 11 Connect the air and electrical lines 12 Raise the landing gear legs until the pads are just above the ground 13 Perform a pull test as an INITIAL CHECK by locking the trailer brakes and pulling forward with the tractor to ensure that tractor trailer separation DOES NOT occur Figure 12 14 Place the tractor into neutral and set the parking brake 15 Exit...

Page 10: ...sult in death or serious injury IMPORTANT DO NOT use any fifth wheel that fails to operate properly Failure to repair a malfunctioning fifth wheel before use could result in tractor trailer separation which if not avoided could result in death or serious injury 17 Fully retract the landing gear legs off the ground and secure the crank handle Figure 16 NOTE For proper operation of landing gear foll...

Page 11: ...g air from the tractor suspension before uncoupling could result in difficulty uncoupling the tractor from the trailer which if not avoided could result in damage to the fifth wheel and kingpin 5 Chock the trailer wheels 6 Lower the landing gear until the pads just touch the ground Figure 17 NOTE For proper operation and ability to transfer the trailer weight from the fifth wheel follow the instru...

Page 12: ...wheel is below the contact surface of the trailer Figure 22 13 Visually inspect uncoupling Ensure that the trailer is completely supported by the landing gear 14 Release the tractor parking brake and slowly pull away from the trailer 15 Apply air to the tractor air suspension and allow the suspension to return to ride height Figure 23 9 Positioning Sliding Fifth Wheels NEVER reposition a sliding f...

Page 13: ...se lever If the plungers DO NOT come out lower the landing gear to relieve pressure on the fifth wheel This will allow the fifth wheel to slide easier NOTE Cab switch style may differ by OEM 4 Visually inspect and verify that the plungers are disengaged Figure 25 ILS Sliders Figure 26 Severe Duty Sliders Figure 27 Traditional Sliders 5 Release the tractor parking brake while keeping the trailer br...

Page 14: ...locking plungers by moving the cab switch to the lock position Figure 28 If equipped with manual slide release Traditional Sliders only pull the release arm to allow the plungers to retract 8 Place the tractor into neutral and set the parking brake 9 Visually inspect the plungers to ensure proper engagement Figure 29 ILS Sliders Figure 30 Severe Duty Sliders Figure 31 Traditional Sliders 10 Retrac...

Page 15: ...ld cause loss of vehicle control which if not avoided could result in death or serious injury 10 Fifth Wheel Maintenance IMPORTANT All maintenance MUST be performed by a properly trained technician using proper tools and safety procedures IMPORTANT All maintenance MUST be performed while the tractor is uncoupled from the trailer Failure to properly maintain the fifth wheel could result in tractor ...

Page 16: ...care NOT to lose the pocket inserts Failure to prevent pocket inserts from falling out of the top plate could cause a potentially hazardous situation which if not avoided could result in minor or moderate injury 1 Remove the bracket pin retention nuts and bolts from both sides of the fifth wheel top plate Figure 33 2 Using a pry bar pull the bracket pins out of the fifth wheel top plate Figure 33 ...

Page 17: ...MPORTANT For fifth wheels that operate in snowy or icy winter conditions lubrication should be performed every spring in addition to routine lubrication as noted above to ensure optimum operation 12 1 Proper Lubrication Method 1 Remove old grease and debris from all fifth wheel to trailer contact surfaces Apply new water resistant lithium based grease to all fifth wheel to trailer contact surfaces...

Page 18: ...linder 8 Remove the supply air line and add two to four 2 4 drops of air tool oil to the cylinder through the supply fitting Re install the supply air line Figure 37 9 Activate and de activate the air cylinder two to three 2 3 times to work the air tool oil into the cylinder and onto the piston and verify proper operation 12 2 As Needed Lubrication Maintain lubrication on fifth wheel to trailer co...

Page 19: ... 40 IMPORTANT DO NOT use any abrasives on the exposed shaft as abrasives could damage the piston shaft 2 Remove the supply air line and add two to four 2 4 drops of air tool oil to the cylinder through the supply fitting Re install the supply air line Figure 41 3 Activate and de activate the air cylinder two to three 2 3 times to work the air tool oil into the cylinder and onto the piston and veri...

Page 20: ...l into the cylinder and onto the piston and verify proper operation 14 Fifth Wheel Adjustment Fifth wheel adjustments should be performed at a minimum of every 60 000 miles or if excessive movement between the kingpin and fifth wheel is noticed while driving the vehicle IMPORTANT Excessive movement between the tractor and trailer can affect vehicle handling Failure to maintain proper fifth wheel a...

Page 21: ...lock tester position the adjustment nut on the yoke shaft so that it is slightly compressing the rubber washer making it difficult to turn by hand Figure 47 5 Turn the adjustment nut one 1 additional turn clockwise to further compress the rubber washer Figure 48 IMPORTANT Over compressing the rubber washer with additional turns will take the fifth wheel out of proper adjustment and degrade the per...

Page 22: ...Verify that the locking plungers have engaged properly Figures 50 and 51 3 Tighten the adjustment bolt until it contacts the rack 4 Turn the adjustment bolt clockwise an additional 1 2 turn then tighten the lock nut securely If the locking plungers DO NOT release fully to allow the fifth wheel to slide Check the air cylinder for proper operation Replace if necessary Check the locking plunger adjus...

Page 23: ...re is more than 1 4 6 4 mm free vertical movement the top plate should be removed for further inspection Refer to Section 11 for top plate removal instructions Upshock Cushions 1 Standard Cushion Figure 54 Replace if The hole is elongated to more than 1 3 8 34 9 mm The upshock cushions are cracked cut or otherwise severely damaged 2 ILS Style Cushion Figure 55 Replace if The hole is elongated to m...

Page 24: ...less The pocket inserts are severely chipped cracked or gouged Brackets 1 Standard Bracket Figure 57 and ILS Style Bracket Figure 58 Replace if The thickness of the bracket cap at the top measured approximately 1 4 6 4 mm in from the edge is less than 3 8 9 5 mm The brackets are gouged cracked or otherwise severely damaged STANDARD BRACKET REPLACE BRACKETS IF 3 8 9 5 mm OR LESS EITHER SIDE MEASURE...

Page 25: ...vice 3 Install the bracket pins through the fifth wheel casting and mounting base and secure by installing the bracket pin retention bolts and nuts Figure 60 Torque the retention fasteners to 50 60 ft lbs 68 81 N m 17 1 No Tilt Fifth Wheels After installing the top plate onto the mounting base re install the no tilt shaft assembly by orienting the top plate so the top plate and mounting base no ti...

Page 26: ...built using the appropriate service kit The air cylinder may be dry inside Disconnect the air line at the air cylinder and add 2 3 drops of air tool oil Reconnect and activate air a few times Refer to Section 12 in this manual The release handle may be damaged or bent Replace the release handle using the appropriate service kit The air cylinder tube and or shaft on air release equipped fifth wheel...

Page 27: ...e appropriate service kit The air cylinder tube and or shaft on air release equipped fifth wheels may be dented bent or otherwise damaged Replace the air cylinder using the appropriate service kit The air release system on the tractor is not functioning properly Disconnect the air line at the air cylinder and operate the fifth wheel manually If the fifth wheel functions properly contact the truck ...

Page 28: ... grime are interfering with the release mechanism Clean the mechanism and add light oil to the plunger to bracket contact area Refer to Figures 25 27 and 29 31 The air cylinder tube and or shaft may be dented bent or otherwise damaged Replace the air cylinder using the appropriate service kit The air cylinder may be dry inside Disconnect the air line at the air cylinder and add 2 3 drops of air to...

Page 29: ...ock Adjustment Tag and Hardware RK 351 12416 Pocket Inserts Pair RK PKT 2 19 Rebuild and Replacement Kits POSSIBLE CAUSE SOLUTION The kingpin is too short or the lube plates are improperly installed Check the kingpin and upper coupler plate as detailed in HOLLAND Service Bulletin XL SB020 Repair replace as required Remove any improperly installed or improperly specified lube plates Refer to HOLLAN...

Page 30: ...30 XL FW10009UM en US Rev F 2021 06 16 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 Notes ...

Page 31: ...XL FW10009UM en US Rev F 2021 06 16 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 31 Notes ...

Page 32: ...al component assembly SAF HOLLAND Original Parts are tested and designed to provide maximum performance and durability Will fits look alikes or worse yet counterfeit parts will only limit the performance potential and could possibly void SAF HOLLAND s warranty Always be sure to spec SAF HOLLAND Original Parts when servicing your SAF HOLLAND product SAF HOLLAND USA INC 1950 Industrial Blvd Muskegon...

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