Fontaine 3000 series User manual

FIFTH WHEEL
2” Cast Fifth Wheel
2” Guss-Sattelkupplung
Sellette 2” en fonte
Instruction anual
ontage- und Betriebsanleitung
Notice d’utilisation
®
C O N N E C T Y O U R B U S I N E S S W I T H F O N T a I N E

Safety Information ........................................................................................ 2
1.1 Operation ............................................................................................ 2
1.2 Installation ............................................................................................ 2
1.3 Servicing .............................................................................................. 2
Correct Usage ................................................................................................ 3
2.1 Application .......................................................................................... 3
2.2 Design .................................................................................................... 3
2.3 Warranty ................................................................................................ 4
Operation ............................................................................................................ 5
3.1 Connecting a semi-trailer ............................................................ 5
3.2 Checking the fifth wheel is properly connected .............. 5
3.3 Disconnecting the semi-trailer .................................................... 7
Servicing and Testing ................................................................................ 8
4.1 Servicing .............................................................................................. 8
4.2 Lubrication ........................................................................................ 10
4.3 Spare Parts ........................................................................................ 11
Installation ........................................................................................................ 12
5.1 Choice of fifth wheel .................................................................... 12
5.2 Mounting bolts ................................................................................ 12
5.3 Mounting of fifth wheel coupling to mounting frame ....13
5.4 Mounting of plates, dolly mounting plates, frames
and sliding fifth wheels ................................................................ 13
5.5 Bolt positions .................................................................................... 14
5.6 Positioning of equipment on vehicle .................................. 14
3000 Fifth Wheel Instruction anual
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C O T E T S
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It is important to remember that a fifth wheel is a safety critical item
and should be treated as such.
Proper preventative maintenance, inspection and lubrication are
essential for a long, safe and trouble-free service life.
Please observe the relevant safety regulations that apply for
working with fifth wheel couplings, tractor units and semi-trailers.
These regulations will vary in different countries.
1.1 Operation
• Only authorised users are permitted to use the fifth wheel
coupling.
• Do not use the fifth wheel coupling and rubbing plates if
they show any sign of technical problems.
• The rubbing plate must be larger than the support area
of the fifth wheel coupling.
• Any sharp edges must be removed from rubbing plate to
prevent damage to the fifth wheel coupling or the top
plate liner, if fitted.
• When connecting a semi-trailer ensure all safety
regulations are adhered to. e.g. Health and Safety at Work
Regulations. A semi-trailer should only be connected on
firm, flat ground.
• The rubbing plate should ideally be slightly lower than the
top plate but not by more than 50mm.
• Ensure the locking mechanism is properly locked before
starting every journey. The vehicle must only be driven
when the mechanism is locked and secured, even when
driving without a semi-trailer.
1.2 Installation
• Prior to installation of a fifth wheel on a vehicle the
following should be considered:-
✱Current Legislation
✱OEM Vehicle Installation Instructions
✱Fontaine Vehicle Specific Mounting Instructions
• Installation work must only be completed by authorised
specialists.
• Installation areas are defined by the tractor unit
manufacturer and must not be changed.
• In all cases fifth wheel equipment should be mounted
using the mounting holes positioned as supplied.
The fifth wheel coupling must be mounted on the vehicle in
compliance with the requirements of Appendix VII of
Directive 94/20/EC. It may also be necessary to comply with
the licensing regulations of the appropriate country.
1.3 Servicing
• Only use specified lubricants for the servicing work
• The servicing work should only be completed by trained
personnel.
• Only use Original Equipment parts.
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2.1 Application
Fifth wheel couplings connect the tractor unit and the semi-trailer.
They are designed to be mounted on the tractor unit and should
be done so in a way that complies with Fontaine International’s
mounting instructions.
The fifth wheel coupling and mounting plates are connecting parts
that must meet very high safety standards and design approval
tests.
Any kind of modification to either the fifth wheel or auxiliary
mounting equipment will void the warranty and design approval.
2.2 Design
All Fontaine International fifth wheel couplings are designed to
comply with Directive 94/20/EC Class G50 and are to be used
together with king pins of Class H50 and Class mounting plates
or with comparable licensed equipment. This standard rates fifth
wheel coupling equipment based on the Maximum Imposed
(vertical) load and the Drawbar value, more commonly known as
the ‘D’ value. If any doubts exist as to which is the correct Fifth wheel
Equipment to use then the correct rating can be checked by
calculation using the formula in Figure 1.
Calculating D value where:-
g = 9.81 m/s2
R = Maximum gross weight of the semi-trailer [kg]
T = Maximum gross weight [kg]
U = Maximum imposed load [kg]
The maximum load data can be found on the fifth wheel type
label (see figure 2) and on the Fontaine technical documents. Also
the Fontaine website has a D-value calculator under the “selecting
the right product” section.
The Fifth wheel Coupling chosen should be rated with loads equal
to or higher than the calculated values. Under no circumstances
should a coupling be fitted where the calculated rating is higher
than the values indicated on the equipment type plate.
Allowances to the D-value and Maximum imposed load should be
made if the coupling is subject to additional dynamic forces, for
example if they are used on uneven road surfaces or on
construction sites such as quarry or forestry work. For this type of
application a higher rated fifth wheel may be required. If in any
doubt contact Fontaine technical department.
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Figure 1
Figure 2 - Fifth wheel Type Label
D = 9,81 x 0,6 x T x R
T +R - U
T (kg) R (kg)
U (kg)

2.3 Warranty
Fontaine International Europe Ltd warrants that all fifth wheels
produced by the company to be free from defects in material and
workmanship - excluding mounting components not supplied as
an original part of the fifth wheel assembly.
The Warranty Period for Fontaine Products is:-
• 2 Years Parts and Labour
All Installations must be carried out to within the company’s Fifth
wheel Mounting Instructions.
These Warranty Terms cover failures in material and workmanship
but does not cover failures due to the following:-
a. Vehicles which are not used on normal Highway
conditions
b. Accident
c. Improper Installation (refer to Fontaine official mounting
instructions)
d. General wear and tear
e. Misuse alteration or neglect
f. Failure to properly maintain (refer to Fontaine Official
maintenance instructions) using company’s genuine
parts.
The company must be notified prior to the commencement of any
repair. Failure to do this will cause automatic rejection of the claim.
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3.1 Connecting a semi-trailer
1. Check that the trailer hand brake is set and check that the fifth
wheel is open and ready for coupling (see Figure 3). If there is
any doubt, carry out the uncoupling procedure (section 3.3) until
the fifth wheel is fully open.
2. Ensure that the trailer rubbing plate is slightly below the level of
the fifth wheel (see Figure 4 ), but not by more than 50mm.
3. Reverse the tractor at a steady speed (around 2-3kph is sensible)
keeping the kingpin in the centre of the fifth wheel at all times,
until the fifth wheel locks.
3.2 Checking the fifth wheel is properly connected
To ensure that the fifth wheel is closed with the kingpin correctly
locked inside the mechanism carry out the following safety checks.
Check that the handle is correctly closed. The method for this varies
depending on the type of fifth wheel handle.
Standard Handle
The fifth wheel is only correctly locked when the inside notch in the
handle is hidden under the fifth wheel and the safety clip can be
fitted in the hole (see Figure 5).
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20 0m m a p p r ox
Handle blo ck
Handle will b e p u she d o u t
by 20 0 m m a p p r ox a n d s l o t
latched on h a n dle b l o ck.
Figure 3 - Fifth wheel in Open position
Trailer below level of fifthwheel
Figure 4 - Fifth wheel and trailer heights
Figure 5 - Locking of a fifth wheel with a Standard handle

Interlock Handle
The fifth wheel is only correctly locked when the inside notch in the
handle is hidden under the fifth wheel and the handle plunger is
correctly positioned in the locking slot under the fifth wheel (see
Figure 6).
CAUTION
If the handle does not close f lly by itself (see Fig re 5 and
Fig re 6) the complete co pling proced re m st be
repeated.
Only when you have confirmed that the handle is correctly closed
either:-
1. Carry out a “pull test” - try to pull the tractor forward against the
trailer brakes firstly making sure that the trailer brakes are on.
or
2. Visually check that the lockbar is fully across and that the kingpin
is locked inside the mechanism (See Figure 7).
CAUTION
Fail re to check that the handle is closed correctly before
carrying o t the “p ll test” may res lt in damage to the fifth
wheel.
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Figure 6 - Locking of a fifth wheel with an Interlock handle
Figure 7- Visually inspect kingpin is locked

3.3 Disconnecting the semi-trailer
1. Set the trailer handbrake (if fitted), disconnect the air, electrical
connections and lower the trailer legs.
2. Remove safety catch.
Standard Handle
Unclip the safety clip.
Interlock Handle
Grip the handle and pull the inner handle out as far as it will go. As
shown in Figure 9.
3. Push the fifth wheel handle towards the front of the vehicle by
approx 25mm (see Figure 10).
4. Pull the handle fully out to approximately 500mm (20") from the
edge of the fifth wheel and latch slot in the handle onto handle
block on the skirt of the fifth wheel (see Figure 3). The handle
should remain fully out when released.
5. Drive the tractor away from the trailer slowly. This will unlatch the
handle from the block and reset the fifth wheel ready for the
next coupling (see figure 8).
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Figure 8 - Fifth wheel in Open position Figure 9 - Opening an interlock handle fifth wheel
Figure 10 - Opening the fifth wheel

4.1 Servicing
Routine Fifth Wheel aintenance
Every 10,000km (or 1 month)
1. Uncouple tractor, clean the fifth wheel mechanism, rubbing
plate and kingpin. Inspect the fifth wheel for damage and
defects.
2. Regrease, with clean grease, all points a to h as shown in Figure
11.
Every 50,000km (or 6 months)
1. Degrease the fifth wheel rubbing plate and kingpin.
2. Check the kingpin for wear (use gauge 59006421).
3. Check the fifth wheel for wear. If dimension “A” (see Figure 12) is
less than 20.25mm a replacement jaw kit is required.
4. If the parts are correct, carry out 10,000km maintenance
procedure.
a - Lockbar pivot
b - Adjuster screw
c - Kingpin contact area
d - Fifth wheel top plate
e - Mounting bracket lube point 150CI only
f - Mounting bracket contact area 150SP only
g - Handle pivot
h - Lockbar “track”
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Table 1 - Part numbers for tools required in servicing
Figure 11 - Labelled diagram of fifth wheel parts
Kingpin test unit 59004124
Kingpin gauge 59006421
Pivot Bolt Puller 59002231

NOTE
Th jaw pin (s Figur 12) is only a pivot pin and is d sign d to
b small r than th hol in th jaw. This cl aranc nabl s th
jaw to fully contact th kingpin and lockbar at all tim s.
Adjustment Procedure
1. Undo the adjuster locknut and wind out the adjuster (anti-
clockwise) until it is completely free from the end of the lockbar.
2. Insert the new kingpin (or kingpin test unit part no 59004124) and
ensure the mechanism fully closes.
3. Screw the adjuster clockwise until it touches the end of the
lockbar.
4. Screw inwards a further 3 complete turns (to give 0.525mm
running clearance).
5. Tighten the adjuster locknut.
6. Remove the kingpin/test unit
Replacement of Worn Parts
If the jaw is undersized (dimension A in Figure 12) is less than
20.25mm) a new jaw kit is required.
For precise fitting instructions, please contact Fontaine
International.
IMPORTANT
Aft r fitting th n w jaw kit, th m chanism must b r -adjust d
to allow corr ct running cl aranc around th kingpin.
A compl t jaw kit MUST ALWAYS b fitt d to nsur th jaw and
lockbar ar corr ctly match d.
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Figure 12 - Location of the aw pin