INSTALLATION INSTRUCTIONS COUPLING NUT MOUNTED CHAIN UNIT KIT Dealer Customer Vehicle Truck # P.O. # Unit # -6350 Bracket # Chain Wheel Kit#
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Parts List for Unit 995 S 1950 W Ste. B, Springville, UT 84663-800-633-0699 - (fax) 801-489-9797 - www.insta-chain.com - traction@insta-chain.com Customer: P.O. # Vehicle Type: Vehicle # Insta-Chain Unit# -6350 - Mounting Bracket#: Chain Unit 1 Insta Chain Unit (Left & Right) - -6350 - A & B 4 2 1/2" Mounting Bolts 0250 4 5/8" Mounting Lock Nuts 0226 8 5/8" Flat Washers 0625 Chain Wheel Kit 2 Chain Wheels Complete 1 Chain Wheel Mtg Hardware Kit 2 Chain Wheel Bolts 7004 2 Chain Wheel Lock Nuts 5211 4 Chain Wheel Spacers 0450 W 2 Chain Wheel Covers Universal Mounting Bracket Kit 6 Coupling nuts Coupling Nut Bolts Coupling Nut Bolts Coupling Nut Spacers Coupling Nut Spacers 14 5/8" Flat Washers 0625 1/4" Cross Plate Spacers 2415 1/2" Cross plate Spacers 2515 1/4" Mounting Plate Spacers 1014 S 1/2" Mounting Plate Spacers 1012 S Additional Parts U Bolts Pressure Protection Valve 0114 Auxilliary Air System 0113 Solenoid Kit# if you have any questions, please call!!! (800) 633-0699 OR CONTACT YOUR LOCAL INSTA-CHAIN DEALER 3
A The Insta Chain Unit and Brackets are to be mounted the axle. B The OEM u bolt nuts should be 1a If the remaining u bolt thread is longer than 1 3/4" it will need to be shortened as the Coupling Nuts are only threaded 2" deep (see figure C). This can be done with a cutoff wheel. Install the Coupling Nuts below the u bolt nuts, leaving the u bolt nuts in place and torque to 128ft. lbs. Use anti seize on the u bolt threads 1b Cut off any remaining threads if the total length of the remaining thread and the u bolt nut together exceed 1 3/4", because the Coupling Nuts are the only threaded 2" deep (see figure C). This can be done with a cutoff wheel. A good rule of thumb is to trim off the remaining thrad just under the u bolt nut before removing the u bolt nut. Remove the u bolt nuts, repace each nut with a grade 8 Coupling Nut; then torque all nuts to OEM specifications. Notes If using the Disc Brake Kit this applies to the front, outside u bolt leg to accomodate the Brake Caliper Torquing the Coupling Nuts too much or too little could result in damage to the Insta Chain unit or the vehicle and VOIDS the warranty. 2 Attach the Mounting Bracket to the Coupling Nuts using the following Bolts and Coupling Nut Spacers FRONT Coupling Nut " Bolts and " Coupling Nut Spacers REAR Coupling Nut " Bolts and " Coupling Nut Spacers Use flat washers an LOC TITE 262 or stronger on all coupling nut bolts. NOTE: you may have to combine spacers to get the proper spacer size listed (i.e. 1" + 1/8" 1 1/8"). Place the spacers between the Coupling Nuts and the Mounting Bracket (see figures A & B). Snug the bolts tight until the final adjustments are made to the Chain Unit. After final adjustments torque all of the Coupling Nut Bolts to 178 ft lbs. 3 The TOP of the Mounting Bracket should be LEVEL, and should be approximately off of the ground after installation. The center of the mounting Hole closest to the tire should be 1 3/4" 2" in from the sidewall of the tire (see Figure B). Check theses measurements now for reference. If these are correct, the Chain Wheel should hit level and at the correct height, but you still have to check the angle and height of the Chain Wheel once it is installed. Mount the Chain Unit to the of the Mounting Bracket. 4
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Mounting Instructions 995 S 1950 W Ste. B, Springville, UT 84663-800-633-0699 - 801-489-9000 - (fax) 801-489-9797 - www.insta-chain.com - traction@insta-chain.com MOUNTING BRACKET INSTRUCTIONS 1. Once the Mounting Brackets are properly installed, mount the Chain Units to the brackets (see bottom of page 3, last sentence for placement, i.e. on top or bottom of the bracket) using the 2½ bolts, lock nuts, and washers. Line up the unit so that it is parallel to the tire (this can be re-adjusted later). 2. Mount the Chain Wheels to the Chain Units as shown in figure D. Insta-Chain uses a non-directional chain, which may be mounted on either side of the vehicle. Place the plastic wheel cover between the arm and the Chain Wheel. We recommend that you place the two spacers between the arm and the bolt head. These can be re-arranged when adjusting at a later time. 3. Next, install the airline and electrical system (see page 7). After installing the airline and electrical system, engage the chains with the vehicle s air. Do not pull the Chain Wheel down by hand. With the Chain Wheel in the engaged position, check the following measurements. IT IS CRITICAL THAT THESE MEASUREMENTS ARE CORRECT TO INSURE PROPER THROW OF THE CHAINS, FAILURE TO DO SO WILL VOID ANY WARRANTY ON THE CHAIN WHEEL. Extra flat washers have been included to help make adjustments. a. Make sure that the chain wheel is LEVEL front to back (check with a degree finder, do not eyeball it). The wheel may tilt towards the rear of the vehicle 1-2 but NEVER to the front of the vehicle (see figure I). To adjust this angle, you may add or remove washers from between the Mounting Bracket and Coupling Nuts on either the front or rear U-bolts. A good rule of thumb is that one flat washer (1/8 thick) will change the levelness of the bracket by one degree. b. The Chain Wheel should tilt towards the tire 8 to 15 (see figure F). To change this operating angle (8 to 15 ), loosen the bolts that attach the Chain Unit to the Mounting Bracket and swivel the Chain Unit from side to side. This will also affect the clearance between Chain Wheel and the drive shaft/differential. c. The wheel should press tightly against the tire. If it is not tight against the tire, you can either swivel the unit inboard and it will increase pressure, or you may adjust the Extension Coupling (the Extension Coupling is the hex bar protruding form the air can that connects to the ball joint). To adjust the Extension Coupling, loosen the jam nuts on both ends and the turn the coupling counter clockwise for more pressure and clockwise for less pressure. There should be about 20 lbs. of pressure against the tire. 4. With the wheel in the engaged position, grab the wheel and rub it back and forth against the tire in order to make a small mark on the sidewall. This mark will be about 3/8 high and 1 long (see figure E). Now disengage the chains and make the following measurements where the wheel contacts the tire. a. The center of the mark should hit the tire at the bulge, 3-4 off the ground (see figure F or E). Adding or removing chain wheel spacers between the arm and the chain wheel may change this height. These chain wheel spacers are 3/8 thick. If the vehicle is an empty truck that will normally be hauling a lot of weight (i.e. over-the-road hauler, dump truck, or fire-tanker), you will want to try to keep this measurement 3½ -4 off the ground because the squash in the tires when the vehicle is loaded will change the wheel height. For vehicles with 16 tires, this measurement will need to be between 2¾ -3 because the bulge sits lower. The wheel needs to hit at the bulge of the tire. Note: If you are mounting the chains on a bare chassis, this measurement needs to be 4-4½ off the ground because the weight of the body will drop the height of the chains slightly. Continued next page 6
Mounting Instructions 995 S 1950 W Ste. B, Springville, UT 84663-800-633-0699 - (fax) 801-489-9797 - www.insta-chain.com - traction@insta-chain.com MOUNTING INSTRUCTIONS, CONTINUED b. Now check to see if the wheel mark is at the CENTERLINE of the tire, this is very critical to ensure the proper throw of the chains. The truck must be on the ground and be level to ensure proper measurement. There are two ways to find the centerline of the tire: 1) Clean the inside of the rim and place a ball bearing in it. The ball bearing will come to rest at the direct center of the tire. Draw a vertical line down from the ball bearing to the mark on the tire. 2) Take a plumb line and hang it from each side of the tire rim. With a piece of chalk, make a small mark on the tire where the plumb line hits the sidewall. Measure the distance between these two marks (R in figure I). Divide this measurement in half and re measure its amount in from one of the plumb line marks (R/2 in figure I). Make a small chalk mark at this point. This is the centerline of the tire and axle. For example, an 11R-22.5 tire has an outside rim measurement of 23½, half of this is 11¾. So the centerline is 11¾ from one side of the rim. Now draw a vertical line on the tire. The center of the chain wheel mark must be lined up with the CENTERLINE of the tire (the vertical line you just drew. It may be up to ¼ behind the centerline but NEVER in front of the centerline. To adjust the unit so it hits on centerline, loosen the two Mounting Tube Bolts and push the unit forward or backward so that the Chain Wheel hits the center of the tire (see figure E.) 5. Each chain strand has 10 links of chain. If the strands drag on the ground in the disengaged position, you may cut 1 link off of each strand (on vehicles with 16 tires, 2 links may be removed). Do not remove more than 2 links. There must be a minimum of 9 links (8 links for 16 tires) for the Insta- Chains to work effectively. If they are still dragging on the ground or are close enough to the ground to cause undue wear, Insta-Chain sells a Chain Tray to raise the chains off of the ground. 6. After all the proper adjustments have been made, torque all the Mounting Bolt Nuts to 130 ft lbs. Torque the Coupling Nut Bolts to 178 ft lbs. You may put a small tack weld between the Mounting Tube an the Cross Plates, and between the Mounting Plates and the Mounting Tube if you are concerned about a lot of vibration, this will ensure no movement will take place through road vibration. Check all connections to be sure that they are tight and do not leak. Test the chains on a parking lot or in the street to be sure they throw properly. If you have ANY questions or problems, PLEASE CALL!! (800) 633-0699 7
Operating Instructions 995 S 1950 W Ste. B, Springville, UT 84663-800-633-0699 - 801-489-9000 - (fax) 801-489-9797 - www.insta-chain.com - traction@insta-chain.com OPERATING INSTRUCTIONS ENGAGING THE INSTA-CHAIN 1. When driving in sow or icy conditions, flip up the red switch cover to allow you to access the switch more easily when the Insta-Chain s are needed. 2. The Insta-Chain system may be engaged anytime between 0 mph and 25 mph (40 km/h). However, the Insta-Chain system works best if engaged while moving before slippage occurs. 3. If you need to engage the Insta-Chain system from a stand still, it is best to SLOWLY (5-10 mph (8-16 kmh)) spin the tires, then flip the switch for a quicker response time. Do Not spin the tires too fast before engaging, this will increase the time it takes to receive traction. 4. When approaching an icy grade and you don t have Insta-Chain engaged, slow down to 25 mph (40 kph) and engage the Insta-Chains (leave plenty of room to slow down and not lose momentum). Maintain your speed, do not exceed 30 mph (48 kph). while using the Insta-Chain system. Exceeding 30 mph while using the Insta-Chain system will void the warranty. Note: For the best performance, maintain speed and momentum. USE OF THE INSTA-CHAINS WHILE THEY ARE ENGAGED 1. You must maintain a minimum speed of 5-6 mph (8-9.5 km/h) for the 6 chain model and a minimum of 3-4 (5.65 km/h) with the 12 Chain Model to receive effective traction. Speeds below these recommended speeds will not allow the Chains to properly throw under the tire. Note; It is important to remember these guidelines when using the Insta-Chain s in Reverse. 2. When climbing a hill with the Insta-Chains, try to maintain your momentum, this will improve the performance of the Insta-Chain system. 3. For best results while moving, accelerate slowly: spinning the tires fast may result in a loss of traction. 4. Insta-Chain loses its effectiveness in snow depths exceeding 6-8 (8-10 cm) (the depth varies depending on the consistency of the snow). 5. DO NOT exceed 30 mph while the Insta-Chain system is engaged. BRAKING AND STOPPING 1. When stopping on snowy or icy roads, engage the Insta-Chain system before braking to increase traction while stopping. In addition, this will insure better traction when restarting. 2. Try to avoid locking the brakes while braking. 3. When stopping on a hill or icy conditions, and you need traction during restart, you may stop with the chains under the tires. This will give you traction during restart. 4. After stopping, start slowly to increase traction, try not to spin the tires too quickly. if you have any questions, please call!!! (800) 633-0699 OR CONTACT YOUR LOCAL INSTA-CHAIN DEALER 10
Maintenance and Troubleshooting 995 S 1950 W Ste. B, Springville, UT 84663-800-633-0699 - (fax) 801-489-9797 - www.insta-chain.com - traction@insta-chain.com MAINTENCE AND TROUBLESHOOTING MAINTENANCE 1. Grease the chain wheel bearings regularly to prolong the life of the bearings. This is usually done along with the regular scheduled maintenance, but it may be done more often if you think it is necessary. 2. Check all nuts and bolts to make sure that they are tight every time you bring the vehicle in for regular maintenance. 3. The Insta-Chain wheels may be removed during the summer months for convenience, but this is not necessary. If you do remove the chain wheels, be sure to mark where the spacers fit on each side of the vehicle. They must be replaced in correct order for the chains to work correctly when re-installed. Please consult Insta-Chain or an Insta-Chain dealer before you remove the chains units if you are unfamiliar with the system s installation. This is because the chain system must be re-adjusted so the wheel will contact the tire at the centerline of the tire when re-installing the system. 4. Frequently drain any water out of the air tank to keep the airlines free of dirt and water. Excess dirt and water may damage the Solenoid Valve or cause it to fail out prematurely. 5. The Solenoid Valve should be actuated periodically to keep it clean and functioning properly. 6. Due to the high spring tension of the return Spring, disassembly of the Insta-Chain Air Cylinders should be done by qualified personnel. Insta-Chain recommends you send the Air Cylinder to the Insta-Chain Factory for any repair work. 7. If the end of the arm has an adjustable Ball & Socket Joint check the operating angles to be sure it hasn t moved out of place. 8. Check to see that the wheel spins freely. TROUBLE SHOOTING 1. Improperly throwing the chain is due to incorrect mounting, adjustments, or worn out chain links. Check the angles and measurements of the chain wheel according to the mounting instructions. 2. Excess chain wear can be attributed to several different factors: using the Insta-Chains on dry pavement, if the Chain Wheel is mounted less than 3 above the ground, if any of the Chain Wheel angles are out of adjustment (see Mounting Instructions), or if the Chain Wheel is not hitting the centerline of the tire properly. Anyone of these, several of them in tandem or even all of them together can be the causes of excessive wear. 3. Excessive wear on the wheels is due to improper chain wheel angles or from the wheel not being lined up on the centerline of the tire. Re-check these measurements when this occurs. WARRANTY The Insta-Chain system is warranted to be from defects in material for one (1) year from the date of purchase or 50.000 miles; which ever comes first, for the purpose intended under normal conditions. This warranty does not include the following: freight charges, labor to replace the defective part, normal wear on the chains or chain wheels, failure to grease the wheel or arm bearings, or any problems resulting from improper installation of the Insta-Chains on the vehicle. Damage resulting from road debris, potholes, curbs, rocks, cattle crossing or other things that could hit and damage the chain unit is also not included. Insta-Chain reserves the right to inspect the parts to determine whether to repair, replace, or return the damaged parts. Defective parts must be returned to Insta-Chain for warranty inspection. Abuse or misuse VOIDS any warranty. 11
Unit Specific Parts List 04-6350 Chain Unit Assembly 1 - "A" Side Chain Unit - P/N -6350-A 1 - "B" Side Chain Unit - P/N -6350-B 1 - "A" Side 04 Cylinder Bracket - P/N 04-3400-A 1 - "B" Side 04 Cylinder Bracket - P/N 04-3400-B 1 - "A" Side 04 Arm - P/N -3150-A 1 - "B" Side 04 Arm - P/N -3150-B 2-3/8"-16 Arm Stop Bolt - P/N 5129 2-3/8"-16 Hex Nut - P/N 5128 2-3/8"-16 Arm Hex Lock-Nut - P/N 5130 2 - Grease Zerk - P/N 5411 4 - Arm Bearing - P/N 3434-B 2 - Ball Joint - P/N 1005 1038 Air Cylinder Complete 2 - Air Cylinder Housing - P/N 5454 2 - Air Cylinder Lid - P/N 0435 2 - Diaphragm - P/N 5248 2 - Dust Boot - P/N 0534 2 - Dust Boot Clamp - P/N 0535 2 - Air Cylinder Spring - P/N 5246 2 - Push Rod Extension Assembly - P/N 1044 2 - Air Cylinder Clamp Kit - P/N 0439 2 - Air Cylinder Gasket - P/N 5450 8-3/8"-24 Chain Plate Lock Nut - P/N 5207 0586 Solenoid Kit (Basic Parts) 2-3/8"x1/4" Brass Elbow Fitting - P/N 5080 2-3/8"x1/4" Brass "T" Fitting - P/N 5121 1-3-Way Solenoid Valve - P/N 5047 1 - Solenoid Mounting Bracket - P/N 5050 1 - Toggle Switch - P/N 5200 1 - Switch Guard - P/N 5199 Chain-Wheel Parts 2 - Chain Wheel Complete (6 Chain) - P/N 0961 2 - Chain Wheel Complete (12 Chain)- P/N 0962 6 - Chain Strand-Single 10 Link - P/N 0951 6 - Chain Strand-Double 10 Link - P/N 0952 2 - Large Chain Wheel - P/N 5424-W 2 - Large Wheel Cover - P/N 5420-W 1 - Chain Wheel Wheel Hardware Pack - P/N 5235 2 - Chain Wheel Pivot Bolt - P/N 7004 2 - Chain Wheel Bolt Lock Nut - P/N 5211 4 - Chain Wheel Spacers - P/N 0450-W 12