Fontaine 3000 series Installation instructions

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FONTAINE
FLEETLINE PRODUCTS
FONTAINE
FIFTH WHEEL
FONTAINE
®
®
®
FONTAINE
INTERNATIONAL
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®
April 2007
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ASSEMBLY, DISASSEMBLY
AND TROUBLESHOOTING
INSTRUCTIONS
FOR 3000 SERIES

3000 SERIES REBUILD DISASSEMBLY
April 2007
2
Set the fifth wheel in the closed position.
To do this rotate the jaw towards the front
of the fifth wheel with a screw driver of
adequate length to keep hands and fingers
out of the throat of the wheel. This will partially close
the wheel. Now pull out on the pull handle a small
amount and complete the rotation of the jaw toward
the front of the wheel. Allow the pull handle to go in
slowly for the wheel to completely close.
1
Degrease fifth wheel before installing new parts.
Remove the jaw spring (item 19). Now
remove the main springs (item 18) from
the pull handle (two springs acting as one).
Remove the outer spring first (large spring)
from the spring clip; then the inner spring (small
spring) from the spring clip.
2
Main spring
Security
clip
Rotate
jaw counter
clockwise
toward front of wheel
Pull
handle
Jaw
spring
Refer to exploded view of assembly on page 6-7 to identify item numbers and parts
Disassembly: Remove the wear ring (item 6) using
an 8 mm hex tool.
Wear ring
Worn or Damaged Wear Ring Disassembly/Reassembly
Assembly: Insert the new wear ring, flat washers and
hex socket button head screws (items 6, 7, & 8)
(Order KIT-RING-3000 and use the new hardware
provided in kit). Torque all wear ring fasteners to
52Nm (38 ft lbs). Note: Do not over tighten.
1.63"
Inspect the wear ring for damage and deterioration. Over
time, friction from the kingpin causes the wear ring to
deteriorate. When the width of the wear ring (measured
at the top of the ring from front to back) is less than 1.63
inches, it’s time to replace it. Order repair kit part number
KIT-RING-3000.
Refer to exploded view of assembly on page 6-7 to identify item numbers and parts

3000 SERIES REBUILD DISASSEMBLY (Cont.)
April 2007
Remove the operating handle (item 15)
and locking wedge (item 17) by pulling the
operating handle to the open position. This
will allow you to remove the operating handle
from the wedge. Remove the wedge (item 17).
Turn the adjustment rod (item 2) counter clockwise
(outward) until it is even with the rod guide. This will
eliminate interference when moving and installing
the locking jaw.
5
Locking
wedge
Remove the pivot pin clip from the pivot pin
(item 9). Raise the top plate and remove
the pivot pin (item 10) that secures the
rotating locking jaw. Remove the rotating
locking jaw.
6
Operating handle
Pivot pin & pivot pin clip
Rotating
locking jaw
Refer to exploded view of assembly on page 6-7 to identify item numbers and parts
Discard used hardware – Do not reuse!
3
Remove pivot pin clip from pivot pin
(items 9 and 10) which attaches the
operating handle (item 15) to the locking
wedge (item 17).
4
Pivot pin
clip &
pivot pin
Remove the 16mm hex head bolt and lock
nut (items 13, 14) which secures the pull
handle (item 12) to the operating handle
(item 15). Remove the handle assembly.
3
Pull
handle
Hex head bolt &
lock nut
Operating
handle
Adjustment rod
Rod
guide

Insert the new pivot pin (item 10) into the
locking wedge (item 17) after applying
a light coat of grease. Insert the locking
wedge into the wheel. Move the locking wedge in
behind the rotating locking jaw (item 16). Now slide
the locking wedge back toward the outside of the
wheel. This will assist in installing the operating han-
dle. Insert the end of the operating handle (item 15)
into the slot at the bottom of the fifth wheel and over
the locking wedge pivot pin. Rotate the operating
handle towards the center of the fifth wheel. This will
slide the locking wedge behind the locking jaw.
Attach the operating handle (item 15) to the
locking wedge using a pivot pin clip (item 9)
to secure the connection.
Insert the rotating locking jaw (item 16) after
applying a light coat of grease. Note: Insert
the jaw so that the hole in the cover
plate lines up with hole in the rotating
jaw. Raise the fifth wheel and then insert the pivot
pin (item 10) into the fifth wheel and then into the
rotating jaw. Note: Make sure the notched portion
of the pivot pin is inserted in to the fifth wheel first.
Secure the pivot pin in place with a new pivot pin
clip (item 9).
3000 SERIES REBUILD ASSEMBLY
April 2007
4
1
Adequate lubrication should be used.
2
3After applying a light coat of grease to the
pivot points, insert the pull handle (item
12) into the top plate. Attach the operating
handle (item 15) to the pull handle using
new lock nut (item 14). Note the orientation of
the bolt (item 13) – the thread should be facing
up. Do not over tighten.
4
Before rebuilding the assembly, check to make sure that there are no cracks in the cross members or other
components. Also check bracket pin holes to ensure they are not worn oversize (pins should fit snugly).
Refer to exploded view of assembly on page 6-7 to identify item numbers and parts. Use part # KIT-RPR-3000L.
Pivot pin & pivot pin clip
Rotating
locking jaw Locking
wedge
Pivot pin
Operating
handle
Pivot pin
clip &
pivot pin
Pull handle
Hex head bolt &
lock nut
Operating
handle

3000 SERIES REBUILD ASSEMBLY (Cont.)
April 2007
Make sure the wheel is completely closed.
Attach the jaw spring (item 19) to the
rotating locking jaw. Now install the main
springs (item 18) (two springs acting as
one), to the pull handle (item 12). Install the inner
spring first to the spring clip. Now install the outer
spring to the spring clip.
5Open the fifth wheel, insert a 2" kingpin and
close the fifth wheel. Turn the adjustment
rod (item 2) clockwise (inward) until it
contacts the end of the locking wedge.
Now turn the adjustment rod clockwise (inward) an
additional 3 complete revolutions. This will give the
recommended 0.525 mm (.02") running clearance.
Tighten the adjustment rod jam nut (item 1). Wheel
should operate freely and smoothly without binding
or interference.
AFTER COUPLING TO A TRAILER OR 2"
KINGPIN INSERT THE SECURITY CLIP.
6
Before rebuilding the assembly, check to make sure that there are no cracks in the cross members or other
components. Also check bracket pin holes to ensure they are not worn oversize (pins should fit snugly).
Refer to exploded view of assembly on page 6-7 to identify item numbers and parts.
Under no circumstances should a fifth wheel
be repaired or used if any component
(cross member, saddle bearing, etc.) is cracked.
4
Main spring
Jaw
spring
Security
clip
Adjustment rod
5

6
April 2007
3000 SERIES REBUILD DIAGRAM
SLTPL3000 (Left Side Release Shown)
Illustration SLTPL3000
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18
Superior Technology Delivers
Superior Locking Performance
The Fontaine TechLock
®
System

7
3000 SERIES KITS
April 2007
FFW Genuine KITS
Note: Available left side (driver’s side) only. *Only available in a Fontaine Parts Kit
Item Description Quantity
No.
KIT-OPR-3000L
3000 Series Operating Handle Kit
13 Hex Head Bolt 1
14 Operating Handle 1
15 Nylok Nut 1
KIT-PIN-3000
3000 Series Pin Kit
3 Bracket Retainer Pin 2
4 Bracket Pin 2
5 Cotter Pin 2
Bracket Bushings 2
KIT-PUL-3000
3000 Pull Handle Kit
11 Pull Handle 1
13 Hex Head Bolt 1
15 Nylok Nut 1
KIT-RING-3000
3000 Wear Ring Kit
6 Wear Ring 1
7 Flat Washer 4
8 Hex Socket Button 4
Head Screw
KIT-ROD-3000
3000 Adjustment Rod Kit
1 Adjustment Rod Nut 1
2 Adjustment Rod 1
KIT-RPR-3000L
3000 Repair Kit
9 Pivot Pin 2
16 Pivot Pin Clip 2
17 Locking Wedge 1
18 Rotating Locking Jaw 1
19 Jaw Spring 1
20 Main Spring 1
Not
Pictured
Item
No. Description Part Number Quantity
Adjustment Rod Nut, M16 Square * (1)
Adjustment Rod * (1)
Bracket Pin PIN-3000 (2)
Bracket Retainer Pin PIN-124P (2)
Cotter Pin PIN-165* (2)
Wear Ring * (1)
Flat Washer, M12 * (4)
Hex Socket Button Head Screw, * (4)
M12X25MM
Pivot Pin * (2)
Security Clip CLIP-3000 (1)
Pull Handle * (1)
Bracket Liners LNR-3000 (2)
Hex Head Bolt, M16 X 45MM * (1)
\ Operating Handle * (1)
Nylok Nut, M16 * (1)
Pivot Pin Clip * (2)
Locking Wedge * (1)
Rotating Locking Jaw * (1)
Jaw Spring * (1)
Main Spring * (1)
Bracket Bushings BSH-3000 (2)
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34 34
18
Not
Pictured

©2007 Fontaine International • LT-107 • 1M May, 2007 • PDF file revised 05/01/07
All specifications are subject to change without notice.
FONTAINE
FLEETLINE PRODUCTS
FONTAINE
FIFTH WHEEL
FONTAINE
®
®
®
FONTAINE
INTERNATIONAL
®
®
www.fifthwheel.com