SAF-HOLLAND FWAL Series User manual

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

2XL-FW535 Rev G · 2014-08-11 · 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.
Contents
Contents Page
Introduction..........................................................................2
Notes, Cautions, and Warnings ..............................................2
Section 1 – General Safety Instructions .................................2
Section 2 – Model Identification............................................3
XA-AL Series Exploded View (Prior to May 2013).................. 4
XA-AL Series Parts List (Prior to May 2013) ...........................5
XA-AL Series Exploded View (After May 2013) ......................6
XA-AL Series Parts List (After May 2013)...............................7
XA-AL-A-80-L (Air Release) Exploded View............................8
XA-AL-A-80-L (Air Release) Parts List ....................................9
Section 3 – Top Plate Removal.............................................10
Section 4 – Front Lock Insert Installation.............................10
Contents Page
Section 5 – Disassembly and Inspection ..............................10
Section 6 – Hook and Lock Installation................................11
Section 7 – Release Handle Installation...............................14
Section 8 – Springs Installation...........................................18
Section 9 – Release Cam Pivot Bolt Installation................... 19
Section 10 – Pocket Insert Inspection .................................. 20
Section 11 – Top Plate Installation
(for fabricated mounting brackets)....................... 20
Section 12 – Top Plate Installation
(for cast mounting brackets)........................... 21
Section 13 – Fifth Wheel Adjustment .................................. 22
Introduction
This manual provides the information necessary to properly
rebuild the HOLLAND®FWAL/XA-AL Series Fifth Wheels.
Read this manual before using or servicing this product and
keep it in a safe location for future reference. Updates to this
manual, which are published as necessary, are available on
the internet at www.safholland.us.
When replacement parts are required, SAF-HOLLAND®highly
recommends the use of only SAF-HOLLAND®Original Parts. A
list of technical support locations that supply SAF-HOLLAND®
Original Parts and an Aftermarket Parts Catalog are available
on the internet at www.safholland.us or contact Customer
Service at 888-396-6501.
Notes, Cautions, and Warnings
Before starting any work on the unit, read and understand all
the safety procedures presented in this manual. This manual
contains the terms “NOTE”, “IMPORTANT”, “CAUTION”, and
“WARNING” followed by important product information. These
terms are defined as follows:
NOTE: Includes additional information to enable accurate
and easy performance 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
situation which, if not avoided, could
result in death or serious injury.
1. General Safety Instructions
Read and observe all Warning and Caution hazard 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 repair and maintenance should be performed by a properly
trained technician using proper/special tools, and safe procedures.
NOTE: In the United States, workshop safety requirements
are defined by federal and/or state Occupational
Safety and Health Act (OSHA). Equivalent laws
could 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 work is performed.
NOTE: Before rebuilding the HOLLAND®Fifth Wheel
review the model number on the identification
tag. This rebuild procedure applies only to model
FWAL/XA-AL fifth wheel top plates.
IMPORTANT: All maintenance must be performed while
the tractor is uncoupled from the trailer.
IMPORTANT: These instructions apply to the proper rebuild
of FWAL/XA-AL Series fifth wheel top plates
only.There are other important checks,
inspections, and procedures not listed here that
are necessary, prudent, and/or required by law.
For proper installation procedures, refer to Installation Manual
XL-FW10008BM-en-US available on the internet at www.safholland.us.
IMPORTANT: Prior to operation of the fifth wheel, verify that the
fifth wheel has been properly installed on the vehicle.
Failure to properly repair and install the fifth
wheel could adversely affect performance
resulting in tractor trailer separation which, if
not avoided, could result in death or serious injury.

3
XL-FW535 Rev G · 2014-08-11 · 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.
Model Identification
3
Figure 1
2. Model Identification
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 (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 CAUSING SERIOUS INJURY OR DEATH.
MADE IN
XXXXXX

4XL-FW535 Rev G · 2014-08-11 · 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.
XA-AL Series Exploded View (Prior to May 2013)
4
7
15
8
9
14
13
5
20
18
17
16
12
6
21
10
17
19
24 23
22
1
23
3
RK-AL-11078
Lock, Standard
510
4
21
22
8
97
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 Pocket Inserts
30 29
27
28
27
31
LUBE PLATES (ON TOP
OF FIFTH WHEEL) AND
CONNECTING HARDWARE

5
XL-FW535 Rev G · 2014-08-11 · 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.
XA-AL Series Parts List (Prior to May 2013)
*Not sold individually – must be purchased in a kit.
FWAL RK-AL-A-L KIT PARTS LIST (PRIOR TO MAY 2013)
ITEM DESCRIPTION PART NUMBER QTY.
1* Front Lock Insert XD-10680-P 1
2Insert Keeper XA-10706-P 1
3
Low Head Socket Cap Screw,
3/8"-16 x 3/4" Long XB-02724-1 2
4* Lock XA-11693-P 1
5* Hook XA-10487-P 1
6 Release Cam, Left-Hand Release XA-10483-AL 1
7 Lock Pin XA-06344-AL 1
8 Retaining Ring, 1-3/8" Dia. XB-08905 1
9 Adjusting Pin XA-10364-3-AL-P 1
10 Retaining Ring, 1-1/8" Dia. XB-05855 1
11* Release Handle, Left-Hand XA-10495-AL-P 1
12 Extension Spring, Release Cam XB-10563-1-P 1
13 Extension Spring, Outer Handle XB-10490-P 1
14 Extension Spring, Inner Handle XB-10489-P 1
15 Extension Spring, Lock XB-05843-1-P 1
16 Hex Head Cap Screw, 1/2"-20 x 1-3/4" XB-2083 1
17
Washer, 1/2" I.D. x 2-1/4" O.D.,
Stainless Steel XB-10294 2
18 Release Cam Bushing XA-10810-1 1
19 Hook Pin XA-10485-1 1
20 Retaining Ring, 3/4" Dia. XB-05855-1 1
21 Shim Ring XB-05859-2 2
22 Never-Seez®, 7.5 g Tube XB-02967 1
23 Hex Head Cap Screw, 1/2"-20 x 1-1/4" XB-C-95 2
24 Lock Nut, 1/2"-20 XB-T-69-A 2
RK-10495-AL-P 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 4
RK-AL-11078 PARTS LIST
ITEM DESCRIPTION PART NUMBER QTY.
4* Lock XA-11693-P 1
5* Hook XA-10487-P 1
7 Lock Pin XA-06344-AL 1
8 Retaining Ring, 1-3/8" Dia. XB-08905 1
9 Adjusting Pin XA-10364-3-AL-P 1
10 Retaining Ring, 1 -1/8" Dia. XB-05855 1
21 Shim Ring XB-05859-2 2
22 Never-Seez®, 7.5 g Tube XB-02967 1
RK-AL-1 PARTS LIST
ITEM DESCRIPTION PART NUMBER QTY.
29* Lube Plate, Left-Hand XA-08125-L 1
30* Lube Plate, Right-Hand XA-08125-R 1
31 Lock Nut, 5/16"-18 XB-08931 16
27* Pocket Insert XD-10923 2
28* Double Face Tape XB-09422 4
RK-331-1 PARTS LIST
ITEM DESCRIPTION PART NUMBER QTY.
29* Lube Plate, Left-Hand XA-08125-L 1
30* Lube Plate, Right-Hand XA-08125-R 1
31 Lock Nut, 5/16"-18 XB-08931 16
RK-06973-1 PARTS LIST
ITEM DESCRIPTION PART NUMBER QTY.
23 Hex Head Cap Screw, 1/2"-20 x 1-1/4" XB-C-95 2
24 Lock Nut, 1/2"-20 XB-T-69-A 2
32 Bracket Pin XE-06356-P 2
33 Rubber Cushion (for fabricated brackets) XB-0011-2 2
RK-10605 PARTS LIST
ITEM DESCRIPTION PART NUMBER QTY.
23 Hex Head Cap Screw, 1/2"-20 x 1-1/4" XB-C-95 2
24 Lock Nut, 1/2"-20 XB-T-69-A 2
32 Bracket Pin XE-06356-P 2
34 Rubber Cushion (for cast brackets) XB-10605 4

6XL-FW535 Rev G · 2014-08-11 · 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.
XA-AL Series Exploded View (After May 2013)
40
4
7
15
8
9
14
13
5
20
18
17
16
12
6
21
10
17
19
24 23
22
1
23
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
510
4
21
22
8
97
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
Bracket Shims and Rubber Washers
26
25
RK-AL-1
Lube Plate and Pocket Inserts
30 29
27
28
27
31

7
XL-FW535 Rev G · 2014-08-11 · 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.
XA-AL Series Parts List (After May 2013)
*Not sold individually – must be purchased in a kit.
FWAL RK-AL-A-L MET KIT PARTS LIST (AFTER MAY 2013)
ITEM DESCRIPTION PART NUMBER QTY.
1* Front Lock Insert XD-10680-P 1
2Insert Keeper XA-10706-P 2
3
Low Head Socket Cap Screw,
M10 x 1.5 x 16 mm Long XB-02724-M 3
4* Lock XA-11693-P 1
5* Hook XA-10487-P 1
6 Release Cam, Left-Hand Release XA-10483-AL 1
7 Lock Pin XA-06344-AL 1
8 Retaining Ring, 1-3/8" Dia. XB-08905 1
9 Adjusting Pin XA-10364-3-AL-P 1
10 Retaining Ring, 1-1/8" Dia. XB-05855 1
11* Release Handle, Left-Hand XA-10495-AL-P 1
12 Extension Spring, Release Cam XB-10563-1-P 1
13 Extension Spring, Outer Handle XB-10490-P 1
14 Extension Spring, Inner Handle XB-10489-P 1
15 Extension Spring, Lock XB-05843-1-P 1
16
Hex Head Cap Screw
M12 x 1.75 x 40 mm Long XB-HCS-M12-40-Z 1
17
Washer, 1/2" I.D. x 2-1/4" O.D.,
Stainless Steel XB-10294 2
18 Release Cam Bushing XA-10810 1
19 Hook Pin XA-10485-1 1
20 Retaining Ring, 3/4" Dia. XB-05855-1 1
21 Shim Ring XB-05859-2 2
22 Never-Seez®, 7.5 g Tube XB-02967 1
23 Hex Head Cap Screw, 1/2"-20 x 1-1/4" XB-C-95 2
24 Lock Nut, 1/2"-20 XB-T-69-A 2
RK-10495-AL-P 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 4
RK-AL-11078 PARTS LIST
ITEM DESCRIPTION PART NUMBER QTY.
4* Lock XA-11693-P 1
5* Hook XA-10487-P 1
7 Lock Pin XA-06344-AL 1
8 Retaining Ring, 1-3/8" Dia. XB-08905 1
9 Adjusting Pin XA-10364-3-AL-P 1
10 Retaining Ring, 1 -1/8" Dia. XB-05855 1
21 Shim Ring XB-05859-2 2
22 Never-Seez®, 7.5 g Tube XB-02967 1
RK-AL-1 PARTS LIST
ITEM DESCRIPTION PART NUMBER QTY.
29* Lube Plate, Left-Hand XA-08125-L 1
30* Lube Plate, Right-Hand XA-08125-R 1
31 Lock Nut, 5/16"-18 XB-08931 16
27* Pocket Insert XD-10923 2
28* Double Face Tape XB-09422 4
RK-331-1 PARTS LIST
ITEM DESCRIPTION PART NUMBER QTY.
29* Lube Plate, Left-Hand XA-08125-L 1
30* Lube Plate, Right-Hand XA-08125-R 1
31 Lock Nut, 5/16"-18 XB-08931 16
RK-06973-1 PARTS LIST
ITEM DESCRIPTION PART NUMBER QTY.
23 Hex Head Cap Screw, 1/2"-20 x 1-1/4" XB-C-95 2
24 Lock Nut, 1/2"-20 XB-T-69-A 2
32 Bracket Pin XE-06356-P 2
33 Rubber Cushion (for fabricated brackets) XB-0011-2 2
RK-10605 PARTS LIST
ITEM DESCRIPTION PART NUMBER QTY.
23 Hex Head Cap Screw, 1/2"-20 x 1-1/4" XB-C-95 2
24 Lock Nut, 1/2"-20 XB-T-69-A 2
32 Bracket Pin XE-06356-P 2
34 Rubber Cushion (for cast brackets) XB-10605 4

8XL-FW535 Rev G · 2014-08-11 · 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.
XA-AL-A-80-L (Air Release) Exploded View
RK-AL-11384
Release Handle
13
41
40
39
18
16
36
37
11
RK-PKT-3
Pocket Inserts
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
23
3
11
HANDLE SUPPORT BRACKET
AND HARDWARE
LUBE PLATES (ON TOP
OF FIFTH WHEEL) AND
CONNECTING HARDWARE
BOTTOM PLATE
AND HARDWARE
RK-AL-11798
Bracket Shims and Rubber Washers
26
25
38 40 35
38

9
XL-FW535 Rev G · 2014-08-11 · 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.
XA-AL-A-80-L (Air Release) Parts List
FWAL RK-AL-A-80-L KIT PARTS LIST
ITEM DESCRIPTION PART NUMBER QTY.
1* Front Lock Insert XD-10680-P 1
2 Insert Keeper XA-10706-P 2
3
Low Head Socket Cap Screw,
M10 x 1.5 x 16 mm Long XB-02724-M 5
4* Lock XA-11693-P 1
5* Hook XA-10487-AR-P 1
6 Release Cam, Left-Hand Release XA-10483-ALA 1
7 Lock Pin XA-06344-AL 1
8 Retaining Ring, 1-3/8" Dia. XB-08905 1
9 Adjusting Pin XA-10364-3-AL-P 1
10 Retaining Ring, 1-1/8" Dia. XB-05855 1
11* Release Handle XA-AL-11384-P 1
12 Extension Spring, Release Cam XB-10563-1-P 1
13 Extension Spring, Handle XB-10490-P 1
15 Extension Spring, Lock XB-05843-1-P 1
16
Hex Head Cap Screw,
M12 x 1.75 x 40 mm Long XB-HCS-M12-40-Z 2
17
Washer, 1/2" I.D. x 2 1/4" O.D.,
Stainless Steel XB-10294 2
18 Release Cam Bushing XA-10810 2
19 Hook Pin XA-10485-1 1
20 Retaining Ring, 3/4" Dia. XB-05855-1 1
21 Shim Ring XB-05859-2 2
22 Never-Seez®, 7.5 g Tube XB-02967 1
23 Hex Head Cap Screw, 1/2"-20 x 1-1/4" XB-C-95 2
24 Lock Nut, 1/2"-20 XB-T-69-A 2
35 Air Cylinder Assembly XA-10999-AL 1
36 Air Cylinder Pickup XA-11384-ALA 1
37 Hex Head Cap Screw, 1/4"-20 x 5/8" XB-10775 3
38
Hex Head Cap Screw,
M12 x 1.75 x 20 mm, Class 10.9 XB-HCS-M12-20-Z 2
39
Hardened Steel Washer,
5/8" I.D. x 1-1/4" O.D. XB-06180 1
40
Hardened Steel Washer,
1/2" I.D. x 1" O.D. XB-06378 2
41 Lock Nut, M12 x 1.75 XB-HLN-M12-Z 1
RK-AL-10999 PARTS LIST AIR CYLINDER
ITEM DESCRIPTION PART NUMBER QTY.
35 Air Cylinder Assembly XA-10999-AL 1
38
Hex 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 PARTS LIST RELEASE HANDLE
ITEM DESCRIPTION PART NUMBER QTY.
11* Release Handle XA-AL-11384-P 1
13 Extension Spring, Handle XB-10490-P 1
16
Hex Head Cap Screw,
M12 x 1.75 x 40 mm Long XB-HCS-M12-40-Z 1
18 Release Cam Bushing XA-10810 1
36 Air Cylinder Pickup XA-11384-ALA 1
37 Hex Head Cap Screw, 1/4"-20 x 5/8" XB-10775 3
39
Hardened Steel Washer,
5/8" I.D. x 1-1/4" O.D. XB-06180 1
40
Hardened Steel Washer,
1/2" I.D. x 1" O.D. XB-06378 1
41 Lock Nut, M12 x 1.75 XB-HLN-M12-Z 1
RK-AL-1 PARTS LIST LIBE PLATES AND POCKET INSERTS
ITEM DESCRIPTION PART NUMBER QTY.
29* Lube Plate, Left-Hand XA-08125-L 1
30* Lube Plate, Right-Hand XA-08125-R 1
31 Lock Nut, 5/16"-18 XB-08931 16
27* Pocket Insert XD-10923 2
28* Double Face Tape XB-09422 4
RK-331-1 PARTS LIST LUBE PLATES
ITEM DESCRIPTION PART NUMBER QTY.
29* Lube Plate, Left-Hand XA-08125-L 1
30* Lube Plate, Right-Hand XA-08125-R 1
31 Lock Nut, 5/16"-18 XB-08931 16
RK-06973-1 PARTS LIST BRACKET PINS AND CUSHIONS
ITEM DESCRIPTION PART NUMBER QTY.
23 Hex Head Cap Screw, 1/2"-20 x 1-1/4" XB-C-95 2
24 Lock Nut, 1/2"-20 XB-T-69-A 2
32 Bracket Pin XE-06356-P 2
33 Rubber Cushion (for fabricated brackets) XB-0011-2 2
RK-10605 PARTS LIST BRACKET PINS AND ILS CUSHIONS
ITEM DESCRIPTION PART NUMBER QTY.
23 Hex Head Cap Screw, 1/2"-20 x 1-1/4" XB-C-95 2
24 Lock Nut, 1/2"-20 XB-T-69-A 2
32 Bracket Pin XE-06356-P 2
34 Rubber Cushion (for cast brackets) XB-10605 2
*Not sold individually – must be purchased in a kit.

10 XL-FW535 Rev G · 2014-08-11 · 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.
Top Plate Removal and Rebuild Procedures
3. Top Plate Removal
NOTE: Fifth wheel assembly has replaceable pocket
inserts installed between the fifth wheel top plate
and the mounting base. Take care when removing
the fifth wheel top plate NOT to lose 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 bracket pin retention bolts and nuts from both
sides of fifth wheel top plate and discard (Figure 3).
IMPORTANT: Some fifth wheel assemblies contain
bracket shims between the top plate
and the mounting base. Take care when
removing bracket pins as the bracket
shims could fall out.
2. Using a pry bar, pull bracket pins out of fifth wheel top
plate (Figure 3).
3. Remove and discard the low head socket cap screw(s),
insert keeper(s), and front lock insert (Figure 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 insert keepers into the detent
in the top plate. Secure the insert keeper(s) with the low
head socket cap screw(s) (Figure 5).
2. Install the adjusting pin low head socket cap screw.
Torque to 11-13 ft.-lb. (14-18 N•m).
5. Disassembly and Inspection
1. Using a lifting device capable of lifting 500 lbs. (227 kg),
remove top plate from mounting base. Place fifth wheel
upside down on a flat, clean working area.
NOTE: Follow instructions published by lifting device
manufacturer for proper operation of lifting device.
Figure 3
Figure 4
Figure 5
TOP PLATE
RETENTION BOLT
RETENTION NUT
BRACKET PIN PRY BAR
LOW HEAD
SOCKET CAP
SCREWS
FRONT LOCK INSERT
ADJUSTING PIN
INSERT KEEPER
PRIOR TO MAY 2013 AFTER MAY 2013
AND AIR RELEASE
INSERT KEEPERS (2)
LOW HEAD
SOCKET CAP
SCREWS (2)
FRONT LOCK INSERT ADJUSTING PIN LOW HEAD
SOCKET CAP SCREW
FRONT LOCK
INSERT
ADJUSTING
PIN
LOW HEAD
SOCKET CAP
SCREWS
INSERT
KEEPERS

11
XL-FW535 Rev G · 2014-08-11 · 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.
Rebuild Procedures
2. Completely remove and discard all components for both
top plate versions EXCEPT the lube plates, bottom plate, and
handle support bracket along with their connecting hardware.
Refer to the exploded view illustrations and parts lists for
component identification.
IMPORTANT: DO NOT remove the pocket inserts unless
they are cracked or worn. Refer to Section 9
for inspection information.
NOTE: Lock pin and adjustment pins could be difficult to
dislodge and could require force to remove.
DO NOT hit steel parts with a steel
hammer as parts could break, sending
steel fragments flying in any direction
creating a hazard which, if not avoided,
could result in minor to moderate injury.
3. Thoroughly steam clean remainder of top plate.
4. Inspect fifth wheel top plate for cracks and flatness.
Fifth wheels with 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 to replace fifth wheels with
cracks, elongated lock pin or adjusting
pin holes could result in tractor trailer
separation which, if not avoided, could
result in death or serious injury.
6 Hook and Lock Installation
1. Lubricate both holes of the hook with Never-Seez®.
Also lubricate the areas that make contact with the lock
with grease (Figure 6).
2. Lubricate both holes of the release cam with Never-Seez®
and coat the cam slot with grease (Figure 7).
3. Maneuver the hook into place and the release cam so
that it is fed through the slot in the main rib of the top
plate. Place the release cam over the hook and align the
holes as illustrated (Figure 8).
Figure 7
RELEASE CAM
LUBRICATE
WITH GREASE
LUBRICATE WITH
NEVER-SEEZ®
Figure 8
Figure 6
HOOK
NEVER-SEEZ®GREASE
RELEASE CAM
SLOT IN
MAIN RIB
ALIGN
HOLES
HOOK

12 XL-FW535 Rev G · 2014-08-11 · 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.
Rebuild Procedures
NEVER-SEEZ®
GREASE
LOCK PIN
LOCK
ADJUSTING PIN
RETAINING 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 10
HOOK PIN
HOOK
RELEASE CAM
ROUNDED HEAD TOWARD TOP PLATE

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XL-FW535 Rev G · 2014-08-11 · 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.
Rebuild Procedures
Figure 13
Figure 12
FIRST ADJUSTMENT
NOTCH
ADJUSTING
PIN
1-3/8" DIA
RETAINING RING
LOCK PIN
LOCK
HOOK
SHIM
RINGS
8. Align the hook and insert the adjusting 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.
10. Align the lock, insert the lock pin and install the 1-3/8"
diameter retaining ring to secure lock pin (Figure 13).
ADJUSTING PIN
1-1/8" DIA
RETAINING RING

14 XL-FW535 Rev G · 2014-08-11 · 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.
Figure 16
Figure 15
Figure 14
Rebuild Procedures
7. Release Handle Installation
7.1 Standard (Non-Air Release)
1. Insert the release 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 RELEASE CAM
UNFASTEN HANDLE
SUPPORT BRACKET
AND HARDWARE
REFASTEN HANDLE
SUPPORT BRACKET
AND HARDWARE
"S" BEND
OF HANDLE

15
XL-FW535 Rev G · 2014-08-11 · 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.
Rebuild Procedures
Figure 19
Figure 18
Figure 17
1/2" I.D. x 1"O.D.
HARDENED STEEL
WASHER
M12 x 1.75 x 20 mm
HEX HEAD CAP SREW
AIR CYLINDER
HOLE IN AIR
CYLINDER BRACKET
HANDLE EXTENSION SPRING
HANDLE SUPPORT
BRACKET WINDOW
NOTCH IN AIR
CYLINDER BRACKET
AIR CYLINDER ROD
7.2 Air Release
(Including Air Cylinder Installation)
1. 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
bracket window with the bend of the handle facing up
(Figure 19).
4. Maneuver the release handle through the notch in the air
cylinder bracket and place the end of the release handle
underneath the end of the release cam, aligning the
holes (Figure 19).
BEND OF
HANDLE
FACING UP
HANDLE END
UNDER CAM END,
HOLES ALIGNED

16 XL-FW535 Rev G · 2014-08-11 · 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.
Figure 22
Figure 21
Figure 20
Rebuild Procedures
5. Refer to Figure 20 for the following three (3) steps:
a. Insert the M12 x 1.75 x 40 mm hex head cap screw
through the aligned holes of the release handle and
release cam with the bolt head toward the top plate.
b. Place the release cam bushing and the hardened 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 pickup in
areas illustrated (Figure 22).
RELEASE CAM
HANDLE
RELEASE CAM BUSHING
M12 x 1.75 LOCK NUT
M12 x 1.75 x 40 mm
HEX HEAD CAP SCREW
1/4"-20 x 5/8"
HEX HEAD CAP SCREWS
AIR CYLINDER
PICKUP
LUBRICATE
LUBRICATE
1/2" I.D. x 1" O.D.
HARDENED STEEL WASHER
5/8" I.D. x 1-1/4" O.D.
HARDENED STEEL WASHER

17
XL-FW535 Rev G · 2014-08-11 · 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.
Rebuild Procedures
Figure 24
Figure 23
AIR CYLINDER
FITTING
AIR CYLINDER ROD
M12 x 1.75 x 20 mm
HEX HEAD CAP SCREW
RELEASE
HANDLE
AGAINST
BRACKET
WINDOW
8. Connect a 1/4" air line by inserting it into the air cylinder
fitting (Figure 23).
9. Refer to Figure 24 for the following four (4) steps:
a. Turn on the air supply to pressurize the air cylinder
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 ft.-lbs. (54-68 N•m).
d. Release the pressure from the air cylinder and verify
that the cylinder rod retracts fully. Replace air cylinder
if it is faulty.
Failure to replace a faulty air cylinder
could result in tractor trailer separation
which, if not avoided, could result in
death or serious injury.
"V" OF AIR
CYLINDER PICKUP

18 XL-FW535 Rev G · 2014-08-11 · 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.
Rebuild Procedures
Figure 26
Figure 25
8. Springs Installation
8.1 Standard (Non-Air Release)
1. Refer to Figure 25 for the following three (3) steps:
a. Hook one end of the release handle extension springs
(smaller diameter spring inside the larger diameter
spring) onto the release handle and the other end to
the fifth wheel top plate. Make sure the spring hook
ends face away from the fifth wheel top plate.
b. Connect one end of the release cam extension spring
into the release cam and the other end to the fifth
wheel top plate. Make sure both spring hook ends
face away from the fifth wheel 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 end faces away from the fifth wheel top plate.
b. Install the release cam extension spring, connecting
the release cam to the top plate. Make sure both
spring hook ends face away from the fifth wheel top plate.
c. Install the lock extension spring, connecting the hole
on the lock to the top plate. Make sure both spring
hook ends face away from the fifth wheel top plate.
RELEASE CAM
EXTENSION
SPRING
RELEASE CAM
EXTENSION
SPRING
RELEASE HANDLE
EXTENSION SPRING
LOCK
EXTENSION
SPRING
LOCK
EXTENSION
SPRING
RELEASE HANDLE EXTENTION SPRINGS
(SMALLER SPRING INSIDE LARGER SPRING)

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XL-FW535 Rev G · 2014-08-11 · 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.
Rebuild Procedures
Figure 28
Figure 27
9. Release Cam Pivot Bolt Installation
1. To complete installation of the release cam, refer to
Figures 27 and 28 for the following three (3) steps:
a. Place one 1/2" I.D. x 2-1/4" O.D. washer between
the tapped boss of the top plate and the bottom of
the release cam, with the rounded side of the washer
toward 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"
hex head cap screw through the washers and release
cam bushing, into the tapped boss of the top plate
and tighten to 40-50 ft.-lb. (54-68 N•m).
NOTE: Be sure the threads of the hex head cap screw
have a thread-locking compound.
RELEASE CAM
BOSS WITH
TAPPED HOLE
RELEASE CAM BUSHING
RELEASE CAM WASHER
WASHER
HEX HEAD CAP SCREW

20 XL-FW535 Rev G · 2014-08-11 · 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.
Figure 29
Figure 30
Top Plate Installation
10. Pocket Insert Inspection
Replace pocket inserts (Pocket Inserts Kit, RK-PKT-2) if:
The pocket insert thickness is 1/16" (1.59 mm) or less.
The free vertical movement of top plate on the bracket
is 1/2" (12.70 mm) or greater, without compressing
rubber bushings (Figure 29).
The pocket inserts are severely chipped, cracked or gouged.
11. Top Plate Installation
(for fabricated mounting brackets)
For mounting brackets with a one piece rubber bushing,
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 forging and apply a strip
of double face tape in the bottom of pockets. Install
pocket inserts by pressing down into pockets
(Figure 30).
2. Using a lifting device capable of lifting 500 lbs.
(227 kg), install the fifth wheel top plate onto its
mounting base.
NOTE: Follow instructions published by lifting device
manufacturer for proper operation of lifting device.
REPLACE IF
1/16"OR LESS
PUSH DOWN
1/2"MAX. (MEASURED AT EAR)
POCKET AREA
POCKET INSERT
DOUBLE-FACE TAPE