Montracon MT45 Service manual

www.montracon.com(Rev 3 Edition)Machinery CarrierOPERATOR HANDBOOKthe trailer for road transport

CONTENTSthe trailer for road transport e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]. General2. Operating Instructions3. Air Suspension4. Brake System5. Electrical System6. Trailer Maintenance & Care7. Fault Finding8. Useful ContactsPage 3 - 7Page 8 - 27Page 28 - 32Page 33 - 41Page 42 - 46Page 47 - 61Page 62 - 72Page 732MACHINERY CARRIERS

the trailer for road transport e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]GENERAL INFORMATIONMACHINERY CARRIERSCONTENTS1. Vehicle Identification2. General Description3. To the Driver4. Warranty & Claims ProcedurePage 4 Page 5 Page 5 Page 6This trailer has been manufactured by Montracon to:BS EN ISO9001:2008Registered for the design and manufacture of trailersand rigid bodies.3

the trailer for road transport e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]VEHICLE IDENTIFICATIONEach Montracon trailer has a unique Vehicle Identification Number (VIN) that, as well as other data, identifies its dimensions, its model type, its chassis number and subsequent weight information.Figure 1Figure 2The trailer will also be fitted with a Montracon Ministry Plate showing the “C number”(Ministry number) which has been allocated to that trailer by VOSA before delivery to the Customer. This plate is usually fitted in the default position adjacent the landing legs on the near side of the trailer attached to the main chassis beam, an example of this plate is shown below.The plate fixed near to the chassis plate is the load sensing valve data plate.This plate identifies the relevant weight informationoperating under Special Types Use.MACHINERY CARRIERS4Figure 3Figure 43421

the trailer for road transport e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]GENERAL DESCRIPTIONTO THE DRIVERThis manual covers the main safety, operation andmaintenance aspects of Montracon machinery carriertrailers. Before operating the trailer, this manual shouldbe read and fully understood. It is important youfamiliarise yourself with the functions and operationof your trailer.Montracon Limited reserves the right to make modifications to the design and/or technical specificationof equipment without this resulting in making suchmodifications to products already sold. Whilst everyeffort is made to make sure descriptions, illustrationsand specifications within this handbook are correct atthe time of going to print, these are also subject to change.It is your responsibility to read and comply with all safety instructions quoted in this handbook. Understand that your safety and the safety of others is measured by how you operate your vehicle.SAFETY ALERT SYMBOLThis safety symbol is used to alert the driver/operator that SAFETY IS INVOLVED.When ever you see the safety alert symbol used within this handbook carefully read the message that follows and be made aware to the possibility of serious injury.SAFETY IS IMPORTANT! Accidents can disable or kill. Accidents are costly. Accidents can be avoided.MACHINERY CARRIERS5

the trailer for road transport e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]WARRANTY Every care and attention is taken in the production of your trailer/ chassis, however, should you feel that a claim on warranty should be made please contact the company without delay quoting the CHASSIS number stamped on the VIN plate. We cannot act on your claim without this number.MACHINERY CARRIERS6WARRANTY CLAIMS PROCEDUREIn the event of a problem occurring the following procedure should be adhered to, which will enable the claim to be processed efficiently and effectively.Contact the Customer Service Department (during office hours) on Tel No. 01302 732500, Fax No. 01302 732503 prior to any repairs being commenced. Please ensure the following information is quoted before any claim can be processed.1. Nature of problem2. Detailed location of trailer3. Date in service4. Chassis No5. Contact name and telephone number6. Name of driver and telephone number (if applicable)Once we have this information, Montracon will either appoint an approved repairer to attend or make other arrangements for the work to be completed. OWNERS RESPONSIBILITYDue to the wide variance in the operating conditions of equipment, the owner and/or operator must exercise reasonable diligence in the maintenance and/or operation of this trailer. The owner must assume responsibility for proper care of their trailer, even while it is within the warranty period, including use of Montracon approved lubricants and other approved service parts.Due to the numerous variations in braking systems and electrical circuits and their effects on the performance of the prime mover trailer combination as a whole, Montracon cannot guarantee or be held responsible for any incompatibility between the two vehicles. Should there be the need to undertake a repair; it is up to the owner to release the trailer that has failed within the warranty period and for a reasonable amount of time to allow Montracon to carry out the necessary repairs. It is the owner's responsibility to deliver the trailer to the Montracon nominated premises in a clean condition for inspection and rectification, if applicable. Where the trailer has to be recovered to the nominated premises or if travel or cleaning costs are incurred in order to carry out repairs, the owner will be invoiced for the costs accordingly.

the trailer for road transport e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]MACHINERY CARRIERS7AxlesSuspensionBrakesDisc Caliper/RoterSpring Brake-(Brake chamber)All ABS/EBS SensorsHubAutoslacksAirbagShock AbsorberValveECURaise/Lower ValvePark/Shunt ValveTimber FloorChassis ConstructionValvesElectricsLanding LegsPaint (2 Pack)WinchECOECOECO - This item must be registered with BPW by the operator - ECO PLUS BPWECO MAXECO PLUSECO MAX33N/A12132122233321131YearsMonths3636N/A12241236241224242436363632412123612BPW AXLESHALDEX BRAKING SYSTEMSANCILLARY EQUIPMENTTERMS AND CONDITIONSIf the trailer is found to be defective within the warranty period due to faulty materials or workmanship, then the defective part(s) will be repaired or replaced without charge for parts or labour subject to the following conditions:-1. The work must be carried out by an authorised Montracon representative/repair agent.2. The trailer must not have been neglected, misused or modified. Model designation and serial number plates/stampings must be intact.3. The trailer must have been serviced as recommended in the Operator Handbook using only replacement parts, lubricants and fluids approved by Montracon. Suitable service records should be maintained at the owner's premises as evidence a specific service has been undertaken. 4. This warranty does not apply to those proprietary items whose manufacturers have their own Warranty Policy, e.g. Tyres, Axles, Braking Systems - refer to appropriate proprietary warranty policies for their warranty terms and conditions.5. For more details of the company's warranty terms refer to the 'business terms' which form part of the purchase contract.The warranty given on this trailer is expressly in lieu of and excludes (to the fullest extent permitted by Law) all other representations, conditions, guarantees or warranties expressed or implied. It shall be governed by UK Laws and all claimants under this warranty shall submit to the exclusive jurisdiction of the Courts of the UK. Montracon reserves the right to update or change working policies, procedures and operating systems at any time. WARRANTY PERIODS(Bulbs Not Warrantable)MODULAny damage must be repaired by a suitably qualified person. The trailer should be cleanedregularly and maintained to a suitable standard.(Terms & Conditions apply)Refer to Winch Manufacturer

OPERATING INSTRUCTIONSthe trailer for road transport e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]CONTENTS1. Bolt-in King Pin2. Coupling Trailer to Tractor3. Uncoupling Trailer from Tractor4. Landing Legs5. Checks Before Moving Off6. Know Your Vehicle7. Operating Controls8. Operating InstructionsPage 9Page 9 Page 9 Page 10 Page 11 Page 12 Page 13Page 15This section covers a wide variety of components that are used on Montracon trailers. Not all components will appear on one vehicle, therefore certain instructions contained herein will not apply. Where special instruction beyond the scope of this section is required, this will be supplied as supplementary information.IF IN DOUBT, ASK!MACHINERY CARRIERS

the trailer for road transportBOLT-IN KING PINCOUPLING TRAILER TO TRACTOR UNITUNCOUPLING TRAILER FROM TRACTOR WARNING:WARNING: e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]Check for correct positioning and security. Torque M14 bolts to 190Nm (140lb.ft)To correctly connect the tractor unit to the trailer carry out the following:1. Ensure the trailer park brake is applied.2. Set the trailer Landing Legs to the coupling height(see page 10, Landing Legs, Operation Instructions)3. Check the tractor fifth wheel jaws are open (refer to tractor handbook). To assist trailer coupling, tilt tractor fifth wheel so that the rear end is sloping downwards.4. Remove stabilising support, if applicable.5. With the tractor and trailer correctly aligned, slowly reverse the tractor fully under the trailer fifth wheel plate -into the coupled position.6. Ensure the combination is securely coupled by trying to move forward with the trailer parking brake applied.Visually check to ensure correctly coupled and couplingsecurely locked.7. Connect the tractor’s electrical and air couplings to their respective colour coded couplings on the front of the trailer. Open tractor airline ‘shut off’ cocks, if fitted.Couple hydraulic line(s), if applicable.1. Ensure the trailer park brake is applied.2. Lower the Landing Legs to the ground.(see page 10, Landing Legs, Operation Instructions)3. Disconnect the air and electrical couplings fromthe trailer. Close tractor airline shut-off cocks, iffitted. Disconnect hydraulic lines(s), if applicable.4. Unlock and release fifth wheel coupling. Slowlydrive the tractor unit clear of the trailer.8. Raise the trailer support legs fully and secure correctlyin the running position.9. Test brakes for operation and carry out ‘Checks BeforeMoving Off’ (detailed on page 11).10. Check trailer swing clearance to ensure trailer doesnot foul tractor unit.Before moving away, always check the immediate vicinity of the vehicle.Ensure adequate visibility. Always comply with road traffic regulations.Check height clearance before travelling under bridges etc.Whether loaded or not, when uncoupled from the tractor unit some trailers with a long deck length forward of the support legs or rearward of the running gear may be unstable.MACHINERY CARRIERS9

the trailer for road transportLANDING LEGS e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]WARNING:Never leave landing leg gearbox in neutral.For the purpose of supporting the trailer when uncoupled and for setting the trailer to the required height when coupling.The following instructions should be carried out on firm, level ground. If not, ensure the legs are positioned on suitable foot plates to prevent them from sinking.NOTE: On vehicles fitted with legs operable from either side of the trailer, ensure the handle NOT being cranked is set in the NEUTRAL position before operating.NOTE: The handle on the offside (RH) leg turns in the opposite direction to the handle on the nearside leg(i.e. opposite to the following instructions).To set the legs for coupling:Unclip the cranking handle and push shaft inwards to select low gear. Rotate handle and adjust trailer height so that the coupling plate is level or slightly lower (20mm max) if lead-up ramps are fitted.Couple tractor unit as detailed and then raise the legs.To lower the legs when uncoupling:Unclip the cranking handle and pull shaft outwards to select high gear. Rotate handle clockwise until legs reach the ground - STOP - select low gear by pushing shaft inward and continue cranking until trailer is supported - Do not raise the trailer. Secure handle in stowed position and uncouple trailer as detailed.To raise the legs once coupled:Select high gear, rotate handle anticlockwise until legs are fully raised - Do not force beyond this position. Secure handle in stowed position.MACHINERY CARRIERS10

the trailer for road transportCHECKS BEFORE MOVING OFF e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]The following checks should be carried out in addition tothose quoted in 'Preventative Maintenance and Trailer Care' (Pages 46-60):1. Electrical and Air Lines (and hydraulic lines where applicable)All connections should be tight and clean. Connections should be well supported to prevent pinching or entanglement.2. Lights and MarkersCheck all lights and reflectors are positioned correctly, are clean and functioning properly. Replace damaged components promptly - it's illegal for components not to be functioning correctly.Ensure relevant Emergency Cards or Markings are displayed (refer to Health and Safety information'Dangerous Substances').Ensure correct number plate is affixed to the trailer. NEVER use illegal markings.3. Check Brake OperationAllow system to pressurise, check tractor pressure gauges and if necessary run up until the tractor unit compressor exhausts or “blows off”.Try the service (foot) and third line (hand) controls (where applicable). Listen for air leaks during each application.Carry out an anti-lock brake check, (see page 37).4. Air SuspensionWhen fitted, allow air suspension to reach 'RIDE' height before moving off.Ensure raise/lower or exhaust control (if fitted) is reset prior to moving. Some auto-reset systems require initial energising via the brake light circuit - press the brake pedal prior to moving.5. Lift AxleIf axle is raised ensure the configuration is within legal plated weights.6. Fifth wheelEnsure fifth wheel is locked by pulling forward slightly with the trailer parking brake applied.7. Raise Landing LegsCheck the landing legs are fully retracted and handle is stowed securely.WARNING:WARNING:Always check that fifth wheel coupling islocked before moving off.Ensure landing legs are fully raised before moving off.MACHINERY CARRIERS11

the trailer for road transportCHECKS BEFORE MOVING OFFKNOW YOUR VEHICLE e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]WARNING:8. Check Wheels and TyresGenerally, check the condition of all wheels and tyres, including spares, mudwings, and mud flaps/spray suppression. This includes correct tyre pressures as specified by the tyre manufacturer.9. Check PayloadThe amount and nature of the payload. lf the load is a hazardous one, the driver should be aware of what to do in case of an emergency, i.e. fire or leakage. Check distribution and security of load. See “VOSA Guidance on load security April 2012” available at;www.gov.uk/government/organisations/vehicle-and-operator-services-agency10. Ancillary EquipmentWhere applicable, check the condition of all ancillary equipment and ensure it is correctly positioned/stowed.11. Unsafe EquipmentReport all unsafe equipment before its condition becomes an operational hazard. Check the general condition of your vehicle e.g. load carrying area, sideraves, ladders, handrails, walkways, etc.Know the height, width and length of your vehicle.Check the immediate vicinity of the vehicle.Ensure adequate visibility.Always comply with road traffic regulations.Learn any special operating procedures.MACHINERY CARRIERS12

the trailer for road transportMACHINERY CARRIERSISOLATOR SWITCHREAR RAMP CONTROLSFRONT NECK RAMP CONTROLSDUAL PURPOSE POWER PACK CONNECTOROPERATING CONTROLS e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]This switch isolates power to the winch. When in the off position the winch will not operate.This connector provides power from the tractor unit to the Power Pack of the trailer thus allowing operation of the winch and ramp controls.1. RAMP POWER PACK BUTTON2. N/S RAMP RAISE/LOWER LEVER3. O/S RAMP RAISE/LOWER LEVER4. N/S RAMP SIDE SHIFT LEVER 5. O/S RAMP SIDE SHIFT LEVER The rear ramp controls are strategically located in the side rave ensuring the operator has good visibility of the rear ramps and deployment area. See page 15-18for correct operating procedure.1. SUPPORT PIN CONTROL2. NECK RAMP RAISE/LOWER CONTROLThe neck ramp is pneumatically raised/lowered by inflating or deflating a large airbag positioned underneath the neck ramp. See Page 19 for correctoperating procedure.131132542

the trailer for road transportLIFT AXLE (AS EQUIPPED)SUSPENSION COMBINED RAISE / LOWER AND DUMP CONTROLSWITCHES / BUTTONS (AS EQUIPPED)PARKING BRAKE e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]MACHINERY CARRIERSPull to disable the lift axle functionality.The raise/lower valve allows raising/lowering of the trailerby pressurising/depressuring the air suspension bellows.This control will also ‘dump’ the suspension if required.See page 31 for correct operating procedure.1. WORK LAMPS 2. ROATATING BEACON/STRODE LIGHTING 3. TRACTION HELP BUTTON4. REAR RAMP ACTUATION BUTTON1. PARK BRAKE BUTTON2. TRAILER BRAKE RELEASE BUTTON14132412

the trailer for road transport e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]MACHINERY CARRIERSHYDRAULIC RAMP OPERATIONOPERATING INSTRUCTIONS1. Position the trailer on a firm, flat level surface.2. Apply the trailer parking brake and connect the power pack connector (4).3. Lower the steady legs, (see page 16 for correct procedure).5. Extend reflective triangles before lowering ramps.6. Undo the ramp straps and store the strap in a suitable location, near to the trailer.4. Lower the air suspension using the raise/lower control on the trailer suspension, (see page 31 for correct procedure).WARNING:WARNING:Check the area, make sure it is clear and no-one islikely to walk around the back of the trailer.Make sure the steady legs are stored and securebefore commencing travel.7. Whilst pressing the ramp actuation button (1), operate the relevant control lever (2 or 3) to lower each ramp to the ground.NOTE: If Flip-Toe ramps are fitted, as the ramps are lowered the toe-end of the ramp will automatically unfold.8. Once loading is complete, raise the ramps to the vertical position and secure using the ramp straps.9. Raise the trailer suspension to the normal ride height.10. Return the reflective triangles to their stored position.11. Put the folding steady legs back into the stored position.1. RAMP POWERPACK ACTUATION BUTTON2. N/S RAMP RAISE/LOWER LEVER3. O/S RAMP RAISE/LOWER LEVER152413

the trailer for road transport e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]FOLDING STEADY LEGS (STANDARD FITMENT)HYDRAULIC STEADY LEGS (AS EQUIPPED)FLIP-TOE RAMP OPERATIONMACHINERY CARRIERS1. Pull on the spring loaded locking pin.2. Allow the support leg to swing down into the verticalposition and store the locking pin in the parking hole.3. To raise the leg; swing the leg up by hand and returnthe spring loaded locking pin to its home position.IMPORTANT: Always make sure the steady leg is deployed before loading/unloading.1. Whilst pressing the actuation button (1) operate thesteady leg control lever (2) to raise/lower the leg asrequired.IMPORTANT: Always make sure the hydraulic steady legis in contact with the ground before loading/unloading.As the ramps are lowered the toe-end of the ramp will automatically unfold.1612

the trailer for road transportLOADING/UNLOADING e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]MACHINERY CARRIERSWARNING:Always abide legal weight restrictions when loading.Understand the axle load limitations and the limitations of the tractor unit.Always ensure a straight-line loading angle prior to commencing loading/unloading operations.IMPORTANT: Side loading should not be undertakenunder any circumstances.IMPORTANT: When loading / unloading ensure the steady legs are lowered before lowering the trailer suspension. The steady legs must be used at alltimes as well as lowering the suspension.Load LashingIMPORTANT: Rope hooks should not be used to anchor loads. Rope hooks are not subject to constructional standards and so could vary in strength. Lashing rings should be used at all times to secure the load to the bed of the trailer. If in doubt consult Department of Transports Code of Practice on “Safety of Loads on Vehicles for the correct loading/unloading and securing of load regulations.Care of Deck Lashing RingsDeck lashings must be kept free from foreign objects, ie. stones, gravel, nuts & bolts, sludge etc. Deck lashings are designed to work freely and must be kept “home”, in the recess of the deck. Under no circumstances should the lashing rings be left up and open when not in use.The above shows a desk mounted lashing ring left open and driven over, this is extremely dangerous, the machine could slip and cause it to leave the side of the trailer. In the open position lashings can be a trip hazard. Always check the condition of each lashing ring for damage and replace as necessary.17

the trailer for road transportHYDRAULIC RAMP WIDTH ADJUSTMENT (SIDE SHIFT RAMPS) e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]MACHINERY CARRIERSIMPORTANT: The side-shift ramps must only be moved sideways in the vertical position. Trying to slide the ramps once they are lowered will increase the load bearing on the slide mechanism and subsequent damage may occur.1. RAMP ACTUATION BUTTON2. N/S RAMP SIDE SHIFT LEVER3. O/S RAMP SIDE SHIFT LEVER1. Position the trailer on a firm, flat level surface.2. Apply the trailer parking brake and connect the power pack connector (4).3. Lower the steady legs, (see page 16 for correct procedure).4. Lower the air suspension using the raise/lower control on the trailer suspension, (see page 31 for correct procedure).7. Slacken, but do not remove the ramp straps.5. Extend reflective triangles.6. Unlatch the locking pin in the slider plate (5).8. Undo the ramp straps and store the strap in a suitable location, near to the trailer.WARNING:Check the area, make sure it is clear and no-oneis likely to walk around the back of the trailer.9. Whilst pressing the ramp actuation button (1) operate the relevant control lever (2 or 3) to slide the ramp to the desired position.10. Continue to press the ramp actuation button and operate the relevant control lever to lower each ramp to the ground.IMPORTANT: After raising the ramps slide them back into the normal travel position. Make sure the slider plate locking pins are engaged and locked before commencing travel.1815324

the trailer for road transportFRONT NECK RAMP e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]MACHINERY CARRIERS1. SUPPORT PIN CONTROL2. NECK RAMP RAISE/LOWER CONTROLThe neck ramp is pneumatically operated via a large airbag positioned underneath the neck ramp. The neck ramp is raised and lowered by inflating and deflating the air bag accordingly.1. Push in the support pin control (Red Button)to retract the support pins and rotate the buttonto lock the valve in position.2. Push in the neck raise/lower control (Blue Button), the air bags will inflate and raise the ramp to full height.3. Once the ramp is at full height twist the support pin control thus allowing it to spring from the locating position. The support pins will extend out from the neck (under the neck ramp).To lift the ramp:To lower the ramp:4. When the support pins are fully extended, pull outthe neck ramp raise/lower valve to lower the ramp and rest on the support pins.IMPORTANT: Always make sure the neck ramp is lowered and resting on the support pins before loading onto the neck area.1. Push in the neck raise/lower control (Blue Button)to raise the ramp off the support pins.2. Push in the support pin control (Red Button)to retract the support pins and rotate the buttonto lock the valve in position.3. Pull out the neck raise/lower control (Blue Button) tolower the neck ramp.1921

the trailer for road transport e: [email protected] | w: www.montracon.com t: [phone] | f: [phone]MACHINERY CARRIERSCLIP-ON RAMPS (AS EQUIPPED)GRIP BARS1. REAR CLIP-ON RAMPS2. NECK CLIP-ON RAMPSAs an alternative to the hydraulically powered loadingramps, clip on ramps may have been specified.Always store the ramps safely before commencing travel.Grip bars must be kept free from foreign objects andsludge, dirt etc. Periodically check for damage. Repairor replace as necessary.4. RAMP STOWAGE, REAR LOADING OPTION3. RAMP STOWAGE, SIDE LOADING OPTION20WARNING:Clip-on ramps have a load rating. Make sure thecorrect ramps are used to suit the load.