SAF-HOLLAND FWAL Series Rebuild/Repair Manual Download Page 1

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XL-FW535 Rev G

AL Aluminum NoLube

™

Series

Fifth Wheels

RK-AL-A-L, RK-AL-A-L-MET and RK-AL-A-80-L
Rebuild Kits



FWAL Assembly Series



XA-AL Top Plate Series

Rebuild/Repair Manual

Summary of Contents for FWAL Series

Page 1: ...XL FW535 Rev G AL Aluminum NoLube Series Fifth Wheels RK AL A L RK AL A L MET and RK AL A 80 L Rebuild Kits FWAL Assembly Series XA AL Top Plate Series Rebuild Repair Manual ...

Page 2: ...mance of procedures IMPORTANT Includes additional information that if not 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 ...

Page 3: ...l 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 Figure 1 The part number and serial number are listed on the tag Figure 2 Figure 2 U S AND FOREIGN PATENTS APPLY Model No XXXXXXXXXXXXXXXXXX Serial No XXXXXXXXXXXXXXXXXX FAILURE TO PROPERLY INSTALL MAINTAIN OPERATE THIS PRODUCT COULD RESULT IN TRACTOR TRAILER SEPARATION ...

Page 4: ...3 3 RK AL 11078 Lock Standard 5 10 4 21 22 8 9 7 RK PKT 3 Pocket Inserts 28 27 24 33 32 23 RK 06973 1 Bracket Pins and Cushions 11 24 34 34 32 23 RK 10605 Bracket Pins and Bushings ILS HANDLE SUPPORT BRACKET AND HARDWARE BOTTOM PLATE AND HARDWARE 30 29 31 RK 331 1 Lube Plate 11 13 14 RK 10495 AL P Release Handle Left Hand RK AL 11798 Bracket Shims and Rubber Washers 26 25 RK AL 1 Lube Plate and Po...

Page 5: ...T ITEM DESCRIPTION PART NUMBER QTY 11 Release Handle Left Hand XA 10495 AL P 1 13 Extension Spring Outer Handle XB 10490 P 1 14 Extension Spring Inner Handle XB 10489 P 1 RK AL 11798 PARTS LIST ITEM DESCRIPTION PART NUMBER QTY 25 Bracket Shim XA 11798 4 26 Rubber Washer XB 60144 2 RK PKT 3 PARTS LIST ITEM DESCRIPTION PART NUMBER QTY 27 Pocket Insert XD 10923 2 28 Double Face Tape XB 09422 4 RK AL ...

Page 6: ...3 3 11 HANDLE SUPPORT BRACKET AND HARDWARE LUBE PLATES ON TOP OF FIFTH WHEEL AND CONNECTING HARDWARE BOTTOM PLATE AND HARDWARE RK AL 11078 Lock Standard 5 10 4 21 22 8 9 7 RK PKT 3 Pocket Inserts 28 27 24 33 32 23 RK 06973 1 Bracket Pins and Cushions 24 34 34 32 23 RK 10605 Bracket Pins and Bushings ILS 30 29 31 RK 331 1 Lube Plate 11 13 14 RK 10495 AL P Release Handle Left Hand RK AL 11798 Bracke...

Page 7: ...PARTS LIST ITEM DESCRIPTION PART NUMBER QTY 11 Release Handle Left Hand XA 10495 AL P 1 13 Extension Spring Outer Handle XB 10490 P 1 14 Extension Spring Inner Handle XB 10489 P 1 RK AL 11798 PARTS LIST ITEM DESCRIPTION PART NUMBER QTY 25 Bracket Shim XA 11798 4 26 Rubber Washer XB 60144 2 RK PKT 3 PARTS LIST ITEM DESCRIPTION PART NUMBER QTY 27 Pocket Insert XD 10923 2 28 Double Face Tape XB 09422...

Page 8: ...28 27 RK AL10999 Air Cylinder RK AL 1 Lube Plate and Pocket Inserts 30 29 27 28 27 31 30 29 31 RK 331 1 Lube Plate 24 33 32 23 RK 06973 1 Bracket Pins and Cushions 24 34 32 23 RK 10605 Bracket Pins and Bushings ILS 34 4 7 15 8 9 40 38 36 37 38 13 35 5 20 18 17 16 12 6 21 10 41 40 39 18 16 17 19 24 23 22 1 2 3 3 11 HANDLE SUPPORT BRACKET AND HARDWARE LUBE PLATES ON TOP OF FIFTH WHEEL AND CONNECTING...

Page 9: ...x Head Cap Screw M12 x 1 75 x 20 mm Class 10 9 XB HCS M12 20 Z 2 40 Hardened Steel Washer 1 2 I D x 1 O D XB 06378 1 RK AL 11798 PARTS LIST BRACKET SHIMS AND RUBBER WASHERS ITEM DESCRIPTION PART NUMBER QTY 25 Bracket Shim XA 11798 4 26 Rubber Washer XB 60144 2 RK PKT 3 PARTS LIST POCKET INSERTS ITEM DESCRIPTION PART NUMBER QTY 27 Pocket Insert XD 10923 2 28 Double Face Tape XB 09422 4 RK AL 11384 ...

Page 10: ... 4 4 Using a lifting device capable of lifting 500 lbs 227 kg remove top plate from mounting base Place fifth wheel right side up on a flat clean working area NOTE Follow instructions published by lifting device manufacturer for proper operation of lifting device 5 Thoroughly steam clean the top plate surface and front lock region 4 Front Lock Insert Installation 1 Push front lock insert and inser...

Page 11: ...th cracks MUST be replaced The lock pin and adjusting pin on FWAL Series are slip fit They are not designed to be press fit like other HOLLAND fifth wheels However if either hole is elongated the top plate must be replaced NOTE The maximum allowable lock pin hole diameter is 1 426 36 30 mm The maximum allowable adjusting pin hole diameters are 1 672 42 47 mm top and 1 172 29 77 mm bottom Failure t...

Page 12: ... RING RETAINING RING HOOK PIN HOOK PIN GREASE Figure 11 4 Install the hook pin into the hook s small hole with the rounded head toward the top plate 5 Place the release cam over the hook pin Figure 9 6 Install the 3 4 diameter retaining ring Ensure the retaining ring is fully seated in the hook pin groove Figure 10 7 Lubricate the adjusting pin the lock pin and the lock Figure 11 Figure 9 Figure 1...

Page 13: ...ting pin so that it lines up with the first adjustment notch Figure 12 The adjusting pin will turn counter clockwise to adjust 9 Place the 1 1 8 diameter retaining ring on the adjusting pin Figure 13 Shim rings may be used to reduce the gap between the bottom plate and the adjusting pin retaining ring Two 2 shim rings are included in rebuild kits RK AL A L RK AL A L MET and RK AL A 80 L if needed ...

Page 14: ...handle S bend through the handle support bracket window Figure 14 2 Unfasten the handle support bracket and hardware in order to install the release handle S bend through the end of the release cam with the S bend facing down Figure 15 3 Refasten the handle support bracket and hardware Figure 16 Tighten to 11 13 ft lbs 15 88 N m HANDLE SUPPPORT BRACKET WINDOW S BEND OF HANDLE THROUGH END OF RELEAS...

Page 15: ...Loosely secure the air cylinder to the top plate using the M12 x 1 75 x 20 mm hex head cap screws and a 1 2 I D x 1 O D hardened steel washer on the side nearest the air cylinder rod only Figure 17 2 Install one end of the handle extension spring to the hole in the air cylinder bracket on the side opposite the air cylinder rod Figure 18 3 Insert the release handle through the handle support bracke...

Page 16: ...ened steel washers in order as illustrated over the hex head cap screw c Secure the assembly with the M12 x 1 75 lock nut and tighten to 40 50 ft lbs 54 68 N m 6 Position the release handle to allow room for securing the air cylinder pickup to the release handle using the 1 4 20 x 5 8 hex head cap screws Figure 21 Tighten to 7 9 ft lbs 9 5 12 N m 7 Lubricate the release handle and air cylinder pic...

Page 17: ...ylinder such that the release handle is fully extended Air pressure to be set at approximately 100 psi b Position the loosely bolted air cylinder such that the release handle is against the window of the handle support bracket and the air cylinder rod is centered in the V of the air cylinder pickup c Keeping the air cylinder in place tighten the two M12 x 1 75 x 20 mm hex head cap screws to 40 50 ...

Page 18: ...eel top plate c Install the lock extension spring by hooking one end to the hole on the lock and the other end to the fifth wheel top plate Make sure both spring hook ends face away from the fifth wheel top plate 8 2 Air Release 1 Refer to Figure 26 for the following three 3 steps a Connect the loose end of the release handle extension spring to the air cylinder pickup Make sure the spring hook en...

Page 19: ...ard the release cam and align the hole with the tapped boss of the top plate b Position the release cam bushing within the release cam slot and place the remaining 1 2 I D x 2 1 4 O D washer on top of the bushing and release cam with the rounded side of the washer toward the release cam and align the holes over the tapped boss of the top plate c Secure the assembly by inserting the 1 2 20 x 1 3 4 ...

Page 20: ...hing bracket shims are required for each pocket on both sides of the mounting bracket Replace bracket shims with kit RK AL 11798 if Any of the bracket shims are missing Bracket shims are cracked severely bent or worn NOTE For fifth wheels that DO NOT require bracket shims refer to Section 12 Top Plate Installation 1 If pocket inserts are dislodged from fifth wheel top plate clean pocket area of fo...

Page 21: ...maining metal bracket shim between the other inside ear and mounting bracket IMPORTANT If there is NOT enough room for the rubber washers to be installed or when installed the fifth wheel DOES NOT freely articulate remove rubber washers and install metal bracket shims only 9 Secure bracket pins by installing the 1 2 20 x 1 1 4 hex head cap screws and 1 2 20 lock nuts Figure 32 Torque the hex head ...

Page 22: ... 2 Set lock tester on fifth wheel top plate 3 To lock fifth wheel rotate handle on lock tester clockwise until the locks close around the kingpin Figure 34 4 Slide the lock tester forward and backward while the lock is closed to check for play between lock and kingpin Ensure that the tool remains flat with full contact on the fifth wheel top plate Use a pin gage to measure for free play lf free pl...

Page 23: ...ock should NOT grip the kingpin and the tool should rotate freely Figure 38 9 Re check for free play in the lock by sliding the lock tester forward and backward while measuring free play with a pin gage Figure 38 Free play should be 0 040 1 02 mm minimum If free play still exceeds 0 080 2 03 mm repeat procedure and adjust one more notch 10 Slide the fifth wheel release handle forward and pull comp...

Page 24: ... A SAF HOLLAND GmbH and SAF HOLLAND Inc From fifth wheel rebuild kits to suspension bushing repair kits SAF HOLLAND Original Parts are the same quality components used in the original 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 c...

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