Fulton Performance HDPB350301 - Manual (Page 2)

2x3
Gross
Trailer
Weight
Rating
(lbs.)
Max.
Tongue
Load
(lbs.)
Max.
Pivot
Length
(in.)
5,000 500 24"
4,700 470 27"
4,200 420 30"
3,800 380 33"
3,500 350 36"
3,200 320 39"
3,000 300 42"
2,800 280 45"
2,600 260 48"
3x3
Gross
Trailer
Weight
Rating
(lbs.)
Max.
Tongue
Load
(lbs.)
Max.
Pivot
Length
(in.)
5,000 500 24"
4,700 470 27"
4,200 420 30"
3,800 380 33"
3,500 350 36"
3,200 320 39"
3,000 300 42"
2,800 280 45"
2,600 260 48"
3x4
Gross
Trailer
Weight
Rating
(lbs.)
Max.
Tongue
Load
(lbs.)
Max.
Pivot
Length
(in.)
7,500 750 27"
7,000 700 30"
6,500 650 33"
6,000 600 36"
5,500 550 39"
5,000 500 42"
4,500 450 45"
4,000 400 48"
3x5
Gross
Trailer
Weight
Rating
(lbs.)
Max.
Tongue
Load
(lbs.)
Max.
Pivot
Length
(in.)
9,000 900 27"
8,200 820 30"
7,450 745 33"
6,800 680 36"
6,250 625 39"
5,800 580 42"
5,350 535 45"
5,000 500 48"
Installation Instructions (Cont.)
Measure and Cut Trailer Tongue Section
1. Before starting, be certain to follow all safety
precautions as described in these instructions.
2. Support trailer tongue with jack stand behind the
approximate area of trailer tongue removal.
3. Measure from the center of coupler ball pocket the
desired swing length back and mark (see illustration
and chart for maximum lengths). Be certain the mark
is at least 5” from any obstruction (i.e. winch stand,
jack bracket, etc.). Using a square, scribe a line
around trailer tongue to indicate cut location. Before
cutting, verify measurements.
4. Remove all wiring and brake lines from the trailer
tongue so it is not cut or damaged during installation.
5. Cut trailer tongue along scribe line, being certain to
follow all safety and operating guidelines of products
used. Be careful of sharp edges or burrs and remove
if present.
Drill and Attach Safety Chains
6. Along each side of trailer tongue, measure 4” from cut
end and mark. Measure 1” up from bottom and mark
(see illustration). At line intersections, use
centerpunch to mark drill locations for safety chain
bolts. Drill to 1/2”.
7. Secure safety chains using two separate 1/2” bolts and
locknuts for each. Torque to 45 ft-lbs.
Drill and Attach Castings (Bolt-On Instructions)
8. Place “male casting” on trailer tongue until tube
meets the stops inside the casting making sure it is
straight. Temporarily secure with clamp.
9. Using transfer punch, mark locations of holes on
trailer tongue, top and bottom. With centerpunch,
expand locator marks for drilling.
10. Remove casting and drill 1/8” holes at centermarks.
Be sure to drill square to the trailer tongue. Only drill
through one side at a time.
11. Increase the 1/8” diameter holes to 1/4” holes. Then
increase the 1/4” diameter holes to 3/8”. Increase
again to 1/2”. Carefully remove metal shavings and
burrs.
12. Replace male casting over trailer tongue as shown
below and loosely attach the special shoulder bolts
and flange nuts. Tighten all eight fasteners with 3/4”
box end wrench and T55 Torx bit. Torque each to 75
ft-lbs.
13. Place remaining casting over swing tongue and attach
in the same manner as previously described making
sure the coupler holes are positioned correctly. When
using Bracket Kits only (HDP models), reuse trailer
coupler/tongue and follow previous instructions
starting from step 8 to attach remaining casting.
14. Attach swing tongue to trailer tongue by mating
castings together. Apply light grease to 5/8” pivot
bolt. Secure through the castings with 5/8” locknut
and torque to 50 ft-lbs.
15. Insert lightly greased hinge pin through top of
castings. Secure hinge pin with hairpin cotter.
16. Remove hinge pin and pivot swing tongue to verify
that system works correctly. If product is to be
primed, painted, or galvanized any excess buildup will
need to be removed. Make sure operation has not
been impaired.
Rerouting Wiring, Brake Lines and Chains
17. Pull trailer wiring back through the trailer section and
into the swing tongue. Make sure to reattach any
ground wires that may have needed to be removed
during installation.
18. Route wiring through swing tongue in a way to
prevent wiring from rubbing on sharp edges. A wire
grommet is included on HPB models.
19. Place coupler over swing tongue and secure. Use (1)
1/2-13 x 4.00” hex bolt through rear holes of coupler
and 1/2-13 x 1.25” hex bolts for forward holes.
Secure with 1/2” locknuts and torque to 75 ft-lbs.
Refer to Fulton Coupler Owner’s Manual, F1937, for
coupler warnings, instructions, and installations. For
copies call Cequent Trailer Products’ Customer
Service Department, 1-800-604-9466.
20. Route safety chains through guide on bottom of swing
tongue. Check that safety chains are long enough to
reach a tow vehicle and will not bind or drag during
normal towing conditions.
21. Close swing tongue, being certain not to pinch wires
and lock into place with hinge pin. Ensure that the
hairpin cotter is in place through the hinge pin. Check
for proper operation of trailer lighting. Trailer is now
ready for towing.
Attach Castings (Weld-On Instructions)
22. All welding must be performed by a certified AWS
welder. Perform the previous instructions replacing
steps 9 thru 12 with the following.
23. Making sure casting is straight and fully seated on the
tongue tube. Weld complete on all four sides using a
3/16” minimum fillet weld.
24. Proceed back to step 13 to complete.
Attach Casting (In-Line Actuator)
25. An optional actuator end
casting is designed to fit the
Fulton in-line actuator. To
attach, use 1/2” dia. grade-5
bolts and lock washers and
torque to 75 ft-lbs.
Cequent Trailer Products
1050 Indianhead Dr., P.O. Box 8 Mosinee, WI 54455-0008
800/604-9466 715/693-1700 Fax 715/693-1799
[email protected] www.cequentgroup.com