View Operator`s Manual - Fontaine Chassis Trailers
Contents
1. on FONTAINE ENGINEERED PRODUCTS Decal Locations ABS decal A CD ges ENNI CD mm 1 T p E pk T on ABS Indicator light IF ANY OF THESE DECALS ARE MISSING CONTACT IF ANY OF THESE DECALS ARE MISSING FONTAINE PARTSOURCE FOR REPLACEMENT IN CONTACT FONTAINE ENGINEERED PROD FORMATION AT 866 382 7278 IN SOME INSTANC UCTS FOR REPLACEMENT INFORMATION ES DECALS MAY BE UPDATED OR REPLACED BY THE FOLLOWING DECALS REPRESENT OTHER DECALS THE PRECEDING DECALS REPRE THE STANDARD DECALS AND THEIR LOCA SENTED THE STANDARD DECALS AND THEIR LO TIONS AT THE TIME OF PRINTING CHAS CATIONS AT THE TIME OF MANUFACTURE SIS MANUFACTURE NOTE The decals appearing above are only a representation of some of the decals that may be found in this area of your Fontaine Chassis The decals above are not and are not intended to provide a complete representation of the decals that may be placed in this area FONTAINE ENGINEERED PRODUCTS Your Fontaine chassis is equipped with an OEM selected landing gear designed to meet the needs of the industry The operational characteristics are shown below Extend CW Retract CCW TRAVEL DIRECTIONS Rotate crank clockwise to extend landing gear and counterclockwise to retract landing gear Stow handle when not in use LANDING GE2. T on Suspension System Axle Alignment Your Fontaine chassis 15 equipped with either an air AXLE ALIGNMENT ride suspension or mechanical spring Suspension M NE SINGLE AXLE CHASSIS Common suspension suppliers to Fontaine include Hendrickson Meritor and Hutch Additional informa 1 Raise or lower the landing gear legs to position tion including installation service maintenance rec chassis kingpin plate at design height if Known ommendations warranty and general sales data for all use 49 if actual design height is unknown of ial _ beds i their websites Links 2 Remove the outer wheel assembly or the outer Tel ESI aie SNOWN tires and rims depending on the wheel equip Hendrickson www Hendrickson Intl com ment Meritor www meritor com 3 Remove any parts from under the chassis that can 2 interrupt measuring the distance between the king Hutchens Industries www hutchensindustries com pin and the ends of the axle SAF Holland www SAFHolland us 4 Attach a steel measuring tape to a hook and the hook over the kingpin Measure the distance A and B from the king pin to the ends of the axle The difference between the A and B measure ments must not exceed 1 8 3 2mm A cp quas T Em CD mm 1 T p E pk T on Y 1 FONTAINE ENGINEERED PRODUCTS 10
3. Fontaine Ghassis Operator s Manual FONTAINE ENGINEERED PRODUCTS Marmon Highway Technologies Berkshire Hathaway Company Copyright 2014 Fontaine Engineered Products 07 14 Contents Read this manual carefully and completely before operating or performing maintenance on your Fontaine Chassis If you have any questions regarding your Fontaine Chassis Please contact Fontaine Service at 866 382 7278 Section 1 Operating Instructions Operating ALES CAL SE 3 Operating Limits And Restrictions 4 Bre esce m T PET 9 e c MEER T 9 Suspension System Axle Alignment eene 10 Anti Lock Braking System eene nnne enne nnn 12 Anti Lock Braking System Lamp Codes enn 19 Coupling and Uncoupling EE E T T 14 MMS eM Gosden 17 Sliding Suspension Operation 18 Sliding Suspension Positioning T E 18 Section 2 Optional Features and Instructions Basic Maintenance Schedule 19 Section 3 Preventive Maintenance LT SIS AMO Put WO apra 20 Basic Chassis Maintenance 20 Leaf Type Springs Care And Maintenance 21 Wheel and RIM CARS anna ee ca data en ie 21 How To Service And Install Wheel Bearings 22 Wheel Installation and Maintenance 23 Self Adjusting Slack AdIUSIGF isis ara ed ea e Re pb Aa rae rada 29 Tips for Prolonged Brake Drum Life
4. Suspension System Axle Alignment TANDEM AXLE CHASSIS Measuring the alignment of a tandem axle chassis is not very different from the procedure for the single axle chassis The chassis must be correctly posi NOTE tioned before making the necessary measurements THE LIMITS OF 1 16 1 6MM AND 1 8 1 Move the chassis forward and backward over a 3 2MM ARE THE INDUSTRY STANDARD level floor two or three times with the last move LIMITS FOR CORRECT ALIGNMENT OF THE ment forward to permit the suspension to be AXLES THESE SMALL VARIANCES PERMIT come correctly aligned to center the front and rear TED BY THE STANDARD MAKE ACQUIR ING ACCURATE MEASUREMENTS ALL THE 2 Raise or lower the landing gear legs to position MORE IMPORTANT AND CRITICAL TO THE chassis kingpin plate at design height if known PROPER OPERATION OF YOUR CHASSIS use 49 if actual height is unknown 3 Remove the outer wheel assembly or outer tires How to Correct the Alignment of Axles and rims To correct alignment measurements that are not within the limits inspect the suspension for worn broken or loose parts Adjustment to the suspension and the replacement of worn or broken parts must be made to achieve an acceptable axle alignment 4 Remove any parts from under the chassis that can interrupt measuring the distances between the Kingpin and the ends of the forward axle 5 Attach a steel measuring tape to a hook and the hook over the kingpin
5. cb0786f5da T71005 PRECISION NUT SYSTEM Installation Procedu aspx pdf Hendrickson Standard Wheel end Maintenance http www hendrickson intl com CMSPages GetFile aspx guid e492c099 b3 0 40b4 bb42 ooe20a224b8d Hendrickson HXL3 Wheel end Maintenance http www hendrickson intl com CMSPages GetFile aspx quid 12294 fof 0056 44f0 a907 40e50d76fdce Hendrickson HXL5 Wheel end Maintenance http www hendrickson intl com CMSPages Then tighten to full torque using the same sequence 10 stud Thread Size Torque Standard Capnut 3 4 46 and 1 1 8 16 450 500 Ft Lbs GetFile aspx guid ab 2b69c 5038 4670 809d 118579831179 Hendrickson HXL Wheel end Maintenance http www hendrickson intl com CMSPages GetFile aspx guid 71042c45 39ae 49ea aa6f Aff9b 7 af5 Y 7 1 Adjustment Info can also be found in the TMC Recommended Practices RP618A amp RP622A DISASSEMBLY AND REPAIR OF ANY WHEEL THE TORQUE LISTED IS FOR DRY THREADS WITH NO LUBRICANT PROPER CAPNUT TORQUE 1 IMPORTANT INSUFFICIENT TORQUE CAN CAUSE STUD BREAKAGE AND DAMAGE OVER TORQUE CAN OVER STRESS THE STUDS AND STRIP THE THREADS END IS A COMPLEX AS WELL AS A SAFE INI TY RELATED TASK THAT SHOULD NOT BE i UNDER TAKEN BY AN INEXPERIENCED MECHANIC SPECIAL TOOLS AND INFOR iz MATION ARE REQUIRED REFER THESE FONTAINE REPAIRS TO YOUR FONTAINE DEALER ENGINEERED PRODUCTS 23 Wheel Installation and Maintenance 4 Position t
6. sis at all times and should be left with the chassis when if it is sold M M A CD ges ENNI CD a 1 T p E pk mE T on FONTAINE ENGINEERED PRODUCTS Operating Limits And Restrictions This FONTAINE chassis was designed for operation within legal highway speed limits on reasonable road surfaces for the type of service it was built to perform in accordance with the following 1 This chassis was built to carry cargo within the limitations of two weight ratings on the identifica tion plate These ratings GAWR and GVWR are a The GAWR gross axle weight rating is the structural capability of the lowest rated mem ber of the running gear components suspen sions hub wheels and drums rims bearings brakes axles or tires b The GVWR gross vehicle weight rating is the structural capability of the chassis when supported by the kingpin and axles with the load uniformly distributed throughout the cargo space as defined by the V plate 2 The Concentrated load rating is the structural ca pability of the chassis frame for non uniform loads that are concentrated on the deck of the chassis in a specified location Contact a Fontaine Dealer or Representative for the concentrated rating for your chassis THE PUBLISHED GVWR GAWR AND CONCENTRATED LOAD RATINGS SHOULD NEVER BE EXCEEDED THE MAXIMUM LOAD INDICAT
7. In the event of an ECU malfunction the ABS in the affected wheels is disabled The affected wheels should continue to operate in a non ABS braking mode if the braking valve itself has not failed The ABS should continue to operate on the wheels unaf fected by the ECU malfunction Two ABS indicator lamps one on the dash of the tractor and one on the side of the chassis let the driver know the status of the system M M I FONTAINE ENGINEERED PRODUCTS A CD ges ENNI CD a 1 T p E pk mE T on 12 Anti Lock Braking System Lamp Codes ABS INDICATOR LAMP If the ABS lamp comes ON and stays ON when you The ABS Indicator Lamp amber is located on the apply the brakes to a moving vehicle there is an ABS road side driver side near the rear marker lamp malfunction It is normal for the lamp to come ON red The lamp is identified with the letters ABS This and go OFF to perform a bulb check but it should lamp indicates the status of the chassis ABS not stay ON when the vehicle is moving about 4 MPH As with any safety system it is important not to ignore this indicator If the indicator lamp indicates a malfunction the vehicle can be operated to complete the trio However it is important to have the vehicle serviced as soon as possible using the appropriate maintenance manual to ensure proper braking perfor mance and to ensure
8. Make sure the surface of the parking area can support the weight of chassis Have tractor lined up with chassis Pulling out at an angle can damage landing gear 2 EASE PRESSURE ON LOCKING JAWS Shut off chassis air supply to lock chassis brakes Ease pressure on fifth wheel by backing up gently this will help to release the fifth wheel locking lever Put parking brakes on while tractor is pushing against the kingpin This will hold the rig with pres sure off the locking jaws 3 LOWER THE LANDING GEAR If chassis is empty lower the landing gear until it makes firm contact with the ground turn crank in low gear a few extra turns this will lift some of the weight off the tractor Do not lift chassis off the fifth wheel This will make it easier to unlatch the fifth wheel and easier to re couple DISCONNECT AIRLINES AND ELECTRICAL CABLE Disconnect airlines from chassis Connect airline gladhands to dummy couplers at back of cab or couple them together Hang electrical cable with plug down to prevent moisture from entering it Make sure lines are supported so they won t be damaged while driving the tractor 32 8 9 UNLOCK FIFTH WHEEL Raise release handle lock Pull the release handle to the open position otay clear of the rear of the rear tractor wheels to avoid serious injury in the event vehicle movement PULL TRACTOR PARTIALLY CLEAR OF CHASSIS Pull tractor forward until fif
9. Measure the distance A and B from the king pin to the ends of the for ward axle The difference between the A and _ ACAUTION measurements must not exceed 1 8 3 2mm CAREFULLY FOLLOW THE SERVICE IN 6 Measure the distance C and D between STRUCTIONS MADE AVAILABLE BY THE the front and rear axle centers The difference SUSPENSION MANUFACTURER WHEN between C and D measurements must not WORKING ON THIS COMPONENT A cp quas T Em CD mm 1 T p E pk T on exceed 1 16 1 6mm See art below NOTE SEE HENDRICKSON PROCEDURE L579 FOR MORE DETAILED INFORMATION www Hendrickson Intl com SAF Holland www SAFHolland us in JN FONTAINE ENGINEERED PRODUCTS 11 Anti Lock Braking System ABS NOTICE CONNECTOR WIRING CHANGE NOTICE TO ALL TRACTOR CHASSIS OWN ERS AND USERS Federal Motor Vehicle Safety Standard No 121 Air Brakes Systems was amended by the National Highway Traffic Safety Administration of the DOT to require that truck tractors manufac tured on or after March 1 1997 provide con stant power for a chassis antilock brake system ABS Some manufacturers will provide this feature before the effect date These tractors using a single 7 way electrical connector will have constant power for ABS on the center pin when the key switch 1
10. 26 TGS A IR CIRE AO 26 Demounting and Mounting Tires 28 bui a Lm 29 SIS OB a E ee 30 Section 4 Troubleshooting Guide Wheels Tires and Alignment 31 1 10 0 GE E EET T m 32 ks REPRE 32 Fontaine Chassis Parts 33 Section 5 Important Information T 34 le dt Maintenance Record NT T m m M 37 M M I FONTAINE ENGINEERED PRODUCTS Operating Instructions This manual has been prepared to assist you in the safe operation and maintenance of your FONTAINE Chassis It contains important information on the proper use of your FONTAINE Chassis and the ma jor components and optional equipment included THIS SYMBOL IS USED THROUGHOUT THIS MANUAL TO CALL ATTENTION TO THE PROCEDURES YOU MUST FOLLOW EXACTLY CARELESSNESS OR FAILURE TO FOLLOW INSTRUCTIONS MAY LEAD TO DEATH OR SERIOUS INJURY THIS SYMBOL IS USED THROUGHOUT THIS MANUAL TO CALL ATTENTION TO THE PROCEDURES YOU MUST FOLLOW EXACTLY CARELESSNESS OR FAILURE TO FOLLOW INSTRUCTIONS MAY LEAD TO DEATH OR SERIOUS INJURY THIS SYMBOL IS USED THROUGHOUT THIS MANUAL TO CALL ATTENTION TO OPERA TIONS PROCEDURES AND INSTRUCTIONS THAT ARE IMPORTANT FOR PROPER SER VICE IT MAY ALSO INDICATE INFORMA TION THAT CAN MA
11. ANY DAMAGE TO YOUR TIRES OR WHEELS RIMS SEE ANY OF YOUR TIRE DEALERS AT ONCE Before driving inspect your tires including the spare and check your air pressures If your pressure check indicates that one of your tires has lost pressure of four pounds or more look for signs of penetrations valve leakage or wheel rim damage that may ac count for air loss Always examine your tires for bulges cracks cuts or penetrations If any such damage is found a Tire dealer must inspect the tire at once Use of a dam aged tire could result in tire destruction property damage and personal injury DRIVE CAREFULLY All tires will wear out faster when subjected to high speeds as well as hard cornering rapid starts sud den stops and frequent driving on surfaces that are in poor condition Surfaces with potholes or rocks and other objects can damage tires and cause vehicle misalignment When you drive on such surfaces drive on them carefully and slowly and before driving at normal or highway speeds examine your tires for any damage such as cuts or penetrations DO NOT OVERLOAD The maximum load that can be put on a truck tire is dependent upon the speed at which the tire will be used Consult your Tire dealer for complete informa tion on the allowable loads for your tires in your ap plication Tires that are loaded beyond their maximum allowable loads for the particular application will build up excessive heat that may result in sudde
12. a wrench on the hex will make this rotation easier to see This rotation indicates that an excessive clearance condition has been determined by the slack adjuster and it is making an adjustment to compensate On each subsequent brake release the amount of adjustment and pushrod travel will be reduced until the desired clearance is achieved 5 Refer to the Slack Adjuster manufacturers lit erature for more detailed information and proper pushrod stroke requirements REFER TO THE SLACK ADJUSTER MANU FACTURER RECOMMENDATIONS FOR COMPLETE DETAILS ON MAINTENANCE INSPECTION AND TROUBLESHOOTING OF THIS COMPONENT LUBRICATION The Self Adjusting Slack Adjuster should be lubri cated in conjunction with the lubrication prescribed for vehicle chassis The lubrication interval should not however exceed 10 000 miles or 3 months No spe cial grease is required however the use of moly disul phide loaded grease or oil is not recommended since it may lower friction capabilities in the adjusting clutch parts and decrease automatic adjustment reliability INSPECTION 1 During normal lubrication intervals visually inspect slack adjuster and anchor bracket for damage Check that anchor bracket is tight and the control arm is in its Full Release position refer to manu facturer literature 2 Maintaining proper brake adjustment and brake bal ance cannot be accomplished by the slack adjuster alone The condition of foundation bra
13. and at all inspections for excessive wear deformation and 372 406 372 406 609 677 372 406 47 68 115 129 Structural soundness Always apply torque to nuts possible All fasteners must be re torqued after initial 1 000 miles and thereafter at JA 5 0001 25 000 intervals m au Copyright 2012 SAF HOLLAND Inc www safhalland us XL M5189 01 Rev M TO REPOSITION SLIDER 1 Remove stop bar and move to desired location Lift pull arm and pull until locked in the OUT position If lock pins do not retract after pull arm is locked in the OUT position gently rock trailer with brakes applied and pins will automatically retract Apply trailer brakes and carefully move trailer until contacting stop bar Failure to properly engage the lock pins could result in loss of vehicle Release pull arm to the IN position and visually check all lock OUT control which not avoided could result in death serious injury pins for proper engagement gt POSITION d SE 3 property damage Locate stop bar directly behind slider Before moving the trailer the pull arm must be locked in the IN IN 57 SL0255 position and all lock pins must extend through the rails or beams POSITION S follan Copyright 2012 SAF HOLLAND Inc www safholtand us uurin P A CD ges ENNI CD a 1 T p E pk mE T
14. different spindle nut systems offered and where to find the correct adjustment procedure Feel free to contact Fontaine PartSource a Fontaine dealer or the OEM factory for help in determining the system on your chassis FONTAINE ENGINEERED PRODUCTS 22 Wheel Installation and Maintenance Disc Wheel Mounting Instructions for 6 amp 10 Stud Hubs with BALL SEAT Mounted Disc Wheels How To Service And Install Wheel Bearings Some links to popular websites pertaining to chassis axle and suspension information including wheel end adjustment procedures are shown below Copy the link into your web browser to access recommended Rims must be correctly assembled using the correct adjustment procedures capnuts and must be correctly aligned to assure maxi Webb Wheel Company http www webbwheel com mum service life and maximum safety aftermarket training toolbox html 4 Hendrickson International www Hendrickson Intl com All parts must be clean free of rust dirt or paint 2 Position the inner wheel over the studs being careful Arvin Meritor www Meritor com not to damage the threads Install inner capnuts and tighten to 50 FT LBS in the sequence shown Stemco Bearing Adjustment Procedure 3 http www stemco com wp content up loads 2011 12 STEMCO BearingAdjust 5 1 2902 WEB pdf Hendrickson Poster Precision Nut System http www hendrickson intl com getattachment 501 103c4 c552 4c7 7 98b9 bc
15. that the benefits of ABS remain available to the driver ABS Indicator light System 15 Ignition Powered constant power ER Fault in Indicator Lamps Brakes Ignition Vehicle Speed Chassis and Dash Less than 4 mph ON for 3 seconds then go OFF Released ON Greater than 4 mph Less than 4 Zo ON for 3 seconds then go OFF Applied mE ess than 4 pem ON for 3 seconds then go OFF 0 Blink Codes Blink codes are the number of times the ABS lamp blinks and off The number of blinks refers to the problem area See Meritor Wabco Maintenance And Troubleshooting Manual for complete details A CD ges ENNI CD a 1 T p E pk mE T ENNI I FONTAINE ENGINEERED PRODUCTS 13 Knowing how to couple uncouple correctly is 4 BACK SLOWLY basic to safe operation of combination vehicles Back until fifth wheel touches the chassis General coupling and uncoupling steps are listed below Different tractors and coupling devices require e Do not impact the chassis different techniques so learn the details for coupling 5 SECURE TRACTOR and uncoupling the tractors and coupling devices you e Apply the parking brake operate e Shift the transmission into neutral 6 CHECK CHASSIS HEIGHT A WARNING e The chassis should be low enough so that it is raised slightly by the tractor when
16. under inflated tire builds up excessive heat that may result in sudden tire destruction The correct inflation pressures for your tires are a function of many factors including load speed road surface and handling Consult your tire dealer for the proper infla tion pressures for your application Check inflation pressures on all your tires at least once a week including spares FAILURE TO MAINTAIN CORRECT INFLA TION PRESSURE MAY RESULT IN SUDDEN TIRE DESTRUCTION IMPROPER VEHICLE HANDLING AND MAY CAUSE RAPID AND IRREGULAR TIRE WEAR THEREFORE INFLATION PRESSURES SHOULD BE CHECKED WEEKLY AND ALWAYS BEFORE LONG DISTANCE TRIPS Pressure should be checked when tires are cold before they have been driven over the road The ideal time to check tire pressures is early morning Driving even for a short distance causes tires to heat up and air pressures to increase Never bleed air from hot tires as your tires will then be under inflated Make sure to check both tires in a dual fitment Pressures should be the same For optimum tire performance it is usually best to use the tire inflation pressure recommended by the tire manufacturer for the particular axle load Exceed ing this pressure could result in reduced traction and tread life M M EL I FONTAINE ENGINEERED PRODUCTS 26 Tire Maintenance TIRE INSPECTION While checking inflation pressures it is a good time to INSPECT YOUR TIRES ANY TIME YOU SEE
17. 5 on Fontaine as well as other tractor chassis own ers and users who presently use the center pin for auxiliary power to equipment other than chassis ABS for example dome lights backing lights bottom dumps sliding undercarriages air ride dump valves etc will be affected by this change In certain uses of this constantly pow ered center pin connector unexpected or unintended activation of this equip ment may be hazardous or result in personal injury BEFORE connecting your chassis to a tractor MAKE SURE that the constantly powered cen ter pin WILL NOT UNINTENTIONALLY TURN ON CHASSIS EQUIPMENT If you have any questions about your present wiring or how to rewire your vehicles you should contact Fon taine PartSource at 1 866 382 7278 Meritor WABCO Easy Stop TM Anti lock Braking System ABS is standard equipment on all Fontaine chassis with GVWR less than 120 000 16 The sys tem monitors wheel speed at all times and improves vehicle stability and control by reducing wheel lock during braking ABS INFORMATION IN THIS OPERATOR S MANUAL WAS PROVIDED BY MERITOR WABCO AND IS SPECIFIC TO ITS PROD UCTS IF YOUR CHASSIS IS EQUIPPED WITH ANOTHER MANUFACTURER S ANTI LOCK BRAKING SYSTEM YOU MUST CON TACT FONTAINE OR THE MANUFACTURER OF THE BRAKING SYSTEM FOR THE IN STRUCTIONS SPECIFIC TO THAT BRAKING SYSTEM VISIT WWW MERITORWABCO COM FOR MORE INFORMATION ELECTRONIC CONTROL UNIT ECU MALFUNCTION
18. AR BOLTS USE A MINIMUM 5 8 GRADE 5 BOLT ON ALL LANDING GEAR CONNECTIONS EXCEPT ON CROSS PIPE ON CROSS PIPE USE A MINI MUM 5 16 GRADE 5 BOLT TORQUE CHART 5 16 Grade 5 17 Ft Lbs Dry 13 Ft Lbs Oiled 5 8 Grade 5 150 Ft Lbs Dry 110 Ft Lbs Oiled Gear Speed Operation Pull 2 speed handle out for high speed operation Push 2 speed handle in for low speed operation For low speed extension or retraction push crank in For high speed extension or retraction pull crank out A CAUTION Do not over extend landing gear Never drop chassis on landing gear Al ways extend landing gear until the landing gear foot contacts the ground then lift the chassis approximately 1 inch before re moving the tractor from the chassis Always ensure that the landing gear foot rests on a hard surface capable of sup porting the chassis and load hard ground concrete etc If necessary place foot pads on a support plank to prevent the landing gear from sinking into the surface Always retract landing gear fully before moving the chassis Always store the crank in the crank holder after extending or retracting the landing gear Replace all damaged or worn parts Failure to replace worn or damaged riser nut and retracting screw assembly could cause a failure FONTAINE A CD ges ENNI CD mm 1 T p E pk
19. Correct brakes as required 7 Rapid stopping 7 Apply brakes slowly when approaching stop 8 High speed driving on turns 8 Reduce speed GD oo 1 E E E J E CD 31 DIFFICULTY IN TURNING HANDCRANK Probable Cause Remedy 1 Bent crank shaft 1 Straighten or replace shaft 2 Bent cross shaft 2 Replace shaft 3 Lack of lubricant or correct lubricant 3 Lubricate in accordance with lubri cation chart 4 Gears or components damaged 4 Free up or replace 5 Jackscrew nut jammed 5 Replace inner leg assembly Electrical System WIRING FUSES amp CIRCUIT BREAKER Probable Cause Remedy 1 Circuit breaker kicks off 1 Correct short Splice or repair wir Ing 2 Wires burned 2 Heplace wiring 3 Contact points dirty or corroded 3 Hemove lamp unit and clean 4 Loss of ground at bulb 4 Repair as necessary COMPLETE LOSS OF CHASSIS LIGHTS Probable Cause Remedy 1 Broken main harness 1 Repair or replace wire 2 Blown fuse or breaker 2 Replace fuse GD oo 1 E Gp Ge 3 Broken ground lead between tractor 3 Check repair or replace jumper and chassis cable if equipped 4 Loose or corroded connection in 4 Repair or replace ground lead between tractor and chassis DIM OR FLICKERING LIGHTS Probable Cause Remedy 1 Battery on tractor n
20. ED ON THE IDENTIFICATION PLATE MAY OR MAY NOT BE A LEGAL LOAD ON THE HIGHWAY YOU PLAN TO USE Beginning March 1 1998 all chassis are required by law to have anti lock brake systems on at least one axle per FMVSS 121 49CFR 571 121 A 45 2 system means there are 4 sensors and 2 modulator valves controlling the axles while a 25 1 system is 2 sensors and 1 modulator valve Refer to the manu facturer of the ABS system for specific information on the various components A cp quas T Em CD a 1 T p E pk mE ENNI FONTAINE ENGINEERED PRODUCTS Decal Locations DECALS ARE AN IMPORTANT PART OF THE CHASSIS OPERATION KNOWING WHERE DECALS ARE LOCATED AND WHAT IN FORMATION THEY CONVEY WILL HELP IN THE MAINTENANCE OF THE CHASSIS THE SAFE OPERATION OF THE CHASSIS AND IN MAINTAINING COMPLIANCE WITH STATE AND FEDERAL REGULATIONS IF ANY OF THESE DECALS ARE MISSING CONTACT FONTAINE FOR REPLACEMENT INFORMATION THE FOLLOWING DECALS REPRESENT THE STANDARD DECALS AND THEIR LOCATIONS AT THE TIME OF PRINT ING CHASSIS MANUFACTURE NOTICE If the ABS indicator lamp comes on and stays on when you apply the brakes to a moving vehicle the trailer ABS is not working properly The ABS must be serviced as soon as possible upon completion of your trip to ensure full anti lock braking capability rP 95172 MERIT
21. ED PRODUCTS 34 Index e S ABS NOTICE Connector Wiring Change 12 Maintenance lt Anti Lock Braking System 12 Daily Intervals and Pre Trip 19 Anti Lock Braking System Lamp Codes 13 MODO 19 AXC eme 10 qi cm 19 Maintenance Record 37 E B E Basic Chassis 20 N ES Basic Maintenance Schedule 19 NATSA REDOING 34 o 26 O e E vee A EEE E TET 30 Operating sesotsams oras desi 2 3 a C Operating Limits And Restrictions 4 CONS 29 R EE 2 Saini v genie MUTO 29 1 a ICE ius 29 e Coupling and Uncoupling 14 Ee Reporting Safety 34 5 mE gnum Self Adjusting Slack Adjuster 25 Demounting and Mounting Tires 28 25 Sliding Suspension Operation 18 BICC Sy SII T 29 32 Sliding Suspension POSITIONING 18 Suspension System Axle Alignment How to Correct the Alignment of Axles 11 ENTE
22. KE SERVICE QUICKER OR EASIER All operator instructions are provided for assistance in the proper operation of your chassis Specific com ponent operating instructions and your company s procedures should be consulted These may include DOT and employer training programs or instructions This manual includes safety checks the chassis op erator must perform It is important that every chassis owner and or opera tor have an organized Trailer Preventive Maintenance program TPM The United States Department of Transportation requires by law that maintenance re cords be kept on every commercial highway vehicle It is to your advantage to be able to show that regu larly scheduled TPM inspection checks have been made on every piece of equipment operated A regular TPM program will not only assure you will get the most usage from your chassis but will also assist in demonstrating that the equipment has been properly maintained You can get help in setting up and operating a chas sis preventive maintenance program by sending for a Maintenance Manual for Trailers and Contain ers Contact the Truck Trailer Manufacturers As sociation 1020 Princess Street Alexandria Virginia 22314 IMPORTANT Read this manual carefully Should you have any questions contact a FONTAINE factory representative immediately 1 205 385 0930 For Warranty Parts and Technical Service call 1 866 382 7278 This manual should be kept with the chas
23. LACING ANY PART OF YOUR BODY BETWEEN THE TRACTOR AND CHASSIS TRACTOR MOVEMENT CAN CAUSE SERIOUS INJURY OR DEATH 14 CONNECT ELECTRICAL CORD and CHECK AIRLINES e Plug the electrical cord into the chassis and fasten the safety catch Check both airlines and electrical line for damage Make sure air and electrical lines will not be crushed or damaged by any of the vehicles mov ing parts e Visually inspect to see that the ABS light functions correctly when the power cord is connected If the light stays on or comes on during use have the ABS unit repaired at once 15 RAISE FRONT CHASSIS SUPPORTS LAND ING GEAR e Use low gear range if equipped to begin raising the landing gear Once free of weight switch to high gear range e Raise landing gear all the way up After raising the landing gear fully secure the crank handle When full weight of chassis is resting on tractor check for clearance between rear of tractor frame and landing gear Check that there is enough clearance between the top of the tractor tires and the nose of the chassis NEVER DRIVE WITH THE LANDING GEAR PARTIALLY DOWN IT COULD HANG ON RAILROAD TRACKS OR OTHER OBJECTS FONTAINE ENGINEERED PRODUCTS A cp quas T Em CD mm 1 T p E pk T on 15 UNCOUPLING TRACTOR CHASSIS 1 POSITION RIG
24. MENDATIONS FOR THE USE OF DYNA MOMETERS oevere damage can result in the crown area of radial truck tires when run on dynamometers for extended periods Quite often the damage is internal and not discovered until after the vehicle has been put back in service Demounting and Mounting Tires DEMOUNTING MOUNTING AND INFLA TION OF TIRES SHOULD BE COMPLETED BY A PROPERLY TRAINED EXPERIENCED AND EQUIPPED MECHANIC TECHNICIAN BODILY HARM OR DEATH CAN OCCUR IF CAUTION IS NOT EXERCISED DURING THIS PROCESS ADDITIONAL INFORMATION Always use a safety device when inflating Never stand over tire or in front of valve when inflating Before final inflation check the assembly carefully for apparent sign of weakness or irregularities TIRE MIXING IMPROPER TIRE MIXING CAN BE DANGER OUS ON VEHICLES WITH FOUR OR MORE WHEEL POSITIONS RADIAL AND DIAL TIRES SHOULD NOT BE MIXED IN A DUAL FITMENT ME FONTAINE ENGINEERED PRODUCTS 28 Electrical System LIGHTS AND WIRING The lighting system for your chassis is a heavy duty 12 volt 30 amp system The 7 way receptacle is lo cated on the front of the chassis near the glad hands The jumper cable from the truck tractor plugs into the chassis 7 way receptacle to complete the electrical circuit to the chassis The receptacle is equipped with a hinge type cover to protect it from exposure to dirt and water The same light switches that con
25. NTAINE 17 WARNING FAILURE TO LOCK A SLIDING SUSPENSION CAN CAUSE LOSS OF VEHICLE CONTROL PROPERTY DAMAGE SERIOUS BODILY INJURY AND DEATH ALWAYS CHECK TO ENSURE THAT LOCK PINS ARE FULLY EN GAGED IN THE CHASSIS FRAME OR SLID ER RAIL BEFORE USE When a chassis 15 equipped with a sliding Suspension follow these procedures 1 Make sure the suspension is securely locked into place The suspension is locked into place when the main body of each lock pin extends through the holes in the rails Important Locking Pins Must Extend Thru Holes in the Body of the Chassis Before Moving the Vehicle 2 Inspect the suspension carefully to ensure it is properly positioned and the main body of each lock pin does extend through the holes in the rails 3 Check area around and under chassis to be clear of obstructions or personnel 4 Apply the chassis brakes and gently rock the chassis backwards and forwards to make sure the sliding suspension is secure REFERENCE THE SUSPENSION MANUFAC TURER S RECOMMENDATIONS FOR MORE DETAILED OPERATING INSTRUCTIONS CAUTIONS AND WARNINGS gt Operating Handle in OUT position Operating Handle in IN position 1 Set both the tractor and chassis brakes 2 Remove stop bar and move to desired position 3 To release the lock pins Lift pull arm and pull until locked in the OUT position If lock pins do not retract after pull arm is locked in the OU
26. OR WABCO Rey 7 01 NOTICE 1 Proper coupling height should be maintained between tractor and trailer DO NOT impact trailer upon coupling engagement 2 DO NOT load forward section of trailer without proper coupling support SOT C3 EN MADE IN A CD ges ENNI CD a 1 T p E pk mE T on FONTAINE ENGINEERED PRODUCTS Decal Locations The main beams of this trailer are constructed of High Strength High Tensile Steel Do not drill holes or weld on these beams 50507061 NOTICE suonongsug 60819010 101295 This trailer is equipped with automatic slack adjusters Consult maintenance manual before adjusting HUBS FOR PESE MOUNTED D DISC WHEELS 10 STUD HUBS APPLIES TO M22 X 3 5 STUDS TWO PIECE FLANGE NUT All threads are right hand metric Tighten Flange Nuts to 50 ft Ib using sequence shown Check Disc Wheels for proper positioning on pads and proper seating against flange Tighten Flange Nuts to recommended torque using sequence shown RECOMMENDED TORQUE 450 500 FT LBS Ono 2310 INDUSTRIAL DRIVE qe Ss f Webb Wheel Products rs www WERBWHEELCOM 1 Read and understand this warning and the installation Service and Safety Instruction Manual to understand all safety precautions proper operation and maintenance
27. R FORM REPAIRS IN THE KINGPIN AREA REAR IMPACT GUARDS Your new Fontaine Chassis has been designed and tested to meet the requirements of F M V S S 571 223 and 571 224 The rear bumper should be checked during regular maintenance for cracks bonds amp etc If repair is needed please contact Fontaine Engineered Products and refer to Recommended Practice 732 T EL I FONTAINE ENGINEERED PRODUCTS 20 Leaf Type Springs Care And Maintenance The leaf springs in a heavy duty truck chassis sus pension are working flexible components and the main load supporting members in the assembly They cushion the vehicle and its load from various road shocks and provide the necessary stability to resist roll over brake and drive forces A reason able amount of care and maintenance 15 required to provide a satisfactory service life The spring stack must be tightly clamped to its spring seat and the axle to prevent any movement between the U bolts This area is a dead zone and all flexing must take place between the U bolts and the dead ends of the springs Therefore it is important the spring U bolts be checked for proper tightness once or twice during the first few months of service until such time as the spring leaves wear in with usage Thereafter they should be checked periodically as a matter of normal maintenance One or more broken spring leaves near or through the center bolt hole indicate
28. R UU UU UT 14 Suspension System Axle Alignment 10 Fontaine Chassis 33 gei ONASSIS TT 10 Fontaine Pal UNG 33 Tandem Axle Chassis 11 H Hazard Flasher 29 Hub Wheel Installation and Maintenance 23 L Landing Cis Nm 9 32 Leaf Type Springs Care And Maintenance 21 License 29 Lights 29 M Lights VINA GO EN T 29 Jon scm TET 20 FONTAINE ENGINEERED PRODUCTS 35 Index C2 e Tire Maintenance ee ees 26 Troubleshooting 30 EECCA E o 32 Landing Gear ee 32 E EE Wheels Tires and Alignment o1 29 mm Twistlock Operation 14 e uam U 16 W eem Wheel and Rim Careers 21 Wheel Bearings ane 22 Wheel Installation and Maintenance 29 Ld Wheels Tires and Alignment 31 i FONTAINE ENGINEERED PRODUCTS 3300 Industrial Parkway HH Jasper AL 35501 9243 D 205 385 0930 www fontainetrailer com FONTAINE ENGINEERED PRODUCTS 36 Maintenance Record Date Maintenance Performed FONTAINE ENGINEERED PRODUCTS 37 Maintenance Record Date Maintenance Performed FONTAINE ENGINEERED PRODUCTS 38
29. T position gently rock trailer with brakes applied and pins will automatically retract 4 Apply trailer brakes and carefully move trailer until contacting stop bar 5 Release pull arm to the IN position and visually check all lock pins for proper engagement 6 Locate stop bar directly behind slider 7 Before moving the trailer the pull arm must be in the IN position and all lock pins must extend through the rails or beams 8 With the chassis brakes applied gently rock chassis backward and forward to ensure sliding suspen sion is properly locked and follow proper operating procedures before pulling chassis The lock pin must be checked at each stop to ensure each is locked Note Locator bars are not used on a chassis equipped with a single slider The chassis 5 equipped with stops at the front and rear tremes of the slider movement FONTAINE EE P D GD ph A m 5 A Go Frequent inspection and preventative maintenance are important in the life of any machine Your FON TAINE chassis is no exception Proper care and maintenance will protect the long life of your chas sis and may eliminate unnecessary repair costs and downtime DAILY INTERVALS PRE TRIP INSPECTION Drain Moisture Drain the moisture from air reservoir daily by opening the drain cock on undersi
30. ace brake drum 4 Damaged brake chamber or internal 4 See your nearest Fontaine Service assembly Center 5 Leaky or broken hose between 5 Replace or repair as required relay valve and brake chamber BRAKES DRAGGING Probable Cause Remedy 1 Out of adjustment 1 Adjust brakes ia ber rod end pin Damaged brake assembly or brake 3 Replace See your nearest Fontaine i drum out of round service Center FONTAINE ENGINEERED PRODUCTS 30 MM _ Probable Cause Remedy bution 5 Tracking to one side or excess tire 5 Align axle wear 1 Tire wobble due to uneven rim 1 Torque tighten all rim clamps clamping 2 Burnt worn or damaged wheel bear 2 Replace bearings Ings 3 Bent wheel or rim 3 Heplace wheel or rim 4 Bent axle 4 Replace axle 1 Over and under inflation 1 Inflate to proper pressure 2 Excessive speed on turns 2 Heduce speed 1 Leaf spring broken 1 Replace complete spring 2 Bent axle 2 Replace axle 3 Axles out of alignment 3 Align axles 1 Puncture in tire 1 Repair or replace tire 2 Faulty valve or valve core 2 Replace valve assembly or core 1 Over and under inflation 1 Inflate to proper pressure 2 Loose wheel stud nuts or clamps 2 Tighten wheel stud nuts or clamps Loose or tight wheel bearing adjust Adjust bearings ment 4 Axle bent or out of alignment 4 Replace axle 5 Tires not properly matched 5 Match tires 6 Improper brake actuation 6
31. ay drench red hot drums and cause cracking 3 Do not favor tractor or chassis brakes at the expense of other This reduces braking action of the unit and places a severe burden on the brake components doing the work 4 Periodically inspect valves linings drums cams and other brake parts to see that they are properly adjusted and in good working order 5 Heplace bent or distorted brake shoes immedi ately 6 Replace worn brake linings before the bolts or rivets have a chance to score the drums Hemove small stones or foreign matter that may occasionally get inside drums 8 Consult reputable brake lining specialists for recommended makes and grades of lining that will prolong drum life 9 Make sure tractor chassis units have an adequate ratio of surface lining area to gross vehicle weight 10 Do not overload Balance loads wherever possible to maintain uniform axle load and therefore brake drum distribution 12 Use brake drums of adequate weight and thickness for unusual or severe applications 13 Practice safe sensible driving habits Tire Maintenance INFLATION PRESSURE The most critical factor in tire maintenance is proper inflation No tire or tube is completely impervious to loss of air pressure To avoid the hazards of under inflation lost air must be replaced Driving on any tire that does not have the correct inflation pressure is dangerous and will cause tire damage Any
32. be necessary In some instances an occasional dab of grease at these points will greatly reduce the fretting and wearing away of the wear pads and main spring leaf SERVICE TIPS To obtain maximum service life from a spring assembly the following steps should be followed 1 Before placing chassis in service torque all U bolts evenly to manufacturer s recommendation 2 Hetorque at 3 000 miles and every 3 months there after 3 Broken spring leaves between the U bolts indicates loose U bolts Replace broken leaves at earliest opportunity and lubricate the U bolt threads before tightening 4 Spring leaf failures outside U bolt area are an indi cation of a Hepeated overload b Spring assembly has completed its normal life cycle In either case the entire spring assembly should be replaced 5 On vari rate spring suspensions periodically apply lubricant between the spring assembly and hangers to obtain maximum service life otandard wheel material on your Fontaine chassis is aluminum or steel disc wheels Wheel nuts are inspected and tightened to specifications at the fac tory and must be checked again at pre delivery To maintain the correct torque on the wheels of a new chassis the nut torque must be checked periodically During normal highway operation of a new chas sis this check should be made at the first 100 500 and 1 000 miles and every 5 000 miles thereafter oevere service conditions may require more tigh
33. de of reservoir Leave the drain cock open until the moisture disappears After all moisture has escaped close the drain cock or moisture trap Inflate Tires Check tire pressure daily or every 3000 miles Re move all objects lodged between treads or carcasses or from between duals Refer to the Tire Manufactur ers Load Inflation pressure settings for your appli cable tire size Tighten Mounting Nuts Check that all wheel and hub mounting nuts are pres ent and secure If marked after torquing insure the torque identification mark has not moved Wheel ends Visually inspect the hubcap and around the wheel seal for lubrication leaks Adjust Brakes Check the travel of brake chamber push rod and adjust brakes if necessary Push rod travel should be kept at a minimum of 1 2 without brakes dragging Pushrod travel should not exceed 2 Check Lights Open and close chassis light switches to see if lamps respond properly Clean all lights and warning reflec tors Make sure the ABS system is operating prop erly Check Tools amp Equipment Check the tools flares and other equipment to make certain all are present and in good condition This inspection should become a daily habit Minor repairs or adjustments depend to a great extent upon the tools and equipment carried on the chassis MONTHLY INTERVALS Inspect Hose Assemblies amp Gaskets Inspect all hose assemblies and gladhand coupling gas kets for abrasions s
34. ding fifth wheel make sure it is gland hand locked Check gland hand seals and tractor control ser Make sure the chassis kingpin is not bent broken vice airline to chassis control service gland hand or damaged in any way 2 INSPECT AREA AND CHOCK WHEELS sure area around vehicle is clear e Make sure airlines are supported where they can not be hung up or damaged while tractor is back ing under chassis e Be sure chassis spring brakes are on e Check that all chassis cargo is secured against movement 3 POSITION TRACTOR e Put the tractor directly in front of the chassis e Check position using outside mirrors look down both sides of the chassis M F NEVER BACK A TRACTOR UNDER A CHASSIS FONTAINE AT AN ANGLE PUSHING THE CHASSIS SIDE ENGINEERED PRODUCTS WAYS CAN DAMAGE THE LANDING GEAR OR OTHER STRUCTURES OF THE CHASSIS 14 8 SUPPLY AIR TO CHASSIS e From the tractor cab push in air supply knob or move tractor protection valve control from the emergency to the normal position to supply air to the chassis brake system Wait until the air pressure is normal e Check brake system for crossed airlines e Shut engine off to hear brakes e Apply and release chassis brakes listen for the sound of chassis brakes being applied and re leased e Check the air brake system pressure gauge for signs of major loss e When sure chassis brak
35. es are working properly start the engine e Check to see that tractor air pressure is greater than 120 psi 9 LOCK CHASSIS BRAKES Pull out the air supply knob or move the tractor protection valve from normal Chassis Brakes Re leased to emergency Chassis Brakes Applied 10 BACK TRACTOR UNDER THE CHASSIS Shift into lowest reverse gear Back tractor slowly under chassis to avoid severely impacting the kingpin Stop when the kingpin is locked into the fifth wheel 11 CHECK THAT CONNECTION IS SECURE e Raise chassis landing gear slightly off the ground Gently pull the tractor forward while the chassis brakes are still locked e Fifth wheel should be locked into kingpin at this time 12 SECURE VEHICLE Shift the transmission into neutral e Apply parking brakes Shut off engine and be sure someone else will not move the truck while you are under it 13 INSPECT COUPLING Use a flashlight if necessary Make sure there is no space between upper and lower fifth wheel If there is space something is wrong The kingpin may be on top of closed fifth wheel jaws chassis would come loose very easily Look into the back of the fifth wheel with caution Make sure the fifth wheel jaws have closed around the shank of the kingpin Check that the locking lever is in the lock position MAKE SURE THE PARKING BRAKE IS EN GAGED AND THE TRACTOR CANNOT BE MOVED BEFORE P
36. he outer wheel over the inner capnuts be ing careful not to damage the threads 5 Install the outer capnuts and tighten to 50 FT LBS in the sequence shown in Step 3 Then tighten to full torque using the same sequence 6 After the first 50 to 100 miles of service the capnut torque should be rechecked A Loosen the outer capnuts B Check the torque of the inner capnuts in the tightening direction C Tighten the outer capnuts to 50 FT LBS in the sequence shown if Step 5 Tighten to full torque using the same sequence Disc Wheel Mounting Instructions for 8 amp 10 Stud Hubs with HUB PILOTED Disc Wheels 1 All parts must be clean free of rust dirt or paint 2 Position the inner wheel over the studs being care ful not to damage the threads 3 Position the outer wheel over the studs being care ful not to damage the threads 4 Install flange nuts and tighten to 50 FT LBS in the sequence shown 1 0 Q 3 S 2 7 8 stud 10 stud Then tighten to full torque using the same sequence Thread Size Torque M 22 x 1 5 900 550 Ft Lbs THE TORQUE LISTED IS FOR DRY THREADS WITH NO LUBRICANT PROPER CAPNUT TORQUE 1 IMPORTANT INSUFFICIENT TORQUE CAN CAUSE STUD BREAKAGE AND DAMAGE OVER TORQUE CAN OVER STRESS THE STUDS AND STRIP THE THREADS 5 After the first 50 to 100 miles of service the cap nut torque should be retightened to 500 550 ft Ibs 6 Make sure the surface o
37. ke compo nents has a direct bearing on the effectiveness of brake adjustment therefore periodic inspection of these components is necessary a BRAKE CHAMBERS Check that brake chamber mounting bolts are tight and proper alignment is maintained to avoid interference between chamber pushrod and chamber housing Verify that the brake cham ber pushrod length is equal on opposing brake chambers of the same axle b CAMSHAFT BUSHINGS Optimum brake adjustment cannot be achieved when worn bushings are used c WHEEL BEAHING ADJUSTMENT Accurate wheel bearing pre load is necessary to maintain proper alignment between the brake drum and brake shoes MAINTENANCE During normal chassis lube adjusters should be in spected for damage Check anchor brackets to ensure that they are tight During reline check the de adjustment torque Place a torque wrench on the 7 16 adjusting hex Turn the torque wrench counterclockwise and check that the clutch does not slip at a torque less than 13 Ft Lbs A ratcheting sound will occur while backing off If clutch slips at a lesser torque the adjuster must be replaced M M EL I FONTAINE ENGINEERED PRODUCTS 25 Tips for Prolonged Brake Drum Life 1 Allow periodic cooling off stops when operating in mountainous terrain but do not set brakes when drums are extremely hot Park on level ground in gear for cooling down period 2 If possible avoid water pockets in road that m
38. lasher switch Two flasher units are used for the chassis One unit is used in the turn signal circuit and the other for the hazard flasher system located in the truck tractor The most common problems with the turn signals and hazard flasher system are defective flashers burned out bulbs blown fuses defective switches or faulty wiring REFLECTORS Heflectors are located on the front sides and rear sections of the chassis They should be kept clean by wiping with a damp cloth Replace any reflectors that are cracked or broken STOP TAIL TURN MARKER amp IDENTIFICATION LIGHTS To remove lens and bulb with grommet mount instal lations insert a screwdriver under the lens flange and pry lens out of the soft housing LICENSE LAMP To remove license bulb from the license lamp remove the mounting screws and remove license lamp cover Follow the same instructions used for the clearance marker and identification lights above Re install cover using the mounting screws CONSPICUITY RETRO REFLECTIVE TAPE Proper maintenance of the conspicuity retro reflective tape system is the responsibility of the owner operator as outlined in DOT 49 CFR 393 11 b Conspicuity reflectivity require ments and vehicle coverage requirements are contained in CFR Part 571 under FMVSS 108 Regulations M M EL I FONTAINE ENGINEERED PRODUCTS 29 To directly assist in keeping your chassis the road serious delay and downtime in ser
39. n the disc wheel which is contacted by the flange nuts is flat 7 Disc wheel mounting surfaces should not have more than 1 1 2 Mil Thickness of paint Ex cessive paint thickness can cause loose disc wheels BEFORE INSTALLING TWO PIECE CONE LOCK CAPNUTS LUBRICATE THE CON TACT SURFACES BETWEEN THE CAPNUT AND WASHER WITH SAESOW OIL THIS WILL MINIMIZE CORROSION BETWEEN THE MATING SURFACES WHEEL STUDS ON HUBS OF VEHICLES UTILIZING THE HUB PILOTED WHEEL SYSTEM HAVE RIGHT HAND THREADS M M FONTAINE ENGINEERED PRODUCTS 24 Self Adjusting Slack Adjuster OPERATIONAL CHECK Chassis equipped with Drum Brakes utilize slack adjusters to control the relationship of the brake lining relative to the brake drum surface to minimize spring brake pushrod stroke and maximize braking power It is important to ensure the slack is properly adjusted prior to each trip Functional operation of the slack adjuster can be performed on the vehicle by 1 Block wheels to prevent vehicle from rolling 2 Check that the push rod is fully retracted apply air to release spring brake 3 Manually de adjust brakes turn adjustment hex counterclockwise to create an excessive clearance condition A ratcheting sound will oc Cur 4 Make a full service brake application on release allow sufficient time for brake to fully retract During the brake release observe rotation of the adjustment hex attaching
40. n tire de struction property damage and personal injury Do not exceed the gross axle weight ratings for any axle on your vehicle DRIVE AT PROPER SPEEDS The maximum speed at which tires can be operated is indicated in the tire manufacturer s data book This speed varies for each type of tire and depends on the type of application Consult your Tire dealer for assis tance in determining the maximum speed for your ap plication You should not exceed reasonable speeds indicated by the legal limits and driving conditions EXCEEDING THE MAXIMUM SPEED FOR VEHICLE YOUR TIRES IS RATED CAN RE SULT IN SUDDEN TIRE DESTRUCTION PROPERTY DAMAGE AND PERSONAL IN JURY WHEN DRIVING AT HIGHWAY SPEEDS CORRECT INFLATION PRESSURE 15 ESPECIALLY IMPORTANT However at these speeds even with correct infla tion pressures a road hazard for example is more difficult to avoid and if contact is made has a greater chance of causing tire damage than at lower speed Moreover driving at high speed increases the pos sibility of an accident as a greater distance is required to bring your vehicle to a safe stop BALANCING Under normal conditions truck tires do not need to be balanced Common practice is to check tire bal ance if a ride complaint is made by the driver Before removing the tire wheel assembly from the vehicle check for radial and lateral runout Bent wheels and rims or improper mounting can cause excessive runouts If balance i
41. of your Webb hub Failure to do could result In death or serious injury and could result in a compromise of your vehicles safe operation through loss or failure of a wheel or the compromise of the braking system Copies of the Installation Service and Safety Instruction Manual are available free of charge from Webb Wheel Products Ine upon request 2 Always use a properly calibrated torque wrench to assure proper torque Under torque and over torque can cause thread and or nut damage and could result In the loss of a wheel Fallure to ensure proper torque could result in death or serious injury and could shorten the expected life of this product Recheck torque after the first 50 to 100 miles of service Parts may seat naturally causing the torque to drop drop in torque could result in the loss of a wheel Proper torque is essential to avold damage or compromise of your vehicles safety Fallure to ensure proper torque could result In death or serious injury FONTAINE ENGINEERED PRODUCTS MAINTENANCE amp TORQUE SPECIFICATIONS FOR MECHANICAL SUSPENSION After initial 1 000 mile break in period check trailer axle alignment and correct Fastener composite Springs Steel Springs Bolts Arm Ends Bolts Arm Clamp as necessary as DS j mm The torque arms springs hangers and welds should be visually inspected at 275 300 275 300 450 500 275 300 35 50 85 95 29 000 mile intervals
42. or wear and pits After the bearing is clean hold it up so that the bearing is between the eye and the light Look between the rollers so that the raceway or outer surface of the cone can be seen Holding the cage rotate the cone to check for pits over its entire outer surface Replace bearings if any of these conditions exist Also replace worn or damaged grease or oil seals Always replace a seal if it has been removed from the axle Be sure to grease the lip of the grease seal before sliding it on the axle Check the condition of the hub and axle spindle and remove any nicks or burrs which might prevent proper seating The bearing cup must fit tightly in hub This must be a press fit Use an arbor press to install the cup in the hub checking to make sure that it is square and com pletely bottomed If an arbor press is not available use an old bearing cup as a driving tool and tap it lightly with a hammer Never strike the narrow section of a cup directly with a hammer since this can chip or crack the case hardened surface ADJUSTMENT OF BEARINGS There have been many changes in the spindle nuts being used on chassis axles The new designs have changed the method required to properly adjust the bearings While many wheel end systems still use the old three 3 piece system there are inherent differenc es even in this system depending on the source for the spindle nuts Adjustment of bearings requires a full un derstanding of the
43. ot sufficiently 1 Change battery charged FONTAINE ENGINEERED PRODUCTS 32 Always insist on Fontaine parts and service Call 1 866 382 7278 for Fontaine service center and dealer nearest you www fontainepartsource com We make it easy www fontainepartsource com Mammon Highway Technologies Berkshire Hathaway Carn FONTAINE 33 NHTSA Reporting If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National High way Traffic Safety Administration NHTSA in addition to notifying FONTAINE ENGINEERED PROD UCTS If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in any individual problems between you your dealer or FONTAINE ENGINEERED PRODUCTS To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 366 0123 in Washington DC area or write NHTSA U S DEPARTMENT OF TRANSPORTATION 400 7th Street SW NSA 11 Washington DC 20590 You can also obtain other information about motor vehicle safety from the NHTSA Hotline FONTAINE ENGINEERED PRODUCTS 3900 Industrial Parkway Jasper AL 35501 9243 205 385 0930 www fontainetrailer com ME FONTAINE ENGINEER
44. r signs of wear or damage Excessive wear caused by abrasive dirt is the most common cause for premature bearing failure This can be recognized by a dull appearance to the rollers and raceways they may feel rough or show pit marks or indenta tions Flaking or spalling on the small end of the rollers on their corresponding cup and cone rolling surfaces is caused by improper loose adjustment opalling or excessive wear at the large end of the roll ers indicates an overly tight adjustment Fractures or fine hairline cracks across the cup or cone may be caused by forcing a cone assembly on an oversize spindle or forcing a cup into warped hub bore or by a cocked cup or a cocked cone Brinnel ing a series of lines or indentations on the raceways spaced to a definite pattern indicates a driving force has squeezed the bearing and damaged the roll ers and raceways This can be caused by improper mounting practices or by sudden excessive shock loads Corrosion or its pock marks on the raceways and rollers resulting from water getting into the lubricant can be caused by a worn or damaged grease seal or by handling the bearing with moist hands or by an improper type of lubricant Overheated bearings have a blue or brown blue discoloration and definitely indi cate that the bearing metal has been damaged This can be caused by dirt lack of lubricant excessive friction or over adjustment too tight Be sure to check the bearing cone f
45. s a loose U bolt condi tion which has permitted excessive flexing in the clamp area Failure to keep the U bolts tight can also cause sheared spring center bolts broken U bolts or rounding of the axle spring seat A broken spring leaf adjustment to or outside the U bolt clamp area indicates either there has been an over loaded condition or the spring assembly is nearing the end of its service life Single and multi leaf springs on trucks and chassis should be closely inspected at regular intervals for signs of such failure Broken leaves in a multi leaf pile should be replaced immediately to prevent over loading the remaining leaves Better yet the complete spring stack should be replaced If just the broken leaf is replaced other leaves in the stack will break in a short length of time oprings exhibit a finite limited service life Failures can be expected from normal fatigue after a respon sible service use In suspensions using the vari rate springs and frame brackets the wear pads and main spring leaves should be checked periodically for excessive wear Replacement wear pads are available for most suspensions and it may be necessary to install them long before the main leaf requires replacement Ex cessive wear at these load contact points eliminates the vari rate effect resulting in a rough ride If these load bearing points are left unattended wear can progress to the point where a complete frame hanger replacement will
46. s still required a simple static balance with bubble balance or a wall mounted axle bearing and hub type gravity balance should be suf ficient ROTATION Tires should be rotated only when necessary If the tires are wearing evenly there is no need to rotate If irregular wear becomes apparent or if the wear rate on the tires is perceptively different from axle to axle then the tires should be rotated in such a manner as to alleviate the conditions EL I FONTAINE ENGINEERED PRODUCTS 27 Tire Maintenance STORAGE All tires should be stored in a cool dry place indoors so that there is no danger of water collecting inside them Serious problems can occur with tube type tires when they are mounted with water trapped between the tire and tube Due to pressurization the liquid can pass through the inner liner and into the casing plies This can result in sudden tire failure Most of the problems of this nature have been due to improper storage that allowed water to enter the casing This is a particular problem with tube type tires because of the difficulty in detecting water that collected between the tire and tube When tires are stored they should be stored in a cool place away from sources of heat and ozone such as hot pipes and electric generators Be sure tires do not contact surfaces which could deteriorate the rubber TIRES EXPOSED TO THESE SUBSTANCES COULD BE SUBJECT TO SUDDEN FAILURE RECOM
47. spider and brake shoe and lift the cam end of shoe off cam Lubricate with several drops of oil on brake shoe roller and rotate roller to new contact point Lubrication Interval every 10 000 miles Cam When wheels are removed place a light film of grease on top and bottom surface of S cam CAUTION DO NOT ALLOW GREASE TO COME IN CONTACT WITH BRAKE LINING ubrication Interval every 10 000 miles Basic Chassis Maintenance THEINFORMATION PROVIDED IN THIS SEC TION IS INTENDED TO PROVIDE SUGGEST ED BASIC MAINTENANCE PROCEDURES REFER TO THE VENDOR COMPONENT SUPPLIER S INFORMATION FOR MORE DE TAILED MAINTENANCE INSTRUCTIONS KINGPIN AND FIFTH WHEEL AREA Inspect the kingpin for excessive wear rough edges looseness broken or chipped out areas and cracks Any kingpin showing such condition must be replaced at once Do not under any circumstance weld the kingpin to compensate for wear Once a kingpin has been heated its physical characteristics are changed and its subsequent performance cannot be predicted Contact Fontaine Engineered ProductsCustomer Ser vice for proper replacement services Check and inspect the fifth wheel area for cracks or breaks and for secure attachment to the chassis Any welding performed in this area is to be restricted to those welds specified by Fontaine and is to be per formed in the manner prescribed by Fontaine FONTAINE RECOMMENDS THAT ONLY AN AUTHORIZED FONTAINE DEALER PE
48. ten ing Loose wheel nuts may cause shimmy uneven tire wear and vibration Elongated stud holes in the wheels may result from loose hub nuts Wheel and hub nuts must be torqued to proper specifications to provide maximum service life FONTAINE ENGINEERED PRODUCTS 21 How To Service And Install Wheel Bearings Wheel bearing life depends on three things 1 Proper lubrication 2 Cleanliness and 8 Proper adjustment Chassis axle bearings are normally pro vided with wheel seals which require only keeping the lubrication at the proper level Whether installing new bearings or servicing a chassis in the shop here are the steps to follow Remove the wheel hub and bearing cones Clean all the old grease from wheel hub bearing cones and hub cap with kerosene or diesel fuel oil not gasoline and not in hot solution tank or with water alkaline solutions Use a stiff fiber brush but not a steel brass wire brush Dry the parts with a clean absor bent cloth or paper Compressed air can be used to dry the bearing only if the air is filtered since water in the air line can cause rusting Also clean and dry the hands and tools since grease will not adhere to a surface wet with solvent If bearings are not to be used soon pack with wheel bearing grease and wrap in clean wax paper Don t lay clean bearings on floor or dirty workbench INSPECT FOR DAMAGE While the bearing is clean and free of grease inspect it fo
49. th wheel comes out from under chassis otop with tractor frame under chassis Prevents chassis from falling to ground if landing gear should collapse or sink SECURE TRACTOR Apply parking brake Place transmission in neutral INSPECT CHASSIS SUPPORTS Make sure ground is supporting chassis Make sure landing gear is not damaged PULL TRACTOR CLEAR OF CHASSIS Release parking brakes Check the area then drive the tractor clear ME FONTAINE ENGINEERED PRODUCTS A cp quas T Em CD a 1 T p E pk mE T on 16 Rear Twistlock in Unlocked position Rear Twistlock in locked position N Lift lever 7 Lift lever Twist handle wist handle This photo shows the rear twistlock in the This photo shows the rear twistlock in the unlocked position To lock lift lever and turn locked position To unlock lift lever and turn handle handle Front Twistlock in Unlock position Front Twistlock in Unlock position A cp quas T Em CD a 1 T p E pk mE T on This photo shows the front pin in the unlocked This photo shows the front pin in the locked position To lock lift and push handle back to position To unlock lift and pull the handle to place it in rear slot move it to forward slot Front pin unlocked Front pin locked FO
50. the tractor is INCORRECT COUPLING AND UNCOUPLING backed under it Raise or lower the chassis as OF YOUR CHASSIS CAN RESULT IN AC needed Make sure the chassis is proper height CIDENTS CAUSING SERIOUS INJURY OR and the kingpin and fifth wheel aligned DEATH NOT ALL TRACTORS ARE IDENTI CAL BE AWARE OF THE DIFFERENCES IN THE VEHICLES YOU OPERATE IF CHASSIS IS TOO HIGH IT MAY NOT COU COUPLING PLE CORRECTLY TO THE TRACTOR IF IT IS 1 INSPECT THE TRACTOR FIFTH WHEEL TOO LOW THE KINGPIN MAY BE STRUCK e Check for damaged or missing part Reference AND BENT OR THE FRONT OF THE CHAS the manufacturer s service manual for the fifth SIS MAY BE DAMAGED wheel in use Check to see that mounting to tractor is secure no cracks in frame etc e Be sure the fifth wheel plate is properly greased A WARNING failure to do so may cause severe friction leading DO NOT WALK OR STAND BETWEEN TRAC to loss of control TOR AND CHASSIS TRACTOR MOVEMENT CAN CAUSE SERIOUS INJURY OR DEATH A cp quas T Em CD a 1 T p E pk mE T on Check if fifth wheel is in proper position for cou pling Wheel tilted down towards rear of tractor jaws open and safety unlocking handle in the 7 CONNECT AIR LINES TO CHASSIS automatic lock position e Check glad hand seals and connect tractor supply emergency airline to chassis supply emergency e f you have a sli
51. to make certain they are in good condition SIX 6 MONTH INTERVAL Check structure for cracks in welds or steel Check for any other structural damages Fontaine Engineered Products Fontaine PartSource should be consulted for repair instructions EL I FONTAINE ENGINEERED PRODUCTS 19 Lubrication Notes 1 Coupler amp Kingpin Clean sand grit and other foreign matter from coupler base With a hand paddle coat the machined surface of coupler base pickup ramps and edge of coupler hook Place a light film of grease on the side surface of kingpin Lubrication Interval every 5 000 miles Cam Bearing Lubricate sparingly with grease gun Excessive lubrication will force lubricant into internal brake parts causing faulty brakes ubrication Interval every 10 000 miles Wheel Ends Most Fontaine Chassis are Equipped with Hendrickson suspensions equipped with five 5 year wheel end warranty The typical lubrication for these wheel ends is Chevron Delco SF grease If no leakage is noticed in the first 5 years of service wheel end lubri cation maintenance is required Units with sight glasses in the hubcaps with removable plugs use mineral based Hypoid Oil S A E 80 90 NOTE On units with oil seals change oil and seals every 100 000 miles Brake Shoes Place several drops of oil on inner and outer end of brake shoe where anchor pins pass through the shoe Place bar between
52. trol the lights on the truck tractor control chassis lights Proper maintenance of the lighting system requires periodic cleaning of lamps and reflectors to assure maximum visibility of the tractor and chassis Use a damp cloth to wipe the lenses A dry cloth will cause the dirt to act as an abrasive and scratch the lenses A daily cleaning can be worth the time invested plus its a good safety practice Maintenance of the lighting and wiring system consists of an occasional inspec tion to see that all wiring connections are tight Make sure the lighting units are securely mounted and the wiring is not pinched or damaged Inspect lights cou plings and sockets for their serviceability and replace as required ALL FONTAINE CHASSIS MANUFACTURED AFTER MARCH 1 1997 ARE WIRED TO PRO VIDE CONSTANT POWER TO THE CHASSIS ANTI LOCK BRAKE SYSTEM ABS FROM THE CENTER PIN OF THE MAIN 7 WAY CONNECTOR AT THE FRONT OF THE CHASSIS IF YOU NEED HELP DETERMIN ING HOW YOUR PARTICULAR CHASSIS IS WIRED CONTACT FONTAINE ENGINEERED PRODUCTS AT 1 205 385 0930 TURN SIGNAL and HAZARD FLASHER SYSTEM The turn signal lever and hazard flasher are located in the truck tractor operate the turn signals the igni tion switch must be in the ON position The hazard flasher system is operated independently of the igni tion system in most cases All turn signal lights can be made to flash simultaneously by pulling out the activating knob on the hazard f
53. vicing your chassis and rolling the following troubleshooting guide has if the cause of the trouble can be diagnosed and cor been prepared for your convenience You can avoid rected quickly by you BRAKES WILL NOT RELEASE Probable Cause Remedy 1 Low air Pressure 1 Check air line connections amp verify sufficient air in tank 2 Brake shoes bound up at cams 2 Lubricate brake operating parts 3 Brake out of adjustment 3 Adjust brakes 4 Damaged brake assembly 4 See your nearest Fontaine Service Center 5 Source of air supply shut off at tractor 5 Push control valve IN NO BRAKES OR INSUFFICIENT BRAKES Probable Cause Remedy 1 Low brake line pressure 1 Check air pressure gauge on trac tor Inoperative 2 Brake lines between tractor and 2 Properly couple brake lines chassis not properly coupled 3 Reservoir drain cock open 3 Close drain cock SLOW BRAKE APPLICATION OR RELEASE Probable Cause Remedy 1 Lack of lubrication 1 Lubricate brake operating parts 4 GD oo 1 E Gp Ge 2 Excessive pushrod travel in spring 2 Adjust brakes brake air chamber 3 Restriction in hose or line 3 Replace broken hose or line 4 Defective brake valve 4 Replace brake valve BRAKES GRABBING Probable Cause Remedy 1 Foreign material on brake lining 1 Reline brakes 2 Brakes out of adjustment 2 Adjust brakes 3 Brake drum out of round 3 Repl
54. welling or other damages Replace as necessary Check Brake Linings Check the brake lining thickness Brake lining should be replaced when the lining thickness approaches the wear line indicator built into the lining or when the thickness 15 at 74 Inspect Reservoir amp Brake Lines Inspect reservoir for looseness or damage Make certain all connections are tight and that brake lines are properly supported so as not to chafe on other chassis parts Check Electrical System Inspect lights wiring and coupling sockets Secure loose wires Tighten Assembly Screws amp Nuts Tighten all wheel hub mounting nuts spring clips and U bolts Measure and check all tires Measure and check all tires for proper mating and un serviceable condition Serviceable tires which indicate abnormal wear should be rotated to other wheel posi tions Apparent mechanical defects should be cor rected Check Axle Alignment Check the axle for proper alignment This deficiency is the most probable cause of tire wear Inspect amp Clean Under Side of the Chassis Clean out all objects lodged in the under construction including the suspension area For mechanical spring systems inspect springs bushings and hangers for cracks or excessive wear Check all hanger bolts U bolts and other adjustable points For air ride systems check air springs and shocks for wear or damage Check the suspension rubber bushings and wear wash ers
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