Montracon MT45 Operator'S Handbook Manual Download Page 62 | Manualshive

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FAULT FINDING

the trailer for road transport

e: [email protected] | w: www.montracon.com

t

: +44 (0)1302 732500 |

f

: +44 (0)1302 732503

62

CONTENTS

1. Brakes

2. Running Gear

3. Air Suspension

4. Landing Legs

5. Electrical System

6. Hydraulic System

7. Paint Finish

Page 63

Page 64

Page 68

Page 70

Page 70

Page 71

Page 72

This section covers a wide variety of components that
are used on Montracon trailers. Not all components will
appear on one vehicle, therefore certain instructions
contained herein will not apply. Where special instruction
beyond the scope of this section is required, this will be
supplied as supplementary information.

IF IN DOUBT, ASK!

MACHINERY CARRIERS

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Summary of Contents for MT45

Page 1: ...www montracon com Rev 3 Edition Machinery Carrier OPERATOR HANDBOOK the trailer for road transport...

Page 2: ...4 0 1302 732500 f 44 0 1302 732503 1 General 2 Operating Instructions 3 Air Suspension 4 Brake System 5 Electrical System 6 Trailer Maintenance Care 7 Fault Finding 8 Useful Contacts Page 3 7 Page 8 2...

Page 3: ...GENERAL INFORMATION MACHINERY CARRIERS CONTENTS 1 Vehicle Identification 2 General Description 3 To the Driver 4 Warranty Claims Procedure Page 4 Page 5 Page 5 Page 6 This trailer has been manufactur...

Page 4: ...so be fitted with a Montracon Ministry Plate showing the C number Ministry number which has been allocated to that trailer by VOSA before delivery to the Customer This plate is usually fitted in the d...

Page 5: ...ons to products already sold Whilst every effort is made to make sure descriptions illustrations and specifications within this handbook are correct at the time of going to print these are also subjec...

Page 6: ...or make other arrangements for the work to be completed OWNERS RESPONSIBILITY Due to the wide variance in the operating conditions of equipment the owner and or operator must exercise reasonable dilig...

Page 7: ...s must be intact 3 The trailer must have been serviced as recommended in the Operator Handbook using only replacement parts lubricants and fluids approved by Montracon Suitable service records should...

Page 8: ...ow Your Vehicle 7 Operating Controls 8 Operating Instructions Page 9 Page 9 Page 9 Page 10 Page 11 Page 12 Page 13 Page 15 This section covers a wide variety of components that are used on Montracon t...

Page 9: ...y locked 7 Connect the tractor s electrical and air couplings to their respective colour coded couplings on the front of the trailer Open tractor airline shut off cocks if fitted Couple hydraulic line...

Page 10: ...e handle on the nearside leg i e opposite to the following instructions To set the legs for coupling Unclip the cranking handle and push shaft inwards to select low gear Rotate handle and adjust trail...

Page 11: ...3 Check Brake Operation Allow system to pressurise check tractor pressure gauges and if necessary run up until the tractor unit compressor exhausts or blows off Try the service foot and third line ha...

Page 12: ...age Check distribution and security of load See VOSA Guidance on load security April 2012 available at www gov uk government organisations vehicle and operator services agency 10 Ancillary Equipment W...

Page 13: ...us allowing operation of the winch and ramp controls 1 RAMP POWER PACK BUTTON 2 N S RAMP RAISE LOWER LEVER 3 O S RAMP RAISE LOWER LEVER 4 N S RAMP SIDE SHIFT LEVER 5 O S RAMP SIDE SHIFT LEVER The rear...

Page 14: ...CARRIERS Pull to disable the lift axle functionality The raise lower valve allows raising lowering of the trailer by pressurising depressuring the air suspension bellows This control will also dump th...

Page 15: ...rocedure WARNING WARNING Check the area make sure it is clear and no one is likely to walk around the back of the trailer Make sure the steady legs are stored and secure before commencing travel 7 Whi...

Page 16: ...d store the locking pin in the parking hole 3 To raise the leg swing the leg up by hand and return the spring loaded locking pin to its home position IMPORTANT Always make sure the steady leg is deplo...

Page 17: ...e not subject to constructional standards and so could vary in strength Lashing rings should be used at all times to secure the load to the bed of the trailer If in doubt consult Department of Transpo...

Page 18: ...Lower the air suspension using the raise lower control on the trailer suspension see page 31 for correct procedure 7 Slacken but do not remove the ramp straps 5 Extend reflective triangles 6 Unlatch...

Page 19: ...e the ramp to full height 3 Once the ramp is at full height twist the support pin control thus allowing it to spring from the locating position The support pins will extend out from the neck under the...

Page 20: ...he hydraulically powered loading ramps clip on ramps may have been specified Always store the ramps safely before commencing travel Grip bars must be kept free from foreign objects and sludge dirt etc...

Page 21: ...ger timbers are available as an optional extra to place over the outriggers Pull Out Outriggers as equipped Swing Out Outriggers as equipped The pull out outriggers extend the deck of the trailer by a...

Page 22: ...rotection straps 2 Release the fall arrest posts and lock in the outward position NOTE Each panel is numbered and should be laid out in sequential number order 4 Once the panels are out install on the...

Page 23: ...44 0 1302 732503 MACHINERY CARRIERS Use markerboards as per highway code regulations Before operating the rear ramps make sure the pull out triangles are extended An electrical socket 1 is located un...

Page 24: ...S CHASSIS MOUNTED TOOL BOXES Please refer to the relevant winch manufacturers operating instructions for information and advice on the correct winch operation and any relevant safety notices The winch...

Page 25: ...levelling valve EBS valve and auxiliaries should the need arise The electro hydraulic power pack is mounted between the two main beams in the neck area of the trailer along with the hydraulic oil res...

Page 26: ...ment REMOVABLE TYPE Is secured in sockets and held in position via locking bolts Removing the bolts will allow the headboard to be lifted from the sockets To change position of the headboard remove th...

Page 27: ...ntracon com w www montracon com t 44 0 1302 732500 f 44 0 1302 732503 MACHINERY CARRIERS For easy pedestrian access onto the bed of the trailer release the locking pin 1 Slide the barrier across and l...

Page 28: ...Valve 6 Raise Lower Valve 7 Lift Axle Page 29 Page 29 Page 29 Page 29 Page 30 Page 31 Page 32 This section covers a wide variety of components that are used on Montracon trailers Not all components wi...

Page 29: ...or for service warranty purposes Refer to Manufacturer s literature for more detailed information Load sensing is incorporated in trailers having an electronic braking system EBS On vehicles without a...

Page 30: ...All trailer brakes should be OFF 3 There should be an air supply to the suspension unit of at least 6 5 bar 4 The height control valve should be positioned in the middle of the sensed axle 5 If the t...

Page 31: ...ler is uncoupled Trailer brakes are applied Always leave a parked trailer with the suspension lowered 1 Push control lever handle IN 2 Set control to either RAISE or LOWER position When trailer floor...

Page 32: ...clearance of more than 90mm exists between the tyre and the ground Ensure all personnel stand clear of raised axle when loading and unloading LIFT AXLE The pneumatic lift allows individual axles to b...

Page 33: ...Brake Brake Release 8 Air Loss and Brake Protection 9 Brake Actuator Release Procedure Page 34 Page 34 Page 35 Page 37 Page 37 Page 38 Page 39 Page 40 Page 41 This section covers a wide variety of com...

Page 34: ...e fine tuning Data required for repair and inspection of the brake system is contained on the Load Sensing Valve Data Plate For sample refer tp page 4 Vehicle Identification or page 38 Brake System In...

Page 35: ...ing inspect seals for wear and damage Replace where defective After having connected couplings check for leaks Close protective caps on couplings after disconnection Drain Air Reservoir Tanks The bigg...

Page 36: ...ht away Re assemble ensuring 0 ring is fitted Service brake linkages fig 1 Lubricate service brake cylinder actuator rod linkages and valve pivots Brake cylinder fig 2 Check brake cylinder attaching b...

Page 37: ...ronic load sensing equipment which is powered via the ISO 7638 connector If the tractor unit is fitted with the dedicated ISO 7638 connector there will be a red lamp on its dashboard to display the fu...

Page 38: ...ate contains valuable information required for inspection and repair of the brake system The diagnostic unit is normally mounted on the side of the main frame It provides ready access to trailer relat...

Page 39: ...d at the UK nearside close to the front support legs On disconnection of the emergency red line the brakes are automatically applied As the air is depleted the spring brake system maintains brake enga...

Page 40: ...se the spring brakes Shunt the trailer w o the emergency line 1 Push the black button 2 Push the red button to release the spring brakes you can shunt the trailer 3 After shunting pull the black butto...

Page 41: ...lly Reverse the procedure for spring relief 1 Remove re setting tool from its holder alongside the brake cylinder This has a threaded pin with bayonet type lock at one end and a washer with nut on the...

Page 42: ...System Auxillary Equipment Page 43 Page 43 Page 44 This section covers a wide variety of components that are used on Montracon trailers Not all components will appear on one vehicle therefore certain...

Page 43: ...nel and winches or to control independent circuits like tail lifts internal lifts decks and rear loading ramps Electrical Equipment Outline markers and internal lighting are connected with rear light...

Page 44: ...l Flasher LH Reverse Directional Flasher RH Stop Lights Spare Switch Cab op Spare Switch Cab op Spare Switch Cab op Spare Rear Fog Light Front Side Rear No Plt Lamp Tail LH Spare Front Side Rear No Pl...

Page 45: ...5 ISO 7638 7 PIN NORMAL CONNECTOR 1 2 3 4 5 6 7 ISO 7638 7 PIN 1 24 V VE 24 V VE IGN Red Black Yellow Brown White Brown Green Ground Warning Lamp Ground Can 763F Free Plug Can 20 2 3 4 5 6 7 Function...

Page 46: ...are Maintenance of Trailer Tyres 11 Tyre Problems 12 Suspension Checks Torque Figures 13 BPW Automatic Slack Adjustor Operation Check Page 47 Page 48 Page 49 Page 50 Page 52 Page 53 Page 54 Page 55 Pa...

Page 47: ...ach trailer should therefore be checked before use The remainder of this section contains sufficient technical information to cover maintenance during the first four weeks of trailer operation followe...

Page 48: ...different torque values specified for individual component groups in this handbook Check axle manufacturer s manual for wheel nut torque values Replace self locking nuts after having unthreaded twice...

Page 49: ...intenance Wheel Nuts After First Journey Prior to First Journey Prior to First Journey Prior to First Journey Prior to First Journey Suspension Nuts Bolts King Pin Bolts Body Bolts Tyre Pressures Air...

Page 50: ...ck all brake system valves for correct operation Test emergency valve incorp Park Shunt Overhaul actuators emergency quick release valves Inspect tyres for damage Check tyre pressures Torque load whee...

Page 51: ...rosion and always keep clean A B C D E F Linish is a pattern of very fine lines achieved by abrading the surface with by hand using suitable paper on the brake linings and emery cloth on the drum The...

Page 52: ...nts must be greased to protect against corrosion both during service and when in storage or periods of non operation The Chrome rods can become damaged from normal use and or through routine servicing...

Page 53: ...support pins slide in a housing these need to be lightly greased during routine maintenance given a visual inspection NOTE Copper grease is recommended as it does not attract dirt like normal grease 6...

Page 54: ...e ends if fitted unfold correctly 2 Check the side shift functionality if fitted and no foreign objects are caught restricting side movement 3 Check for any damage to the ramps IMPORTANT Replace any w...

Page 55: ...sure the jack head is suitably shaped to accept the profile of the axle Where it is not possible to jack in the position previously described jacking must only be carried out with consideration to fol...

Page 56: ...the hub place a bar underneath the base of the tyre and lever the wheel upwards and over the studs taking care not to damage the threads Repeat this operation for the second wheel where necessary 5 Re...

Page 57: ...ntinuously running vehicles with low laden axle weights should reduce the pressures in the trailer tyres accordingly and vice versa Refer to tyre manufacturer s technical information Drivers and maint...

Page 58: ...ure of cords Excessive heat build up Wear concentrated on centre of tread Spotty tread wear Scrubbing Tread cuts Irregular wear on shoulder of tyre Rapid wear Symptons Causes End Result Failure Tyres...

Page 59: ...con com w www montracon com t 44 0 1302 732500 f 44 0 1302 732503 MACHINERY CARRIERS 59 SUSPENSION CHECKS AND TORQUE FIGURES IMPORTANT For service intervals and maintenance checks procedures refer to...

Page 60: ...his is done automatic adjustment must take place smoothly Engagement of the clutch coupling is audible and on the return stroke the adjustment screw turns slightly in a clockwise direction Grease with...

Page 61: ...re used The need to thoroughly remove the solution by rinsing cannot be overstressed Even at a pH of 10 5 corrosive attack will occur Hot pressure cleaners can be used but care should be exercised to...

Page 62: ...stem 7 Paint Finish Page 63 Page 64 Page 68 Page 70 Page 70 Page 71 Page 72 This section covers a wide variety of components that are used on Montracon trailers Not all components will appear on one v...

Page 63: ...akes If automatic slack adjuster fitted check for correct operation and rectify if required Lubricate camshaft bushes Check pre dominance from tractor unit Check emergency line red is connected and tr...

Page 64: ...nance from tractor unit Lubricate camshaft bushes Strip down brake assemblies check components replace as necessary required and lubricate Lubricate camshaft bushes Strip down brake assemblies check c...

Page 65: ...mponents replace as required and lubricate Strip down brake assemblies check components replace as required and lubricate Fit new exchange shoes Check for leaks in service line at and at valves with b...

Page 66: ...ng freezing weather Service compressor check seals Check bulb and connections Contact manufacturer customer services if fault persists Remove and clean sensors Check voltage readings Check drier and r...

Page 67: ...lift system Refer to Air suspension faults on next page Inspect for damage leaks and rectify Check for dirt etc clean or replace Check wiring check EBS diagnosis if fitted Axle s out of alignment Ins...

Page 68: ...otection charging valve faulty Clogged in line filter Faulty levelling valve Faulty air load sensing valve Faulty exhaust valve if fitted Faulty raise lower valve if fitted Probable Cause Remedy Suspe...

Page 69: ...e height see page 30 Reset variable height raise lower valve if fitted Check items listed under air bags flat Set to ride position see page 30 Take extra care Use trailers on highways only Levelling v...

Page 70: ...se still intact Are the fuses in the control box intact Is the switch in the cab the main current switch and the battery switch in the control box is switched ON Check connections broken wires motor e...

Page 71: ...ld be set to supply 6 0 bar Reset or replace valve Inspect for damage and test for leaks locate and repair or replace Insufficient air supply Pressure protection charging valve faulty Leak in air line...

Page 72: ...ning solution should not be above pH8 9 see page 60 for further details Rinse with plenty of clean cold water do not let detergent dry on paint surface Too much free caustic present should be 0 5 caus...

Page 73: ...4 0 1302 732500 f 44 0 1302 732503 73 Montracon has a dedicated network of service facilities backed by a comprehensive daily parts service nationwide Ask for service or parts Please have the trailer...

Page 74: ...specification of equipment without this resulting in making such modifications to product already sold Whilst every effort is made to make sure descriptions illustrations and specifications within th...

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