Fontaine 3000 series User manual
Only
Read before mounting or
operating fifth wheel.
After fifth wheel is installed
these important instructions
must be permanently retained
in the tractor glove box.
WARNING: Failure to follow
these instructions could
cause a hazardous operating
condition.
3000 Series
• Installation Instructions
• Pre-Service Procedures
• Operating Instructions
• Inspection & Maintenance
Procedures
• Warranty
Gives You the No-Slack
®
Advantage
October 2007
FOR YOUR SAFETY USE
ONLY GENUINE FONTAINE
SERVICE PARTS.
USING NON-GENUINE
PARTS VOIDS WARRANTY.
CONNECT YOUR BUSINESS WITH FONTAINE
For over 60 years, Fontaine has been passing customer
performance tests by building fifth wheels with innova-
tive technology, uncompromising quality, and features
designed to ensure cost-efficient performance.
This handbook provides instructions and recommended
procedures to ensure optimum performance from
your new Fontaine 3000 Series fifth wheel. Included
are: Installation Instructions, Pre-Service Procedures,
Operating Instructions, Inspection and Maintenance
Procedures, and Warranty Information. Keep this hand-
book in the tractor glove box after your fifth wheel
has been installed.
If you have any questions concerning your new fifth
wheel, our Customer Service Department is available to
help you. (800) 874-9780.
For sales and service locations or for additional copies of
this handbook go to our web site at www.fifthwheel.com.
Fontaine®Fifth Wheel Handbook
2
Contents
Section I – Installation Instructions
General Mounting Instructions.....................................4-6
Air & Manual Slide Bracket (ASB/MSB)........................... 7
Stationary and Adjustable Mounting Bracket
(SMB/APB)...................................................................... 8
Section II – Pre-Service Procedures
Fasteners ....................................................................... 9
Lubrication ................................................................... 10
Operation ..................................................................... 11
Adjustment Procedure .................................................. 11
Section III – Operating Instructions
Coupling Procedures ...............................................12-15
Uncoupling Procedures................................................. 16
Section IV – Inspection and Maintenance
Procedures..............................................................17-18
Section V –
Limited Warranty .......................................19-20
Fontaine®Fifth Wheel Handbook
3
Installation Instructions
General Mounting Instructions
1. Do not modify and/or customize any fifth wheel
or mounting assembly without prior approval from
Fontaine. Modifying or welding to the product
without approval will void product warranty. Only
Fontaine authorized procedures are acceptable.
Welding must be performed by an AWS certified
welder. Note: The 3000 Series top plate is made
of ductile iron.
2. Installation shall be in accordance with DOT
regulations, state and local ordinances, SAE and TMC
practices and standards, and tractor manufacturers’
recommendations.
3. All fifth wheels shall be located so that the tractor and
trailer will maintain clearance at all times. On sliding
fifth wheels, it may be necessary to “block out”
forward slide positions.
4. All mounting fasteners must be a minimum of:
5/8" (16.0mm) diameter - Grade 8 bolts
5/8" (16.0mm) diameter - Grade C lock nuts
5/8" (16.0mm) diameter - Hardened flat washers
5. Outboard mounting angles shall be ASTM-A-36 or
equal with a minimum thickness of 5/16" (7.9mm).
6. Inboard mounting angles must have a 4" (101.5mm)
minimum vertical and horizontal leg and shall not
be less than 36" (913.7mm) long. (Stationary angle
mounts only)
7. Outboard mounting angles must have a minimum
horizontal leg of 3" (76.2mm) and vertical leg of
3-1/2" (88.8mm).
8. The full length, horizontal flange of the outboard
mounting angles must be at the same elevation as
the truck frame. The vertical leg of the angles must
fit flush with the truck frame. Warning: Failure to
follow these specifications will void warranty and
could effect product performance. See Figure A.
Fontaine®Fifth Wheel Handbook
4
Front
Back
Top
Figure B
Fontaine®Fifth Wheel Handbook
5
9. All mounting holes shall be drilled, not burned. All
edges shall be ground smooth to prevent point loading.
10. When required to clear obstructions, cutouts in the
mounting angles shall be smooth and straight with a
minimum radius of 1" (25.4mm). No sharp corners
are permitted and all edges shall be ground smooth. A
minimum of two bolts is recommended beyond a
cutout.
11. Care must be taken to avoid interference or contact
between the fifth wheel and any other component
when rear of fifth wheel is depressed. In order to
prevent this, it is recommended that a stop be used.
The stop should be positioned so that contact is made
with the fifth wheel mounting plate.
12. Do not restrict normal rock of fifth wheel. This could
create a hazardous operating condition.
13. All fifth wheels subjected to weather abuse must be
thoroughly cleaned, inspected, and lubricated prior to
installation.
14. Fifth Wheels should be mounted in the proper
orientation relative to the tractor (See Figure B ).
Do not mount the fifth wheel upside down or
backwards.
Figure A
STRAIGHT EDGE STRAIGHT EDGE
OUTBOARD
ANGLE
OUTBOARD
ANGLE
OUTBOARD
ANGLE
GAP AT THE
MIDPOINT OF THE
TRUCK FRAME FLANGE
SHOULD BE LESS
THAN .030"
GAP AT THE MIDPOINT OF THE OUTBOARD ANGLE
SHOULD BE LESS THAN .030"
TYPICAL TRUCK
FRAME
TYPICAL TRUCK
FRAME
15. The trailer that is attached to the fifth wheel should
impose a consistent vertical load. Repeated nega-
tive loading (trying to pull the fifth wheel off of the
brackets with the kingpin) is not allowed. A minimum
vertical static load applied to the fifth wheel through
the trailer is 10% of the gross trailer weight.
16. Do not center load the fifth wheel. The vertical load
should be distributed over the entire surface of the
fifth wheel.
17. Fixed angle mounts (inboard angles) shall be flush
with the top of the truck frame. (No gap between the
truck frame and the angle). See Figure A on page 5.
18. Do not attempt to “block” 3000 series fifth wheels.
A production “blocked” fifth wheel specifically
designed for this application is available.
Fontaine®Fifth Wheel Handbook
6
Truck frame
Fontaine®Fifth Wheel Handbook
7
Air and Manual Slide Bracket (ASB/MSB)
(Air Slide shown)
Adjustment of 24" mounting slide shown. Assemblies
with greater adjustment require longer angle and addi-
tional mounting bolts. See suggested price list for angle
sizes and lengths available. The full length of the horizon-
tal flange of the outboard mounting angles must be at the
same elevation as the truck frame. The vertical leg of
the angle must fit flush with the truck frame.
See Figure A on page 5.
Mounting Angle
(Do not weld to
truck frame).
All mounting hardware must
be a minimum of: 5/8"
(16.0mm) Grade 8 bolts,
Grade C locknuts with
hardened steel washers,
tightened to 90-122 ft. lbs
55" (1395.9mm)
2"
2"
Bolt Spacing – Maximum 8" (203.0mm), Minimum 4"(101.5mm)
8
Stationary and Adjustable Mounting Bracket (SMB/APB)
Mounting of 18" Adjustable Mounting Bracket shown.
See suggested price list for angle sizes and lengths avail-
able. The full length of the horizontal flange of the out-
board mounting angles must be at the same elevation
as the truck frame. The vertical leg of the angle must fit
flush with the truck frame. See Figure A on page 5.
Mounting Angle
(Do not weld to
truck frame).
Mounting Angle
(Do not weld to
truck frame).
Truck frame
37" (939.1mm)
2"
2"
Bolt Spacing – Maximum 8" (203.0mm),
Minimum 4" (101.5mm)
Fontaine®Fifth Wheel Handbook
All mounting hardware must
be a minimum of: 5/8"
(16.0mm) Grade 8 bolts,
Grade C locknuts with
hardened steel washers,
tightened to 90-122 ft. lbs
Fontaine®Fifth Wheel Handbook
Section II –
Pre-Service Procedures
A. Fasteners
Make sure all nuts and bolts are in place and
properly tightened.
Check all welds for cracks, breaks or separation.
Check to see if both bracket pins are in place and
secured by retainer pins and cotter pins.
See Figure C and D.
9
Retainer Pin
Bracket Pin
Cotter Pin
Figure C
Figure D
Handle
Clip
Handle
Clip
Fontaine®Fifth Wheel Handbook
10
B. Lubrication
1. Inspect the trailer kingpin plate and top surface
of the fifth wheel to make sure each is properly
greased. A liberal coating of grease should be
applied to the complete surfaces of both the trailer
kingpin plate and the top surface of the fifth wheel.
A paddle or brush will make this job easier.
Do not use a lube plate (high density
polyethylene) on top of the fifth wheel or
kingpin bolster plate in lieu of grease without
prior approval by Fontaine.
The additional thick-
ness of this material can prevent the proper opera-
tion of the fifth wheel and can cause a dangerous
condition.
2. Lubricate the fifth wheel lock prior to opening and
closing. Referring to Figure E, grease the jaw and
lockbar (wedge) on top and bottom. Separate the
jaw and lockbar (wedge) with a large screwdriver
and distribute the grease along the full length of the
jaw and lockbar (wedge) mating surfaces. Open and
close the fifth wheel several times to further distrib-
ute the grease.
See Figure E.
Lightly oil other moving parts in the fifth wheel.
3. For sliding fifth wheels, lightly oil the slide locking
mechanism. Operate the mechanism several times
to ensure it is functioning properly.
Jaw
Wedge
Separate Jaw
and Wedge.
Grease full
length.
Figure E
C. Operation
1.
Fontaine’s 3000 Series fifth wheel opens by remov-
ing the handle clip, moving the pull handle slightly
forward and pulling straight out until maximum
opening stroke is achieved. At this point, the pull
handle should again be moved slightly forward
until the handle cut out sets up on the handle block
located on the fifth wheel skirt.
2.
Close the locking mechanism using a test
kingpin or 2" (50.8mm) diameter pipe. Repeat
several times making sure that all moving parts
have adequate lubrication.
3.
The pull handle grip should always be free of
grease or any substance which could prevent a
firm grip, causing the handle to slip and possibly
resulting in injury.
D. Adjustment Procedure
1. With the wheel in the closed position, loosen the
adjuster jam nut and turn the adjuster stud counter
clockwise (outward) until it is free from touching the
end of the lockbar (wedge).
2. Insert a test kingpin or
2" (50.8mm)
diameter shaft
to ensure the locking mechanism is completely
closed.
3. Turn the adjuster stud clockwise (inward) until it
contacts the end of the lockbar (wedge). Now turn
the adjuster stud clockwise (inward) an additional
three complete revolutions. This will give the
recommended .02" (0.525mm) running clearance.
See Figure F.
4. Tighten the adjuster jam nut.
Improper adjustment can cause the mechanism to
bind and/or wear prematurely.
Fontaine®Fifth Wheel Handbook
11 Figure F
Adjuster Stud
Adjuster
Jam Nut
Section III –
Operating Instructions
COUPLING PROCEDURE:
1. Prior to coupling, inspect the fifth wheel to
ensure a proper operation.
• Examinethemountingassemblyforsecurely
fastened bolts, cracked welds or material
separation.
• Tiltthefifthwheelupanddowntomakesure
that it moves freely. Rest the fifth wheel in the
proper position by tilting it to the rear of the
tractor and resting it on the stops.
• Checkthetopsurfaceofthefifthwheelfora
liberal coating of grease.
• Ifthetractorisequippedwithanairsliding
fifth wheel, actuate the air cylinder and check
for air leaks. WARNING: Air cylinder should
not be disassembled as contents are under
pressure.
• Thefifthwheelshouldbeinanunlockedposi-
tion (See Figure G). When unlocked, the handle
should be extended and the tips of the jaw
and lockbar (wedge) visible. DO NOT TRY TO
COUPLE TO A CLOSED FIFTH WHEEL.
2. The trailer kingpin should be inspected prior
to coupling. The kingpin plate should be fully
reinforced and of sufficient size to completely
cover the fifth wheel. If the kingpin plate is
too narrow, the uncovered portion of the fifth
Fontaine®Fifth Wheel Handbook
12
Figure G
wheel will collect dirt and foreign matter. This
material may work into the fifth wheel lock-
ing mechanism, causing wear and difficulty
uncoupling. This material can also cause gall-
ing of the fifth wheel and/or kingpin plate.
If the trailer kingpin plate is not fully rein-
forced, distortion can result causing:
•Non-uniformloading
•Variationinkingpinlength
•Cuttingandgallingofthefifthwheel
or kingpin plate
If the trailer kingpin plate is distorted enough
to cause any of the conditions listed above, it is
recommended that a new plate be installed.
The trailer kingpin plate must be properly
greased.
Fontaine Fifth Wheels are designed and
manufactured for use with all trailer kingpins
that conform to SAE specifications, SAE J700,
February 1993, and subject to the wear limits
of SAE J2228, June 1993. These specifications
cover SAE 2" (50.8mm) kingpins only.
The SAE standard kingpin can be checked using
the dimensions given in Figure H.
Fontaine®Fifth Wheel Handbook
13
SAE STANDARD KING-PIN
(SAE J700, FEB 93)
All dimensions in inches
2.875 ± .005 1.328
1.250
2.782
2.704 3.354
3.256
2.812 ± .015
2.000 ± .005
Figure H
Fontaine®Fifth Wheel Handbook
14
3. Proper tractor/trailer alignment is critical to
obtain a secure coupling and to avoid equipment
damage.
Set the trailer brakes and raise the trailer to the
proper height by extending the landing legs. If
the trailer is positioned too high, the kingpin
may jump the fifth wheel throat and locking
mechanism altogether. Resulting damage may
include: scoring the fifth wheel, bending the
handle thus preventing the fifth wheel from
properly locking to the kingpin, bending the
kingpin, and other significant damage to the
tractor or trailer.
Coupling should not be attempted if the trailer
is too low. Costly damage may be incurred to
the trailer, the kingpin, the kingpin plate, the fifth
wheel, tractor drivetrain and truck frame.
4. To couple the fifth wheel to the kingpin, be sure
the fifth wheel is positioned so that it tilts down
at the rear and is resting on the stops.
Align the kingpin with the throat of the fifth
wheel and ease the tractor toward the trailer.
The trailer should strike the fifth wheel just at
the top of the approach ramps. The fifth wheel
will level with the kingpin plate and the kingpin
should slide into the fifth wheel throat.
Coupling is complete when the fifth wheel
locking mechanism snaps closed behind the
kingpin and the handle clip is properly installed
by the driver (See Figure H next page).
Verifysecurecouplingwitha“tugtest,” by
easing the tractor forward to feel resistance of
the load. If the coupling feels secure, visually
inspect the fifth wheel. The jaw and lockbar
(wedge) must be locked in place behind the
kingpin and the pull handle must be fully
retracted and secured in place using the
handle clip (See Figure H next page).
5. To position an air sliding fifth wheel, set the
trailer brakes, unlock the cab control air valve
and allow the air cylinder to retract the locking
wedges. Ease the tractor forward or backward
to move the fifth wheel to the desired position
and lock the air valve. Note: The fifth wheel
must be in the locked position when chang-
ing slide positions.
After the fifth wheel is properly positioned,
inspect the locking wedges to ensure that they
are fully engaged in the slide rail pockets.
Under no circumstances should a sliding
fifth wheel be repositioned while the tractor
and trailer are in motion.
Do not attempt to slide the fifth wheel until
all persons are clear of the vehicle.
Fontaine®Fifth Wheel Handbook
15
Note: Pull
handle must be
fully retracted
behind skirt
notch and
secured in
place using the
handle clip.
Handle
clip
Pull
handle
Skirt
notch
Figure H
Fontaine®Fifth Wheel Handbook
16
UNCOUPLING PROCEDURE:
1. Prior to uncoupling, set the trailer parking
brakes. Back the tractor gently but tightly
against the trailer before setting the tractor
parking brake. This will help relieve pressure
from the fifth wheel locking mechanism.
IF THE TRUCK IS EQUIPPED WITH AIR RIDE
SUSPENSION, DO NOT DUMP THE AIR BEFORE
OPENING THE FIFTH WHEEL. DOING SO MAY
CAUSE A HARD TO OPEN SITUATION.
2. Block the trailer wheels. If poor ground condi-
tions exist, you may have to provide a base for
the trailer landing gear.
• SpringSuspension:lowerlandinggearuntil
it contacts the ground. Give a few extra turns
in low gear. DO NOT lift the trailer off of the
fifth wheel.
• AirRideSuspension:lowerlandinggear
until it contacts the ground. Add one addi-
tional turn. DO NOT raise the trailer off of
the fifth wheel.
3. Disconnect the air and electrical lines.
4. Remove the handle clip and open the fifth
wheel.
5. Pull out slowly from under the trailer. Let the
trailer slide down the fifth wheel approach
ramps. This will allow the air ride suspensions
to adjust to unloaded height. CAUTION: GOING
TOO QUICKLY WILL CAUSE THE SUSPENSION
TO BOUNCE, POSSIBLY DAMAGING THE
TRAILER, TRACTOR FRAME RAILS OR
SUSPENSION AIR BAGS.
Fontaine®Fifth Wheel Handbook
17
Section IV –
Inspection and
Maintenance Procedures
Lubrication
Recommended every 6 weeks or 15,000 miles
Follow the instructions provided in the Pre-Service
Procedure, section B, on page 10 of this handbook.
Special precautions must be taken during cold
weather to ensure that the Fontaine 3000 Series
locking mechanism operates freely. Ice and sludge
can built up and lubricants become thick and
binding at low temperatures.
When the temperature drops below freezing,
Fontaine recommends use of a cleaner or degreaser
on the latching mechanism, making sure that the
moving parts operate freely. This should be followed
by an application of 90-weight oil to all moving
parts. This procedure may also be necessary in
operations where excessive road grime or grit is
encountered.
Inspections and Adjustments
Perform every 90 days or 30,000 miles
Using a suitable solvent, degrease the fifth wheel
and mounting brackets and inspect for:
1. Cracks in the fifth wheel assembly, mounting
brackets, and mounting parts.
2. Wear and/or damage to moving parts.
3. Correct placement of the handle clip.
4. Loose nuts and bolts in the fifth wheel and in the
mounting hardware.
5. Securely fastened and properly working springs.
6. Check to see if both bracket pins are in place
and secured by retainer pins and cotter pins.
7. Replace liners that are broken or have worn
excessively, or, if the thickness is less than
.125" (3.18 mm) at the top of the liner. See
Figure I. Replace liners every 300,000 miles.
8. Check the locking jaw. If dimension “A” is less
than 0.8" (20.25mm) replacement of the jaw
and lockbar (wedge) is required. See Figure J.
Check the fifth wheel operation and adjustment.
Using a test kingpin or 2" (50.88mm) diameter pipe,
follow the instructions provided in the Pre-Service
Procedure, section C and D, on page 11 of this
handbook.
Fontaine®Fifth Wheel Handbook
18
Dimension “A”
Figure J
.125" (3.18 mm)
Minimum
Figure I
Fontaine®Fifth Wheel Handbook
19
Section V –
3000 Series
Limited Warranty
Basic Limited Warranty
Fontaine International, Inc. (Fontaine) warrants each
3000 series fifth wheel to be free from defects in
material and workmanship for five years from date
of sale, but does not cover failures due to:
1. Use with loads greater than the rated fifth wheel
capacity.
2. Use in loads that are beyond federal, state and
provincial highway limits, or in special over-
weight load permits.
3. Improper installation of fifth wheel (see the
Fontaine 3000 Series Instruction Handbook for
proper installation procedures – booklet LT-103).
4. Normal wear.
5. Accident.
6. Improper application.
7. Misuse, alteration or negligence.
8. Failure to properly maintain the fifth wheel (see
the Fontaine 3000 Series Instruction Handbook
for proper installation procedures – booklet
LT-103).
9. Inadequate repairs or alterations that, in
Fontaine’s judgment, adversely affects the fifth
wheel’s performance or reliability.
Fontaine cannot guarantee the service life of any
fifth wheel since service life can vary with applica-
tion, usage, maintenance, environment, and other
factors beyond Fontaine’s control.
Fontaine®Fifth Wheel Handbook
20
Limited Performance Warranty
Fontaine warrants the performance of each 3000
series fifth wheel that is used in a “standard duty
application,” for five years from the date of sale.
A “standard duty application” requires that (i) the
vehicle is used 100% on highways with more than
30 miles (48.3km) between each stop, (ii) the vehicle
does not exceed a gross combined vehicle weight of
95,000 lbs. (43,000 kilograms), (iii) the total number
of towed axles does not exceed two and (iv) the road
type is maintained concrete or asphalt.
Fontaine warrants that each fifth wheel covered
hereunder shall operate as described in the Fontaine
Instruction Handbook, and the locking mechanism
(rotating locking jaw and locking wedge) will wear
properly on the trailer kingpin when the fifth wheel
is adjusted in accordance with the manufacturers
specifications (see LT-103 Handbook).
Fontaine wheels are designed and manufactured
for use with SAE 2” (50.8mm) trailer kingpins that
conform to SAE specification (SAE J700, February
1993) and are subject to the wear limits of SAE
specification (SAE J2228, June 1993).
Replacement of Parts and Repairs
Authorization from Fontaine must be obtained before
replacing or returning any part under this Limited
Warranty. All requests for reimbursement must
be submitted within 45 days of the repair.
If the fifth wheel does not perform as warranted in
this Limited Warranty, or if there is any defect in the
material or workmanship covered by this Limited
Other manuals for 3000 series
2
Table of contents
