fontaine instructions.pdf

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C O N N E C T Y O U R B U S I N E S S W I T H F O N T A I N E

Read before mounting oroperating fifth wheel.

After fifth wheel isinstalled these importantinstructions must bepermanently retained inthe tractor glove box.

WARNING: Failure tofollow these instructionscould cause a hazardousoperating condition.

• Installation Instructions

• Pre-Service Procedures

• Operating Instructions

• Inspection & MaintenanceProcedures

• Warranty

Gives You the TechLock® System Advantage

January 2004

FOR YOUR SAFETY USEONLY GENUINE FONTAINESERVICE PARTS. USING

PARTS THAT DO NOT MEETFONTAINE SPECIFICATIONS

WILL VOID WARRANTY.

For over 60 years, Fontaine has been passing customerperformance tests by building fifth wheels with innova-tive technology, uncompromising quality, and featuresdesigned to ensure cost-efficient performance.

This handbook provides instructions and recommendedprocedures for optimum performance from your new fifthwheel. Included are: Installation Instructions, Pre-Service Procedures, Operating Instructions, Inspectionand Maintenance Procedures. Keep this handbook inthe tractor glove box after your fifth wheel hasbeen installed.

If you have any questions concerning your new fifthwheel, our Customer Service Group is available to helpyou. (800) 874-9780.

For sales and service locations or for additional copies ofthis handbook go to our web site at www.fifthwheel.com.

Fontaine® Fifth Wheel Handbook

2

Section I – Installation Instructions

General Mounting Instructions .....................................4-5

Application/Restriction Levels .........................................6

Air Wedge Slide Bracket Fifth Wheel (AWB) and Manual Wedge Slide Bracket Fifth Wheel (MWS)...........................................................7

Light Weight Slide Fifth Wheel (LWS) ...............................8

Stationary Fifth Wheel with Long Mounting Plate (PLA).......................................................9

Stationary Fifth Wheel with Short Mounting Plate (PSA) ....................................................10

Adjustable Flat Plate Mount Fifth Wheel (PMA) .................................................................11

Stationary Frame Mount Fifth Wheel (FMA) .................................................................12

Stationary 36" Angle Mount Fifth Wheel (A36) ..................................................................13

Xtra Heavy Duty Air Wedge Slide Bracket Fifth Wheel (XAWX)........................................................14

Xtra Heavy Duty Short Plate Mount Fifth Wheel (XPSA) ........................................................15

Xtra Heavy Duty Long Plate Mount Fifth Wheel (XPLA) ........................................................16

Section II – Pre-Service Procedures

Fasteners ......................................................................17

Lubrication ..............................................................18-19

Operation ................................................................20-22

Wedge Stop Rod Setting ...............................................22

Knock-Out Rod..............................................................23

Section III – Operating Instructions.................................24-29

Section IV – Inspection and Maintenance Procedures ..............................................................30-31

Section V – No-Slack® Limited Warranty ......................32-34

Contents

3

Section I –Installation Instructions

General Mounting Instructions1. Do not modify and/or customize any fifth wheel or mounting

assembly. Modifying or welding to the product will void prod-uct warranty. Only Fontaine authorized procedures, such aswelding the stop blocks or the rocker limiting blocks areacceptable. Welding must be performed by a certified welder.

2. The fifth wheel should be installed with the pivot point of thefifth wheel located on or ahead of the rear axle or bogie centerline. The installation shall be in accordance with DOT regula-tions, state and local ordinances, SAE and TMC practices andstandards, and tractor manufacturers’ recommendations.

3. All fifth wheels shall be located so that the tractor and trailerwill maintain clearance at all times. On sliding fifth wheels, itmay be necessary to "block out" forward locations.

4. All mounting fasteners must be a minimum of:5/8" diameter - Grade 8 bolts5/8" diameter - Grade C lock nuts5/8" diameter - Hardened flat washers

5. Outboard mounting angles shall be ASTM-A36 or equal with aminimum thickness of 5/16".

6. Inboard mounting angles must have a 4" minimum vertical andhorizontal leg and shall be not less than 36" long.

7. Outboard mounting angles must have a minimum horizontal legof 3" and vertical leg of 3-1/2".

8. The full length, horizontal flange of the outboard mountingangles must be at the same elevation as the truck frame. Thevertical leg of the angle must fit flush with the truck frame. Toaccomplish this, firmly clamp the fifth wheel and angle in posi-tion before drilling the tractor frame. Warning: Failure to followthese specification will void warranty and could effect productperformance.

9. All mounting holes in the truck frame or mounting angles shallbe drilled, not burned. All edges and corners shall be groundsmooth to prevent point loading (see illustrations next page).


4

STRAIGHT EDGE STRAIGHT EDGE

OUTBOARDANGLE

OUTBOARDANGLE

OUTBOARDANGLE

GAP AT THE MIDPOINT OF THE

OUTBOARD ANGLESHOULD BE LESS

THAN .030"

GAP AT THE MIDPOINT OF THE OUTBOARDANGLE SHOULD BE LESS THAN .030"

TYPICALTRUCK FRAME

TYPICALTRUCK FRAME

10. When required to clear obstructions (such as spring hangers)cutouts shall be smooth and straight with a minimum radius of 1".No sharp corners are permitted and all edges shall be groundsmooth. A minimum of two bolts is recommended beyond acutout.

11. Care must be taken to avoid interference or contact between thefifth wheel and air brake modulator when rear of fifth wheel isdepressed. In order to prevent this, it is recommended that a stopbe attached to the underside of the rear extension of the fifthwheel. The stop should be positioned so that contact is made withthe fifth wheel mounting plate.

12. Do not restrict normal rock of fifth wheel. This could create a haz-ardous operating condition.

13. All fifth wheels subjected to weather abuse must be thoroughlycleaned, inspected, and lubricated prior to installation.

14. Refer to the Application/Restriction Level guide (page 6) whenselecting a fifth wheel for an appropriate application.

15. Fifth Wheels with sliding or fixed mounts should be mounted in the proper orientation relative to the tractor (See Figure 1).Do not mount the fifth wheel upside down orbackwards.

16. The trailer that is attached to the fifth wheel should impose a con-sistent vertical load. Repeated negative loading (trying to pull thefifth wheel off of the brackets with the king pin) is not allowed. Aminimum vertical static load applied to the fifth wheel through thetrailer is 10% of the gross trailer weight. See the load rating for thespecific fifth wheel for maximum vertical load values.

17. Do not center load the fifth wheel. The vertical load should be dis-tributed over the entire surface of the fifth wheel.

18. Fixed angle mounts (inboard angles) shall be flush with the top ofthe truck frame. (No gap between the truck frame and the angle).

19. Do not attempt to “block” 6000 series fifth wheel. A production“blocked” fifth wheel specifically designed for this application isavailable

Installation Instructions

5

FIGURE 1

TOP

FRONT

REAR

1.50" Max.1.00" Min.

1.00" R. MIN.GRIND SMOOTH–NO SHARP EDGES

NO SHARPCORNERS

WRONG


6

APPLICATION/RESTRICTION LEVELS

STANDARD DUTY: 6000, 7000, H5092 top plate modelsdepending on application, rated vertical capacity and GCW.Fifth Wheel must be used in a 100% on-highway applica-tion, with more than 30 miles between each stop. Thetotal number of towed axles equals 2. Road type must bemaintained concrete or asphalt. Gross Combination Weight(GCW) is less than 95,000 pounds or 43,000 kilograms.

MODERATE DUTY: 6000, 7000, H5092 & X5092 top platemodels depending on application, rated vertical capacityand GCW. Fifth Wheel must be used in a less than 10% off-highway application, with no minimum mileage betweeneach stop. The maximum total number of towed axlesequals 4. Road type must be maintained concrete, asphalt,gravel, or crushed rock. Gross Combination Weight (GCW)is less than 115,000 pounds or 52,000 kilograms.

SEVERE DUTY: 7000, H5092 & X5092 top plate modelsdepending on application, rated vertical capacity andGCW. Fifth Wheel can be used in any off-highway applica-tion, with no minimum mileage between each stop. Thetotal number of towed axles equals 5 or more. All roadtypes are acceptable including hard packed dirt and non-maintained roads. Gross Combination Weight (GCW) ismore than 115,000 pounds or 52,000 kilograms.

Important Application Notes:

1. If any single restriction factor within your applicationis surpassed within a given duty level, the next dutylevel must be selected.

2. When selecting a fifth wheel, if the application orvehicle usage places the maximum capacity on acertain fifth wheel, then the selection of a fifth wheelwith a higher capacity is advised. For example, atractor that is at a maximum vertical load of 50,000 lbs. in a moderate duty application should beusing a fifth wheel with a vertical load capacity of55,000 lbs. or greater. This additional capacityshould give better service life over a longer period of time.

3. All logging applications are considered severe duty.Do not select fifth wheels in the standard or moderatelevels when a logging application is designated.


7

Weld

left &

righ

t rea

rsli

de st

op b

locks

assh

own

in re

d (A

WB

left

side s

hown

).

1.75

" M

ax.

Mou

ntin

g An

gle

(Do

not w

eld

totru

ck fr

ame)

.

All m

ount

ing

hard

war

e m

ust b

e a

min

imum

of:

5/8"

- 1

1 Gr

ade

8Bo

lts,G

rade

C lo

cknu

ts w

ith h

ard-

ened

ste

el w

ashe

rs,t

ight

enin

gto

rque

90-

122

ft.lb

s.

Bolt

Spac

ing

– M

axim

um 8

" –

Min

imum

4"

55"

2"2"

Truc

kFr

ame

Air Wedge Slide Bracket Fifth Wheel (AWB) & ManualWedge Slide Bracket Fifth Wheel (MWS) -- AWB Shown

Adjustment of 24" shown. Greater adjustment requireslonger angle and additional mounting bolts. See suggest-ed price list for angle sizes and lengths available. The fulllength of the horizontal flange of the outboard mountingangles must be at the same elevation as the truck frame.The vertical leg of the angle must fit flush with the truckframe.


8

Full

leng

th .2

5"

Fille

t wel

d as

sho

wn

abov

e in

red.

Mou

ntin

g An

gle

(Do

not w

eld

totru

ck fr

ame)

.

All m

ount

ing

hard

war

e m

ust b

e a

min

imum

of:

5/8"

- 1

1 Gr

ade

8Bo

lts,G

rade

C lo

cknu

ts w

ith h

ard-

ened

ste

el w

ashe

rs,t

ight

enin

gto

rque

90-

122

ft.lb

s.

Bolt

Spac

ing

– M

axim

um 8

" –

Min

imum

4"

50.2

5"

2"2"

Truc

kFr

ame

Light Weight Slide Bracket & Fifth Wheel (LWS)


Wel

d le

ft &

right

rear

slid

est

op b

lock

s as

sho

wn

in re

dab

ove

(left

side

sho

wn)

.


9

Mou

ntin

g An

gle

(Do

not w

eld

totru

ck fr

ame)

.

All m

ount

ing

hard

war

e m

ust b

e a

min

imum

of:

5/8"

- 1

1 Gr

ade

8Bo

lts,G

rade

C lo

cknu

ts w

ith h

ard-

ened

ste

el w

ashe

rs,t

ight

enin

gto

rque

90-

122

ft.lb

s.

8"8"

8"8"

36"

2"2"

Truc

kFr

ame

Stationary Fifth Wheel with Long Mounting Plate (PLA)

The full length of the horizontal flange of the outboardmounting angles must be at the same elevation as thetruck frame. The vertical leg of the angle must fit flushwith the truck frame.


10

Mou

ntin

g An

gle

(Do

not w

eld

totru

ck fr

ame)

.

All m

ount

ing

hard

war

e m

ust b

e a

min

imum

of:

5/8"

- 1

1 Gr

ade

8Bo

lts,G

rade

C lo

cknu

ts w

ith h

ard-

ened

ste

el w

ashe

rs,t

ight

enin

gto

rque

90-

122

ft.lb

s.

5"5"

5"5"

2"24

"

2"

Truc

kFr

ame

Stationary Fifth Wheel with Short Mounting Plate (PSA)



11

Mou

ntin

g An

gle

(Do

not w

eld

totru

ck fr

ame)

.

All m

ount

ing

hard

war

e m

ust b

e a

min

imum

of:

5/8"

- 1

1 Gr

ade

8Bo

lts,G

rade

C lo

cknu

ts w

ith h

ard-

ened

ste

el w

ashe

rs,t

ight

enin

gto

rque

90-

122

ft.lb

s.

Bolt

Spac

ing

–M

axim

um 8

"–

Min

imum

4"

2"37

"

2"

Truc

kFr

ame

Adjustable Flat Plate Mount Fifth Wheel (PMA)

Adjustment of 18" shown. Greater adjustment requireslonger angles and additional mounting bolts. See sug-gested price list for angle sizes and lengths available. Thefull length of the horizontal flange of the outboard mount-ing angles must be at the same elevation as the truckframe. The vertical leg of the angle must fit flush with thetruck frame.


12

Mou

ntin

g An

gle

(Do

not w

eld

totru

ck fr

ame)

.

All m

ount

ing

hard

war

e m

ust b

e a

min

imum

of:

5/8"

- 1

1 Gr

ade

8Bo

lts,G

rade

C lo

cknu

ts w

ith h

ard-

ened

ste

el w

ashe

rs,t

ight

enin

gto

rque

90-

122

ft.lb

s.

2"5"

5"5"

5"24

"

2"

Truc

kFr

ame

Stationary Frame Mount Fifth Wheel (FMA)

The full length of the horizontal flange of the outboardmounting angles must be at the same elevation as thetruck frame. The vertical leg of the angle must fit flushwith the truck frame. The full length of the vertical andhorizontal legs of the inboard angles must be flush withthe inside of the truck frame.


13

Mou

ntin

g An

gle

(Do

not w

eld

totru

ck fr

ame)

.

All m

ount

ing

hard

war

e m

ust b

e a

min

imum

of:

5/8"

- 1

1 Gr

ade

8Bo

lts,G

rade

C lo

cknu

ts w

ith h

ard-

ened

ste

el w

ashe

rs,t

ight

enin

gto

rque

90-

122

ft.lb

s.

2"8"

8"8"

8"36

"

2"

Truc

kFr

ame

Stationary 36" Angle Mount Fifth Wheel (A36)

The full length of the horizontal and vertical legs of theangles must fit flush with the truck frame.


14

Mou

ntin

g An

gle

(Do

not w

eld

totru

ck fr

ame)

.

All m

ount

ing

hard

war

e m

ust b

e a

min

imum

of:

3/4"

- 1

0 Gr

ade

8Bo

lts,G

rade

C lo

cknu

ts w

ith h

ard-

ened

ste

el w

ashe

rs,t

ight

enin

gto

rque

155

-210

ft.l

bs.

2"Bo

lt Sp

acin

g –

Max

imum

8"

–M

inim

um 4

"67

"

2"

Truc

kFr

ame

Xtra Heavy Duty Air Wedge Slide Bracket Fifth Wheel(XAWX)


1.75

" M

ax.

Wel

d le

ft &

right

rear

slid

e st

op b

lock

s as

show

n in

red

(Lef

tsi

de s

how

n).


15

Mou

ntin

g An

gle

(Do

not w

eld

totru

ck fr

ame)

.

All m

ount

ing

hard

war

e m

ust b

e a

min

imum

of:

3/4"

- 1

0 Gr

ade

8Bo

lts,G

rade

C lo

cknu

ts w

ith h

ard-

ened

ste

el w

ashe

rs,t

ight

enin

gto

rque

155

-210

ft.l

bs.

2"5"

5"5"

5"2"

24"

Truc

kFr

ame

Xtra Heavy Duty Short Plate Mount Fifth Wheel (XPSA)



16

Mou

ntin

g An

gle

(Do

not w

eld

totru

ck fr

ame)

.

All m

ount

ing

hard

war

e m

ust b

e a

min

imum

of:

3/4"

- 1

0 Gr

ade

8Bo

lts,G

rade

C lo

cknu

ts w

ith h

ard-

ened

ste

el w

ashe

rs,t

ight

enin

gto

rque

155

-210

ft.l

bs.

2"8"

8"8"

8"2"

36"

Truc

kFr

ame

Xtra Heavy Duty Long Plate Mount Fifth Wheel (XPLA)


Section II –Pre-Service Procedures

A. Fasteners

Make sure all nuts and bolts are in place and prop-erly tightened.

Check to see if both bracket pins are in place andsecured by retainer pins and cotter pins.

Pre-Service Procedures

17

Bracket PinRetainer Pin

Cotter Pin

No-Slack® IIFifth Wheel

Bracket Pin Retainer Pin

5000/5092Series Fifth Wheel

Cotter Pin

B. Lubrication

1. Tilt the top plate forward (front of the fifth wheeldown) and apply grease to each bearing areathrough the zerk fitting (No-Slack® II has two fittingseach side) located on each side of the top plate justto the front of the bracket pins. Continue to applygrease until it is coming out of the back of the bear-ing. It may be necessary to raise the rear of the fifthwheel with a pry bar to open up the pocket slightlyand allow the grease to flow through. Periodicallyremove the fifth wheel to clean old grease from thebracket grease channels to help insure an even dis-tribution of fresh grease. A substantial amount ofgrease may be required initially to fill the reservoir.Tilt the wheel to the rear (rear of the wheel down)and repeat the procedure. Rock the top plate backand forth several times to spread the grease over thebearing surface.

Inspect the trailer kingpin plate and top surface ofthe fifth wheel to make sure each is properlygreased. A liberal coating of grease should beapplied to the complete surfaces of both the trailerkingpin plate and the top surface of the fifthwheel. A paddle or brush will make this job easier.

Do not use a lube plate (high density polyethylene)on top of the fifth wheel or on the kingpin in lieu ofgrease without prior approval by FontaineInternational. The additional thickness of this mater-ial can prevent the proper operation of the fifthwheel and can cause a dangerous condition.

2. Lubricate the fifth wheel prior to opening and clos-ing. Referring to Figures 2-4 (at right), grease thejaw and wedge on top and bottom. Separate the jawand wedge with a large screwdriver and distributethe grease along the full length of the jaw andwedge mating surfaces. Open and close the fifthwheel several times to further distribute the grease.

Fontaine suggests the use of a Moly based lubricantsuch as Mobilgrease Moly 50 or equivalent when


18

FIGURE 2 – NO-SLACK® II

FIGURE 3 – 5000/5092 SERIES

FIGURE 4

Wedge

Wedge

SeparateJaw andWedge.Grease FullLength.

Pull Handle

Pull HandleSpring

Jaw

Jaw

Wedge

Jaw

applying lubricant to the locking jaw and wedge.

Lightly oil other moving parts in the fifth wheel.

3. For sliding Fifth Wheels, lightly oil the locking mech-anism. Operate the mechanism (air or manual) sev-eral times to ensure it is functioning properly.

4. Grease the top plate. Spread grease all over themating surface of the top plate. Be sure the greasepockets built into the top plates are full of grease.


19

C. Operation

1. Fontaine’s No-Slack® II fifth wheel shown inFigure 2 (previous page) opens by a straight pullon the release handle which releases the sec-ondary lock automatically as the mechanismopens.

2. Fontaine 5092 series offers several types of pullhandles. The Side Release Fifth Wheel is shownin Figure 3 (previous page). To open, lift the pullhandle and pull. A slight jerk on the handlemakes the opening easier.

3. Figure 5 shows a Retractable Handle. To open,move the handle to the rear and pull.

4. Fontaine’s air actuated No-Slack® II air-actuated fifth wheel is shown in Figure 7 andFontaine’s 5092 air-actuated fifth wheel isshown in Figure 8. They open with a releasevalve located on the dash or in a lock boxmounted on the rear of the cab. To open, setthe tractor parking brake and pull the releasevalve. Hold the valve open until the lockingmechanism is locked in the open position. Thepull valve will not activate the air cylinder unlessthe tractor parking brakes are set.


20

FIGURE 5

Retractable Handle

5. Close the locking mechanism using a test kingpin or2" diameter pipe. Repeat several times making surethat all moving parts have adequate lubrication.

6. The pull handle should always be free of grease orany substance which could prevent a firm grip,causing the handle to slip and resulting in injury.


21


FIGURE 8 – 5092 SERIES

D. Wedge Stop Rod Setting

Close the fifth wheel on a standard 2" kingpin or a2" diameter shaft inserted vertically. Push on thewedge stop rod. (Extends from the side of the topplate and looks like the head of a bolt). It shouldmove in 1/4" with hand pressure, then spring back.To obtain a proper setting, turn the wedge stop rodclockwise to reduce the dimension and counter-clockwise to increase it. Adjust until the free travel is1/4" (See Figure 9 & 10). This will allow the auto-matic slack adjustment feature of the Fontaine FifthWheel to function properly.

This Wedge Stop Rod can also be used to releasea tight wedge (hard to pull handle) by tapping therod with a hammer to release the wedge.


22


FIGURE 10 – 5000/5092 SERIES

WedgeWedge Stop Rod

WedgeWedge Stop Rod

E. Knock-Out Rod

The knock-out rod requires no adjustment (SeeFigure 11) and is used to release a tight wedge (hardto pull handle) by tapping the rod with a hammer.


23

Figure 11

Knock-out Rod

Section III –Operating Instructions

COUPLING PROCEDURE:

1. Prior to coupling, inspect the fifth wheel to ensurea proper operation.

• Examine the mounting assembly for securelyfastened bolts.

• Tilt the fifth wheel up and down to make surethat it moves freely. Rest the fifth wheel in theproper position by tilting it to the rear of thetractor and resting it on the stops.

• Check the surface for a liberal coating ofgrease. The indented pockets on top of thefifth wheel act as a grease reservoir for the topsurface and should be filled with grease.

• If the tractor is equipped with an air sliding fifthwheel, actuate the air cylinder and check for airleaks. WARNING: AIR CYLINDERDISASSEMBLY SHOULD NOT BE ATTEMPTED.

• The fifth wheel should be in an unlocked position.When unlocked, the handle should be extended(see Figure 12) and the fifth wheel throat unob-structed (For the 5092 Series the ends of the jawand wedge are visible). If the fifth wheel isequipped with a retractable handle, the handlewill not be fully extended. DO NOT TRY TO COUPLE TO A CLOSED FIFTH WHEEL.


24

FIGURE 12 –NO-SLACK® II

2. The trailer kingpin should also be inspected priorto coupling. The kingpin plate should be fullyreinforced and of sufficient size to completelycover the fifth wheel. If the kingpin plate is toonarrow, the uncovered portion of the fifth wheelwill collect dirt and foreign matter. This materialmay work into the fifth wheel locking mecha-nism, causing wear and occasionally difficultuncoupling. This material can also cause gallingof the fifth wheel and/or kingpin plate.

If the trailer kingpin plate is not fully reinforced,distortion can result causing:• Non-uniform loading• Variation in kingpin length• Cutting and galling of the fifth wheel or

kingpin plate

If the trailer kingpin plate is distorted enough tocause any of the conditions listed above, werecommend that a new plate be installed.

The trailer kingpin plate must be properlygreased.

Fontaine Fifth Wheels are designed and manu-factured for use with all trailer kingpins thatconform to SAE specifications, SAE J700,February 1993 and subject to the wear limits ofSAE J2228, June 1993. These specificationscover SAE 2" kingpins only.

The SAE standard kingpin can be checked usingthe dimensions given in Figure 13 (next page).

Operating Instructions

25

3. Proper tractor/trailer alignment is critical toobtain a secure coupling and to avoid equipmentdamage.

Set the trailer brakes and raise the trailer to theproper height by extending the landing legs. Ifthe trailer is positioned too high, the kingpinmay jump the fifth wheel throat and lockingmechanism altogether. Resulting damage mayinclude: scoring the fifth wheel, bending thehandle thus preventing the fifth wheel fromproperly locking to the kingpin, bending thekingpin, and other significant damage to thetractor cab.

Coupling should not be attempted if the trailer istoo low. Costly damage may be incurred to thetrailer, the kingpin, the kingpin plate, the fifthwheel, and the entire tractor drivetrain.

4. To couple the fifth wheel to the kingpin, be surethe fifth wheel is positioned so that it tilts downat the rear and is resting on the stops.

Align the kingpin with the throat of the fifthwheel and ease the tractor toward the trailer.The trailer should strike the fifth wheel just atthe top of the approach ramps. The fifth wheelwill level with the kingpin plate and the kingpinshould slide up the fifth wheel throat.


26

FIGURE 13 SAE STANDARD KING-PIN (SAE J700, FEB 93)

2.875 ± .005 1.3281.250

2.7822.704 3.354

3.256

2.812 ± .015

2.000 ± .005

Coupling is complete when the fifth wheel lock-ing mechanism snaps closed behind the kingpin.

Verify secure coupling with a "tug test," by eas-ing the tractor forward, with trailer brakes on, tofeel resistance of the load. If the coupling feelssecure, visually inspect the fifth wheel. The jawand wedge must be locked in place behind thekingpin, completely across the throat of the fifthwheel, and the pull handle must be retractedand securely latched in the secondary lock.

HOW TO TELL IF THE FIFTH WHEEL IS LOCKED.

No-Slack® II 6000/7000 Series (see Figure 14).Verify secure coupling with a "tug test," by eas-ing the tractor forward, with trailer brakes on, tofeel resistance of the load. The locking jaw andwedge must be fully across the throat of thewheel. In addition, the pull handle must bewithin 1" of the skirt of the wheel. The pull han-dle should be used as a positive lock indicator.

No-Slack® 5092 Series (see Figure 15).Verify secure coupling with a "tug test," by eas-ing the tractor forward, with trailer brakes on, to


27

Fifth Wheel Fully Closed

NOTE: Gap between pull handle and skirt of wheel

less than 1”

NOTE: Gap of 1" or more between wheel skirt and pull handle

Pull handle

Pull handle

Fifth wheel skirt

Fifth wheel skirt

Fifth Wheel Not Fully Closed

FIGURE 14

feel resistance of the load. The locking jaw andwedge must be fully across the throat of thewheel and the bottom section of the (2) piecepull handle should be in and down behind thetriangular piece located just inside the fifthwheel skirt.

5. To position an air sliding fifth wheel, set the trail-er brakes, unlock the cab control air valve andallow the air cylinder to retract the locking


28

Fifth Wheel Fully Closed

NOTE: The 2 piece pull handle dropping in behind triangular piece

NOTE: The 2 piece pull handle notdropping inbehind triangularpiece

Fifth wheel skirt

Pull handle

Triangle piece

Note: Baris visible

Fifth Wheel Not Closed

Side View

Pull handle

Triangle piece

Side View

FIGURE 15

wedges. Ease the tractor forward or backwardto move the fifth wheel to the desired positionand lock the air valve.

Position a manual sliding fifth wheel, by pullingup and out on the pull handle. Drop it outsidethe handle guide. Ease the tractor forward orbackward to position the fifth wheel. Pick upthe pull handle and allow it to spring back into alocked position.

After the fifth wheel is properly positioned,inspect the locking wedges to ensure that theyare fully engaged in the slide rail pockets.

Under no circumstances should a slidingfifth wheel be re-positioned while the tractorand trailer are in motion.

Do not attempt to slide the fifth wheel untilall persons are clear of the vehicle.

UNCOUPLING PROCEDURE:

1. Prior to uncoupling, set the trailer parkingbrakes. Back the tractor gently against thetrailer. This will release the load on the fifthwheel locking mechanism.

IF THE TRUCK HAS AN AIR SUSPENSION, DONOT DUMP THE AIR BEFORE OPENING THEFIFTH WHEEL. DOING SO MAY CAUSE A HARDTO OPEN SITUATION.

2. Block the trailer wheels. If poor ground condi-tions exist you may have to provide a base forthe trailer landing gear.

3. Lower landing gear until it contacts the ground.Give extra turns to reduce load on fifth wheel.DO NOT RAISE TRAILER OFF OF THE FIFTHWHEEL.

4. Disconnect air lines and open the fifth wheel.

5. Slowly drive tractor from under trailer.


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Section IV –Inspection and

Maintenance ProceduresUsing a suitable solvent, degrease the fifth wheeland mounting brackets every 90 days or 30,000miles, whichever comes first, and inspect for:

1. Cracks in the fifth wheel assembly, mountingbrackets, and mounting parts.

2. Wear and/or damage to moving parts.

3. Free operation of the secondary lock spring(5000 & 5092 series only).

4. Loose nuts and bolts in the fifth wheel and in themounting hardware.

5. Securely fastened and properly working springs.

6. Check to see if both bracket pins are in placeand secured by retainer pins and cotter pins.

7. Free front to rear rock on brackets with grease-less liners (LWS). If the fifth wheel does notrock freely, remove the top plate and inspect thebracket liners. Replace liners that are broken orhave worn excessively. Replace liners every300,000 miles in standard duty applications andevery 180,000 miles in moderate or severe duty,or any application using the H5092 series topplate. Check the bracket liner thickness at everyscheduled maintenance. Replace liners if thethickness is less than .125" at the top of theliners.

8. Proper operation of the slide locking mecha-nism. Check for air leaks in the cylinder andsupply line.


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Lubrication

Following the instructions provided in the Pre-Service Procedure on pages 17-23.

Special precautions must be taken during coldweather to ensure that the locking mechanismoperates freely. Ice and sludge can build up and lubricants become thick and binding at lowtemperatures.

When the temperature drops below freezing,Fontaine recommends the use of a cleaner ordegreaser on the latching mechanism, makingsure that the moving parts operate freely. Thisshould be followed by an application of 90-weight oil to all moving parts. This proceduremay also be necessary in operations whereexcessive road grime or grit is encountered.

The regular performance of the routine,"90-Day/30,000 Mile Preventative MaintenanceProcedure," is also recommended


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Section V –No-Slack®Limited Warranty

Basic Limited Warranty

Fontaine International, Inc. (Fontaine) warrants eachNo-Slack® (5092 series), and No-Slack® II(6000,7000 and 7000 Clean Connect series) fifthwheel sold in North American on or after January 1,2004 to be free from defects in material and work-manship for five years from date of sale, but doesnot cover failures due to:

1. Use in loads that are beyond federal, state andprovincial highway limits or in special overweightload permits.

2. Improper installation of fifth wheel.3. Normal wear.4. Accident.5. Improper application.6. Misuse, alteration or negligence.7. Failure to properly maintain the fifth wheel.8. Inadequate repairs or alterations that, in

Fontaine’s judgment, adversely affect the fifthwheel’s performance or reliability.

Fontaine cannot guarantee the service life of anyfifth wheel since service life can vary with applica-tion, usage, maintenance, environment, and otherfactors beyond Fontaine’s control.

Limited Performance WarrantyFontaine warrants the performance of each No-Slack® (5092 series), and No-Slack® II(6000,7000 and 7000 Clean Connect series) fifthwheel sold in North America on or after January 1,2004 that is used in a “standard duty application”for five years from the date of sale. A “standardduty application” requires that (i) the vehicle is used100% on highways with more than 30 milesbetween each stop, (ii) the vehicle does not exceed

No-Slack® Limited Warranty

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a gross combined vehicle weight of 95,000 lbs.(43,000 kilograms), (iii) the total number of towedaxles does not exceed two and (iv) the road type ismaintained concrete or asphalt.

Fontaine warrants that each fifth wheel coveredhereunder shall operate as described in theFontaine Instruction Handbook, and the lockingmechanism (jaw & wedge) will wear properly on thetrailer kingpin when the fifth wheel is adjusted inaccordance with the manufactures specifications

Fontaine fifth wheels are designed and manufac-tured for use with SAE 2" trailer kingpins that con-form to SAE specification (SAE L700, February1993) and are subject to the wear limits of SAEspecification (SAE L2228, June 1993).

Low Lube Specific WarrantyFifth wheel lube free components are warranted fortwo years unlimited mileage per "standard dutyapplication" requirements as listed.

Replacement of Parts and Repairs Authorization from Fontaine must be obtainedbefore replacing or returning any part under thisLimited Warranty.

If the fifth wheel does not perform as warranted inthis Limited Warranty, or if there is any defect in thematerial or workmanship covered by this LimitedWarranty, Fontaine will, at its option, provide buyerwith parts or reimburse the buyer for parts at itsreasonable acquisition cost, up to the amount of theoriginal suggested retail price. Further, Fontainewill cover labor cost in repairing the fifth wheel aslong as the labor rate is reasonable and the repairtime does not exceed Fontaine’s Standard RateTime chart. Fontaine may require the unit or part tobe returned to Fontaine’s factory or a Fontaineauthorized representative for evaluation. All freight

to and from Fontaine or a Fontaine authorized representative must be prepaid.

This is Fontaine’s only warranty. Fontainemakes no other warranty of any kind, expressedor implied. All implied warranties or mer-chantability and/or fitness for a particular pur-pose are hereby disclaimed by Fontaine andexcluded. This Limited Warranty may not bechanged except in writing by an authorized officerof Fontaine. Any action for any alleged breach ofthis Limited Warranty must be commenced withinone year after such alleged breach occurred or shallbe forever barred.

The remedies stated above shall be exclusive forany and all claims by the original user, or anybodyclaiming through the original user, against Fontaine,whether based on contract, negligence, tort, or anyother theory. In no event shall Fontaine be liablefor any incidental or consequential damages,losses, or expenses.

This limited warranty gives the buyer specific legalrights, and buyer may also have other rights, whichmay vary depending on the state, province or coun-try where the truck is registered.


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For sales and service locationsor for additional copies of thishandbook go to our web site atwww.fifthwheel.com.

Audio and Video tapes are available, free ofcharge, with instructionsfor fifth wheel mainte-nance, driver use of thefifth wheel and driver coupling/uncouplinginstructions. Please contact Customer Servicesat 1-800-874-9780 to orderthese tapes.

Service Locations / Audio & Video Tapes

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©2004 Fontaine International • LT-001 • Revised Apr. 1, 2004All specifications are subject to change without notice.

Fontaine International, Inc • World Wide Headquarters 5000 Grantswood Road • Irondale, AL 35210

800-874-9780 • Fax: 205-421-4440www.fifthwheel.com

FONTAINEFONTAINE®

fontaine instructions.pdf

Documents

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wheel handbook2section

wheel pma

wheel mws

wheel xawx

wheel xpsa

wheel xpla

wheel lws