A Leader in Trailer Transportation OWNER S MANUAL

Transcription

1 Karavan an Trailers, Inc. A Leader in Trailer Transportation OWNER S MANUAL Enclosed is operator s instructions and warranty information for your new Karavan Trailer. Please read them carefully before operating. Watercraft Trailer Snowmobile Trailer Boat Trailer Utility Trailer Congratulations on your purchase of a new Karavan Trailer. We are confident that you will be completely satisfied for years to come with the quality and versatility of your Karavan Trailer. We have paid special attention to all the details that make your investment choice a step above the others, to ensure this satisfaction. We do however suggest that you read this manual completely and follow all recommendations made, to ensure that the excellence of your Karavan Trailer will last for many years. We at Karavan Trailers, Inc. take pride in our products and our ability to continue to provide you, the customer, with a quality recreational trailer, which meets and exceeds your expectations. Product and Specifications subject to change without notice. Lit NA-A Owners Manual

2 Karavan an Trailers, Inc. Quality PolicP olicy It is Karavan s policy to bring to market the highest quality, most cost effective product that will meet or exceed our customer s needs. Karavan believes the key to achieving this policy is happy, healthy and well trained employees. Proper training and fair treatment of our employees will be reflected in the product we produce and the services we provide our customers.

3 Table of Contents Item Page Bow Eye Safety Chain 2 Brakes 2 Hydraulic Brake System (Atwood) 3-6 Hydraulic Surge Brake Actuator (Fulton) 7-9 Model 66 Actuator for Trailer Brakes (Tie Down Engineering) Instructions for Bleeding Tie Downs Model Actuators 14 UFP Operating Instructions Model A UFP Maintenance & Service Model A UFP Dismantling & Assembly of Actuator Model A UFP Warranty Model A-60 Brake Actuator 27 UFP Disc Brakes (Trailer Buddy) Coupler Use; Maintenance, Installation, Service Information (Fulton) Hubs, Bearings, Seals and Adjustments Lighting and Wiring Changing Tire 37 Tire Warranty (Loadstar)(Carlisle) Towing your Trailer 41 Marine Trailer Jack Manual (Fulton) Tongue Weight 44 Wheel Size 44 Winch Post Assembly 44 Marine Trailer Winch Owners Manual (Fulton) Trailer Warranty 48 Vendor Warranty Information 48 Registration Important Read this manual carefully with special attention directed towards all, CAUTION and IMPORTANT information specially marked. Because of the continual improvements being made in our line, Karavan Trailers, Inc., reserves the right to add or discontinue models at any time or to charge design and specifications without notice and incurring obligations. All specifications contained herein were in effect at the time this manual was printed. Trailer laws covering such things as brakes, licenses, etc., will vary from state to state. Be sure that your trailer is in full compliance with your state laws. Your trailer dealer usually can help you in this regard. If not, contact your nearest state motor vehicle department office for full information. The key to carefree trailering is a proper matching of the trailer to your needs. A proper match is one in which the total weight and size of the load you intend to haul falls under the capabilities that your trailer was designed and built to handle. Note All references to the left or right are made when standing behind the trailer, facing the trailer. 1

4 Bow w Eye e Safety Chain : Failure to tie down the bow independently from the winch strap could allow your boat to shift while traveling, causing loss of control of the tow vehicle and result in serious injury or property damage. Karavan Trailers, Inc. starts using bow eye safety chains on trailers with a 1200-lb. winch rating and over. It is very important that you use the bow eye safety chain at all times when loading and unloading. The bow eye safety chain is an added protection should the winch or winch strap fail. Brak akes In most states trailers with a Gross Vehicle Weight Rating of 1,500 pounds or more, are required by law to have brakes on all wheels. Upon special request, you can order axles with brake flanges to be able to install brakes. Brakes are becoming more of a necessity especially since the introduction of the smaller size car. Most trailer brakes are designed to operate automatically when the towing vehicle brakes are applied. When the towing vehicle slows down or stops, the forward momentum of the trailer against the ball hitch applies pressure to a master cylinder in the trailer coupler. This pressure activates the trailer brakes through a hydraulic brake system. CAUTION: Weight equalizing or sway control devices inhibit the performance of surge brake actuators and must not be used. Air shocks on the rear axle of the tow vehicle offer a good means of leveling the vehicle and trailer when necessary. 2

5 LITERATURE NUMBER MPD HYDRAULIC SURGE BRAKE SYSTEM SAFETY ALERT SYMBOLS Safety Symbols alerting you to potential personal safety hazards. Obey all safety messages following these symbols. avoid possible injury or death CAUTION avoid possible injury and/or property damage FOR YOUR SAFETY READ ALL INSTRUCTIONS BEFORE OPERATING BRAKE SYSTEM Installer: Provide this instruction to consumer. Consumer: Keep documents for future reference. The installation instructions must be followed to insure safe operation of Atwood brake actuators and foundation brakes. Failure to install according to installation instructions nullifies warranty. DRUM BREAK APPLICATIONS: For best performance use Atwood Foundation Brakes with an Atwood Brake Actuator. These components are system matched. DISK BRAKE APPLICATIONS: Use only Atwood 80360, 80366, 88730, Disc Brake Actuators for disc brake applications. Atwood Disc Brake Actuators have been tested for compatibility with Kodiak brand and Reliable brand Disc Brake Systems. To be used with a maximum of 4 2-1/4 diameter calipers. For more information call Atwood Mobile Products ( ), Kodiak Trailer Components ( ), or Reliable Tool & Machine ( ). PERSONAL INJURY & PRODUCT DAMAGE Observe maximum trailer weight for Atwood brake actuator Gross Vehicle Weight Rating (GVWR) and tongue load. Do not exceed these capacities. Gross Vehicle Weight Rating is total weight of trailer fully loaded included personal belongings. Know your trailer GVWR. CAUTION PRODUCT DAMAGE / BRAKE FAILURE Use only a 2 machined or forged ball with Atwood brake actuator. Ball capacity must be equal to or greater than trailer GVWR. DO NOT use a worn hitch ball-it is unsafe and must be replaced. DO NOT submerge actuator in water. Water may enter and corrode master cylinder, contaminating Brake System, causing brake failure. INSTALLATION BRAKE FAILURE Brake actuator MUST BE installed with frame stops in contact with trailer tongue. Installation Operation Maintenance Effective 3/7/01 STRAIGHT TONGUE - BOLT ON APPLICATION (FIG 1) 8000 LB. BRAKE ACTUATORS SAE CLASS 4 - DISC AND DRUM APPLICATIONS 8000 LB. GVWR, MAX. TONGUE LOAD 1000 LB. - DO NOT EXCEED THESE RATINGS PART NO , DRUM APPLICATION / PART NO DISC APPLICATION 1. Determine proper location of brake actuator on trailer tongue. Set actuator on trailer tongue, push down and back until frame stops (FIG 1-A), making contact with tongue. 2. Drill 17/32 holes in trailer tongue where bolt holes are positioned. 3. Reinforcement of trailer tongue spacer must be 1/2 ID pipe or equiv. (FIG 3-A). 4. Attach brake actuator to trailer tongue with 1/2 diameter bolts (3) S.A.E. grade 8 lockwasher (3) and nuts (3) (FIG 1-B). Torque nuts to ft/lbs LB. BRAKE ACTUATORS SAE CLASS 4 - DISC AND DRUM APPLICATIONS 6000 LB. GVWR, MAX. TONGUE LOAD 900 LB. - DO NOT EXCEED THESE RATINGS PART NO , 82543, 83153, 83154, 84131, 84132, 84133, 88730, Determine proper location of brake actuator on trailer tongue. Set actuator on trailer tongue, push down and back until the frame stops (FIG 1-A), making contact with tongue. 2. Drill 17/32 holes in the trailer tongue where bolt holes are positioned. 3. Reinforcement of trailer tongue spacer must be 1/2 ID pipe or equiv. (FIG 3-A). 4. Attach brake actuator to trailer tongue with 1/2 diameter bolts (2) S.A.E. grade 5 or greater lockwasher (2) and nuts (2) (FIG 1-B). Torque nuts to ft. lbs. BRAKE FAILURE Trailer tongue must have adequate strength to support attachment of brake actuator without mounting nuts losing torque during life of trailer. Trailer tongue must be properly reinforced to prevent any potential loosening of brake actuator during service. STRAIGHT TONGUE - WELD ON APPLICATION (FIG 2) WELDING INSTRUCTIONS M.I.G. OR STICK - 5/32 Fillet weld minimum. M.I.G. WELDING - Use A.W.S. ER 70S-3 or 6 wire or equivalent with a diameter of The recommended shielding gas mixture is 75% - 95% Argon & 25% - 5% CO 2. STICK WELDING - Use E6011 A.W.S. welding rod or equivalent. Recommended machine settings for specific electrode diameter are as follows: 1/8 electrode set power between Amps DC or 5/32 electrode set power between Amps DC LB. BRAKE ACTUATORS SAE CLASS LB. GVWR, MAX. TONGUE LOAD 1000 LB. - DO NOT EXCEED THESE RATINGS PART NO DRUM APPLICATION / PART NO DISC APPLICATION 1. Determine proper location of brake actuator on trailer tongue. Set actuator on trailer tongue, push down and back until frame stops (FIG 2-A), making contact with tongue. 2. Using WELDING INSTRUCTIONS weld actuator to trailer with a minimum of 9 weld per side. Make a 5/32 fillet weld (FIG 2-B). 3. Make sure to return weld on front end of frame of trailer up inside actuator frame to forward frame stop (see FIG 2-C) LB. BRAKE ACTUATORS SAE CLASS 4 - DISC AND DRUM APPLICATIONS 6000 LB. GVWR, MAX. TONGUE LOAD 900 LB. - DO NOT EXCEED THESE RATINGS PART NO , 82543, 83153, DRUM APPLICATION ONLY PART NO DISC APPLICATION ONLY 1. Determine proper location of brake actuator on trailer tongue. Set actuator on trailer tongue, push down and back until frame stops (FIG 2-A), making contact with tongue. 2. Using WELDING INSTRUCTIONS weld actuator to trailer with a minimum of 7 weld per side. Make a 5/32 fillet weld (FIG 2-B). 3. Make sure to return weld on front end of frame of trailer up inside actuator frame to forward frame stop (see FIG 2-C). 3

6 4 CAUTION DAMAGE TO CABLE Breakaway cable and hook must not touch ground during welding operation. A-FRAME - WELD-BETWEEN APPLICATION (FIG 4) 8000 LB. BRAKE ACTUATORS SAE CLASS 4 - DISC AND DRUM APPLICATIONS 8000 LB. GVWR, MAX. TONGUE LOAD 1000 LB. - DO NOT EXCEED THESE RATINGS PART NO DRUM APPLICATION / PART NO DISC APPLICATION 1. Position actuator between A-Frame members with leading edge of A- Frame located 8 from back of actuator (FIG 4). 2. Using WELDING INSTRUCTIONS weld actuator to trailer tongue by welding along entire length where trailer frame contacts actuator. Weld must be a minimum of 9 along each side (FIG 4) LB. BRAKE ACTUATORS SAE CLASS 4 - DISC AND DRUM APPLICATIONS 6000 LB. GVWR, MAX. TONGUE LOAD 900 LB. - DO NOT EXCEED THESE RATINGS PART NO , 82543, 83153, DRUM APPLICATION ONLY PART NO DISC APPLICATION ONLY 1. Position actuator between A-Frame members with leading edge of A- Frame located 5 from back of actuator (FIG 4). 2. Using WELDING INSTRUCTIONS weld actuator to trailer by welding along entire length where trailer frame contacts actuator. Weld must be a minimum of 7 along each side (FIG 4). CAUTION PRODUCT DAMAGE Breakaway cable and hook must not touch ground during welding operation. Weld trailer A-Frame members together with additional bracing (i.e. cross members or jack mounting plates (FIG 4). Brake actuator alone is not designed to withstand torsional twist of trailer. Cross member(s) should be comparable in strength to trailer frame, and located as close to brake actuator as possible. NOTE: If Atwood top and bottom jack mounting plates are used (MPD or MPD 80255) (FIG 4A), move jack mounting plates as close to brake actuator as possible and weld along entire area where plates and trailer frame contact. Use WELDING INSTRUCTIONS. PAINTING THE BRAKE ACTUATOR DIP PAINTING PROCEDURE NOTE: Carefully perform procedure in order given. 1. Plug vent hole in master cylinder boot. 2. Fully apply brake actuator. 3. Plug master cylinder outlet port (1/8)" NPTF thread). 4. Plug master cylinder reservoir port to prevent paint from entering master cylinder. 5. Paint brake actuator. 6. Remove all plugs and fully release brake actuator. 7. Inspect for paint contamination of master cylinder and shock absorber shaft after painting. Replace parts if contaminated with paint. 8. Continue with MANDATORY FUNCTIONAL CHECK AFTER PAINTING. SPRAY PAINTING PROCEDURES 1. Fully apply brake actuator. 2. Plug master cylinder outlet port (1/8" NPTF thread). 3. Plug master cylinder reservoir port preventing paint from entering master cylinder. 4. Paint brake actuator. 5. Fully release brake actuator & paint unpainted portions of socket assembly. 6. Remove all plugs. 7. Inspect for paint contamination of master cylinder and shock absorber shaft after painting. Replace parts if contaminated with paint. MANDATOR FUNCTIONAL CHECK AFTER PAINTING 1. Check function of ball socket and latching mechanism by inserting, locking and removing a 2" diameter hitch ball. Once hitch ball is fully inserted in socket, release handle must close completely and freely when released. 2. If ball socket and latching mechanism does not close completely and freely as described above: a. Check for paint build-up in ball socket and clean if necessary. b. Lubricate ball socket and latching mechanism with SAE 30 oil and work mechanism by inserting, locking and removing a 2" diameter hitch ball until latching mechanism does work freely. 3. Move back-up lever to indicated back-up position and lock. Operate brake actuator back-up lever, return to towing position freely using only return spring force. Clean off excess paint and lubricate as necessary to ensure lever assembly operates freely. CAUTION TRAILER COULD DISCONNECT DO NOT use actuator if latching mechanism does not operate freely. Contact Atwood Service Department as FOUNDATION BRAKES (FIG 5-8) 1. Check if axle has brake flanges (FIG 5-A) if so, skip step No If axle does not have brake flanges, install flanges as follows: a. Secure flange to back of brake assembly (FIG 5-B) with 4 bolts (FIG 5-C). b. Insert brake assembly into hub and drum assembly (FIG 5-D). Drum must completely cover surface of brake shoes (FIG 6). Be certain brake assembly back plate does not contact drum edge (FIG 6-A), and inside edges of shoes are not in contact with hub or drum. c. Adjust brake shoes snugly against drum by inserting brake adjusting tool (FIG 7-A & B) through adjusting slot (FIG 7-C). Back plate must be centered within drum diameter after adjustment. Visually check for equal space between edge of back plate and edge of drum. d. Mount brake/drum/flange assembly on spindle and secure with spindle nut. Be sure brake/drum/flange assembly is fully mounted on spindle. e. With trailer level, locate top of brake flange parallel with bottom of trailer frame (FIG 8) f. Tack wild flange to axle (a tack weld is a small semipermanent weld used for securing). g. Remove brake/drum assembly. h. Finish welding flange securely to axle, using WELDING INSTRUCTIONS. 3. Mount brake and shoe assembly to flange. Wheel cylinder must be at top of brake with rubber boot toward the front of trailer. For 7" brakes use nuts and lockwashers provided (torque to 50 ft. lbs.) 4. Mount drum and bearings on axle spindle, secure with washer and spindle nut. 5. Tighten spindle nut securely and then loosen or untighten nut one quarter (1/4) turn Consult installation instructions to connect brake piping MPD NOTE: Consult Atwood Engineering Dept. when using non-atwood brake piping or other components or when questions arise concerning installation or application. 7. Raise one trailer wheel at a time, remove dust clip from adjusting slot at lower part of back side of brake assembly and insert brake adjusting tool (FIG 7). Adjust brake shoes out by moving end of adjusting tool as illustrated, only until adjustment wheel (FIG 7-D) will not turn. When this condition is felt by rotating wheel, back-off (loosen) adjustment until wheel will just turn freely. INSTALLATION - DISC BRAKE ACTUATOR SOLENOID BACK-UP VALVE DEATH OF PERSONAL INJURY This system requires the solenoid wire leads be connected ONLY into the tow vehicle back-up light circuit. 8,000 LB. ACTUATORS are equipped with a solenoid back-up valve. 1. Connect the solenoid valve wire leads to the tow vehicle back-up light circuit. 2. Connect trailer brake line to actuator. 3. Bleed brake system. 6,000 LB. ACTUATORS are not equipped with a solenoid back-up valve. When a solenoid back-up valve is desired please contact Atwood for the solenoid back-up kit. Atwood Mobile Products To install Atwood solenoid back-up valve- 1. Remove the plug in return port of master cylinder (this is the upper port in the master cylinder). 2. Install straight barbed fitting (torque to in/lb). 3. Install assembly in supply port of master cylinder (this is the lower port in the master cylinder). 4. Connect the solenoid wire leads only into the reverse back-up light circuit. 5. Connect trailer brake line to actuator. 6. Bleed brake system. FOR DISC BRAKE SYSTEMS CAUTION DAMAGE TO BRAKE ACTUATOR OR VEHICLE If brass orifice fitting is not installed (FIG 10B), trailer-braking action may cause vehicle(s) to shake during brake applications. The brass orifice fitting installed in master cylinder (FIG 10A) of brake actuator assembly must remain in hydraulic circuit to brakes (FIG 10C) of trailer. If brass orifice fitting must be moved to accommodate plumbing (FIG 10E) for a back up solenoid valve (FIG 10D), it must be replaced in hydraulic circuit in line to brakes.

7 DEATH OR PERSONAL INJURY Contaminated brake fluid in system could plug brass orifice fitting. This could render brakes inoperative. Be especially careful to clean all fittings, tubing and threads between master cylinder and brass orifice fitting. A very small particle of dirt or thread sealant can plug hole in orifice. Do not use Teflon tape on fittings If a liquid or paste thread sealant is used, keep it back two threads from end of male fitting. Do not apply sealant to female threads. Clean female threads thoroughly. BLEED BRAKE SYSTEMS CAUTION BRAKE FAILURE DO NOT use brake fluid drained from brake system in refilling master cylinder. Brake fluid can be contaminated from the system. 1. Remove master cylinder filler cap and fill reservoir with DOT type 3 or 4 automotive brake fluid. 2. Check all hydraulic line fittings & connections to make sure they are leak free. 3. At brake assembly, connect a bleeder hose to bleeder fitting on wheel cylinder and submerge free end in a container with brake fluid. DO NOT reuse brake fluid. NOTE: Use power bleeder or bar with 2" diameter hitch ball attached (FIG 9). Do not use breakaway cable for purpose of bleeding brake system. If a power bleeder is used air pressure 35 PSI is most effective. NOTE: Bleed brake on rear most axle furthest from the actuator first. 4. Loosen bleeder fitting at top of brake assembly. 5. Apply actuator (See FIG 9) and tighten bleeder fitting. Return actuator to forward position. Again, loosen bleeder valve one turn and apply actuator. Repeat this procedure until fluid expelled from bleeder hose is free of air bubbles. It is helpful to lower the trailer tongue to promote air bubble movement in the brake tubing. It is also helpful to tap gently along the brake tubing during brake bleeding to keep air bubbles from sticking to the inside of the brake tubing. During this procedure, master cylinder reservoir fluid level must be maintained at no less than 1/2 full and no more than 1/2 " from top of reservoir. 6. When no air bubbles are visible, close bleeder valve securely and remove bleeder hose. 7. Repeat STEP 1-6 for remaining brake, then brakes on forward axle. 8. If installation is tandem axle with brakes on both axle, repeat bleeding procedure on rear axle brakes for the second time to assure positive purging of all air in system. 9. After bleeding has been completed, re-check fluid level in master cylinder. OPERATION - TOWING CAUTION TRAILER MAY DISCONNECT Release handle (FIG 12A) must be fully closed before towing. Do not force release handle into closed position. 1. Position actuator ball socket above 2" ball. NOTE: Do not damage actuator when backing up towing vehicle for hookup. 2. Hold release handle in open position (FIG 11A). Release handle must be held in fully open position to remove from or place on ball. 3. Lower trailer tongue until ball rests in ball socket. 4. Close release handle (FIG 12A). Release handle will close freely with finger pressure when ball is properly inserted into ball socket. 5. To make sure actuator is securely latched onto ball, extend trailer tongue jack to ground and lift car and trailer combination 2" to 4". If ball does not disengage, actuator is securely attached. 6. Insert padlock or bolt through lock hole for theft protection. 7. Connect breakaway cable solidly to bumper or frame of tow vehicle as near to center as possible. Cable must hang clear of trailer tongue and long enough to permit short radius turns without pulling breakaway cable forward. 8. Make sure breakaway cable (FIG 13C) is in released position with indicator bead (FIG 13B) touching or resting against cable spring stop (FIG 13A). CAUTION PRODUCT DAMAGE DO NOT use breakaway cable as a parking brake. NOTE: Check location of breakaway cable periodically during each trip, indicator should rest against spring stop. Accidental application will cause brakes to drag and heat up, causing failure. 9. Cross safety chains under tongue & securely attach to bumper or frame of tow vehicle. Safety chains must be used. CAUTION TRAILER DAMAGE 10. Retract jack fully. Remove and store caster, if applicable 11. Check for proper car-trailer hook-up: tow vehicle and trailer should be level with positive tongue load. For further information, consult a dealer or Atwood Service Department. 12. Back-up lever knob must be positioned in TOWING POSITION (FIG 15-A). 13. If actuator is used with equalizing hitch, be sure hanger chains (FIG 14D) hang between straight down and forward up to 34 (FIG 14C). DO NOT use less that 6-1/2" hanger chain length (FIG 14x). For optimum brake performance, hang chains forward 34 (FIG 14). 14. DO NOT use Atwood brake actuator with a sway controller, unless prior Atwood Engineering approval of sway control system has been received. 15. You are now ready to tow your vehicle. CAUTION PRODUCT & TRAILER DAMAGE Avoid sharp turns. This could bend, create extreme stress or fracture either actuator of trailer tongue. BACKING UP 1. Follow step 1 through 15 for TOWING. 2. If equipped with solenoid valves skip to STEP Before backing up a slope or through soft ground, pull trailer forward slightly to assure actuator socket is in fully forward position. 4. Move lever knob on side of actuator downward from TOWING POSITION (FIG 15A) along curved slot in actuator frame to BACK-UP POSITION (FIG 15B). Slot has a notch at bottom of its travel. Push lever knob down to engage locking notch. 5. Back trailer up. CAUTION PRODUCT & TRAILER DAMAGE Avoid sharp turns. This could bend, create extreme stress or fracture either actuator or trailer tongue. 6. If trailer is to be uncoupled from tow vehicle after backing with lever knob engaged, block all trailer wheels and pull forward slightly to take strain off actuator. Uncouple actuator by lifting release handle and raising trailer tongue. Make sure lever knob is in TOWING POSITION (FIG 15A) when uncoupling from trailer. CAUTION PRODUCT & TRAILER DAMAGE Before towing trailer, lever knob must be disengaged and in TOWING POSITION. MAINTENANCE 1. Keep all links and pivots lubricated to prevent rusting and ensure ease of operation. Use SAE 30 oil, lubricate inside release handle and inside actuator body reached from underside of actuator. NOTE: Lubricate hitch ball with conventional automotive grease or a lubricant made for hitch balls. 2. Check for leaks in brake system. Periodic checks should be made on all hoses and fittings to guard against cuts and worn hoses which may cause failure (leaks, rupturing under pressure, and collapsing). Replace defective hoses. 3. Check brake fluid level in master cylinder reservoir. Keep filled to within 1/2" from top of reservoir. Use only DOT Type 3 or 4 brake fluid. Check electrical connections on reverse solenoid if system has one. Electrical connections should be sound and free of corrosion. Check reverse solenoid function. CAUTION BRAKE FAILURE DO NOT fill master cylinder reservoir with used brake fluid. DO NOT fill reservoir beyond 1/2" from top. DO NOT overfill, brake fluid will damage paint. DO NOT use silicone type brake fluid. Yearly inspect brakes for excessive wear, replace lining if necessary. 5

8 6 4. Flush system yearly or when system is known to be contaminated. For Disc Bake Systems remove orifice fitting (FIG 10) before flushing. Check fitting orifice to make sure it is clear. The orifice is.015" DIA it may be replaced if it is plugged with Atwood P/N # MPD The orifice fitting must be replaced after flushing the system. NOTE: Wheel bearing and seals should be inspected and packed at this time. ADJUSTING 7" & 10" DRUM BRAKES Trailer brakes should be adjusted after the first 1,000 miles of use and at least every 2,000 miles of use thereafter, in addition, trailer brakes should also be inspected for excessive wear, replace lining if necessary and adjusted at the beginning of each season or yearly. Wheel bearings and seals should be inspected and packed at this time. Raise one trailer wheel at a time, chock opposite wheel to prevent trailer from rolling. Remove dust clip from adjusting slot at lower part of back side of brake assembly and insert brake adjusting tool. Adjust brake shoes out until wheels will not turn by moving end of adjusting tool towards top of brake. When this condition is felt, by rotating wheel, back-off (loosening) adjustment until wheel will just turn freely. Atwood Hardware Systems & Components Limited Warranty Atwood Mobile Products warrants to the original consumer purchaser this product will be free of defects on material and workmanship for a period of two years from the date of purchase. Atwood s liability hereunder is limited to the replacement of product, repair of product or replacement of product with a reconditioned product, at the discretion of the manufacturer. The warranty is void if the product has been damaged by accident, unreasonable use, neglect, tampering or other causes not arising from defects in material workmanship. The warranty extends to the original consumer purchaser of the product only, and is subject to the following conditions: 1. For two (2) years commencing with the date of purchase, Atwood will replace or repair any Hardware System & Components that are found to be defective by Atwood in material or workmanship. 2. In the event of a warranty claim, the Original Purchaser must contact the Atwood Consumer Service Department, 4750 Hiawatha Drive, Rockford, Illinois , Telephone: Fax: Warranty claim service must be performed as approved by the Atwood Consumer Service Department. Warranty replacement hardware systems and components or parts will be furnished freight prepaid. Labor cost to repair or replace will be limited to the amount of the original purchase price of the systems and components. The replaced warranty products or parts become the property of Atwood Mobile Products and must be returned to the Atwood Consumer Service Department freight prepaid, unless prior arrangements have been made. 3. This limited warranty is valid only when the product is applied, installed, maintained and operated in accordance with this Atwood Installation, Maintenance and Operating Manual (MPD 87984). Any deviation from these recommended specifications must be approved in writing by Atwood. 4. Any implied warranties are limited to the duration of this limited warranty as stated above. Atwood does not assume responsibility for consequential damages or loss, including loss of use of vehicle, loss of time, inconvenience, expense of gasoline, telephone, travel, lodging, loss or damage to personal properties, or loss of revenues. Some states do not allow limitations on how long an implied warranty lasts or limitations on consequential damages, so the above limitations may not apply to you. This limited warranty gives you specific legal rights which may vary from state to state. 6/00 TROUBLE SHOOTING GUIDE Guides are only intended for use on Atwood products by service technicians who have successfully completed Atwood training. This guide should be used in conjunction with appropriate Instruction Manual provided with the product and any applicable Industry Standards. This is not intended to be a complete list. Please direct questions concerning service of Atwood products to before proceeding. PERSONAL INJURY AND/OR PRODUCT DAMAGE If any of the following conditions develop, trailer must not be used until proper corrective action is taken. SQUEAKING, CLATTER OR CHUCKING CONDITION SOLUTION LACK OF HITCH BALL LUBRICATION Lubricate with conventional automotive grease or commercial lubricant made for hitch balls BINDING LINKAGE & PIVOTS ON BRAKE ACTUATOR Oil linkage & pivots on brake actuator LOOSE HITCH BALL Inspect hitch & tighten LOOSE HITCH Inspect hitch & tighten ACTUATOR LOOSE ON TRAILER FRAME Inspect brake actuator & tighten HITCH BALL WORN OR TOO SMALL Replace OVERHEATED BRAKES Replace wheel bearing BROKEN BRAKE DRUM(S) Replace brake drum(s) & check brake shoes LOW BRAKE FLUID LEVEL Fill & bleed brakes, per IOM instructions WORN OUT SHOCK ABSORBER Replace PARTIAL APPLICATION OF BREAKAWAY CABLE - Fully release breakaway cable BRAKES IMPROPERLY ADJUSTED Check brakes for adjustments per IOM instructions BROKEN BRAKE RETURN SPRING Replace return spring SEIZED ACTUATOR MASTER CYLINDER Replace/rebuild actuator master cylinder WORN OUT BRAKE SHOES Replace brake shoes and check brake drums LEAKY WHEEL CYLINDER Replace/rebuild wheel cylinders and replace brake shoes. Clean drums and other hardware RELEASE HANDLE DOES NOT CLOSE EASILY CONDITION SOLUTION OVERSIZED BALL Check ball size BALL NOT FULLY INSERTED INTO SOCKET Check for proper ball size. Check to see if tongue jack is fully retracted. Hold release handle open when inserting ball. FOREIGN MATERIAL IN ACTUATOR SOCKET Clean and lubricate BRAKE OVERHEATING, SIDE PULL, BRAKES DO NOT OPERATE, POOR BRAKE PERFORMANCE CONDITION SOLUTION ONLY ONE BRAKES IS APPLYING Check brake adjustment per IOM instructions. LEAKING WHEEL CYLINDER Check and replace wheel cylinder and bleed brakes per IOM instructions. SEIZED WHEEL CYLINDER PISTON Check and rebuild/replace wheel cylinder and bleed system per IOM instructions. FOREIGN MATERIAL IN BRAKE UNIT Clean thoroughly LOW HYDRAULIC FLUID LEVEL Fill and bleed brakes, per IOM instructions. A BENT SHOULDER BOLT Replace A BEND PUSH ROD IN THE SHOCK ABSORBER - - Replace shock absorber A DAMAGED SOCKET ASSEMBLY Replace actuator BROKEN/PINCHED BRAKE LINES Replace BRAKE ACTUATOR FRAME DAMAGED Replace actuator WORN BRAKE SHOE(S) Replace broken shoe(s) TOWING VEHICLE SHAKING BACK AND FORTH CONDITION SOLUTION WORN VEHICLE SUSPENSION Replace shock absorber HITCH NOT SECURE Tighten all bolts and nuts UNDER-SIZED HITCH BALL Ball should be 2" machined/forged type EXTENDED STORAGE INSTRUCTIONS Preventative maintenance is recommended for extended periods of storage. 1. Check brake system for proper fluid level in master cylinder, bleed all lines. 2. Lubricate all links and pivots to prevent any rusting. 3. Remove wheel and drum assemblies and spray a good anti-corrosion compound (CRC formula 5-56) under rubber boot on forward end of brake wheel cylinder. Avoid spraying drum and brake lining. 4. Grease all bearings and reinstall wheel and drum assemblies. 5. Make sure breakaway cable is fully released. 6. After extended storage refer to MAINTENANCE Steps 1 through 5, to insure trailer readiness for towing. 7. Adjust drum brakes. PROPER TOWING CHECKLIST Inspect brake fittings for leaks. Adjust brakes every 2000 miles. Lubricate all mechanical moving parts. Inspect the breakaway cable for any kinks. Verify a one-piece 2" ball is used, without chips, dirt or hairline cracks. Securely attach safety chains to trailer and tow vehicle. For proper braking, trailer should set level when attached to tow vehicle to produce a positive tongue load. DOT 3 or 4 brake fluid should be used in master cylinder and fill it from 1/2 full to 1/2" from top of cylinder reservoir

9 A60B Class IV, 6,000 LB. Hydraulic Surge Brake Actuator FULTON Performance Products READ, UNDERSTAND, FOLLOW AND SAVE THESE INSTRUCTIONS Owner s Manual Read, understand and follow all instructions before installing and/or using this product. NEVER allow anyone unfamiliar with the operating instructions to use this product. Read, understand and follow all instructions provided by the manufacturer of the product(s) that this brake actuator will be installed on and used with. Fulton is not responsible for accidents, occurrences, injuries and losses to or of any person or property wherever which arises as a result of Purchaser s alterations, modification, assembly, reassembly or installation of this product. Installation, use, and maintenance of these Fulton actuators must conform to the following instructions only. Fulton cannot be held liable for improper installation, use, or maintenance of this product. Never position any part of your body under any portion of the coupler or the load being supported. Never allow anyone or any bodily parts to be positioned on or under the load being supported. Disregard could cause property damage and/or serious bodily injury. Use only a 2" diameter ball rated for 6,000 lbs. minimum. Use of any other ball will create an extremely dangerous condition which can result in separation of the coupler and ball, or ball failure. Maximum capacity of the A60B coupler is 6,000 lbs. Before towing, ensure that hitch ball is fully seated in the coupler ball pocket AND the locking lever is rotated back into the closed position. DO NOT TOW IF BALL IS NOT FULLY SEATED AND/OR HANDLE IS OPEN. (See Operating Instructions) Before towing, check vehicle, hitch, hitch ball and actuator for signs of wear or damage and that the coupler handle opens and closes freely. Replace any worn or damages components before towing. If the actuator is deformed or damaged, replace complete actuator.. Before towing, check mounting hardware for wear and proper tightness. Replace bent, broken, or worn hardware. Tighten hardware to 20 ft lbs. Use only Grade 5 hardware. Weigh your trailer plus added load. Do not exceed lesser of actuator, hitch, hitch ball, vehicle, or trailer weight ratings. Before latching/unlatching coupler, make sure vehicle, trailer and load will not shift, roll, etc. Before towing, ensure that the trailer safety chains are properly connected to the towing vehicle and trailer. After installing this actuator/coupler to a trailer, if coupler operation has been impaired in any way, DO NOT USE. Ensure that all trailer lighting is hooked up and working correctly before each use. When parking or storing your trailer, keep the actuator off the ground so dirt and/or other foreign material will not build up in the coupler ball pocket and/or slide area. All welds must be performed by an American Welding Society (AWS) certified welder. Do not weld on outer cover without disassembling actuator, damage to inner slides and master cylinder will occur. Failure to follow these warnings and instructions may result in property damage and/or serious bodily injury, resulting in death. INSTALLATION INSTRUCTIONS MOUNTING BRAKE ACTUATOR TO TRAILER TONGUE Model A60B is completely assembled and ready to bolt into place. Do not weld on outer cover (Item #1) without disassembling actuator, damage to inner slides (Items #9 & #10) and master cylinder (Item #2) will occur. 1) Position outer cover as far back as possible on trailer tongue for maximum overlap. 2) Secure actuator to trailer frame using at minimum (2) 1/2", 4.50" long, grade 5 through bolts and locknuts/lockwashers (See Fig. 1). Torque to ft-lbs without excessive deformation of the cover or the trailer tongue. 3) After installation, ensure coupler operation is not impaired in any way. Do not use if coupler operation is impaired. CONNECTING BRAKE ACTUATOR TO TRAILER BRAKE LINES 1) Properly connect and tighten the trailer brake line to the actuator. 2) Fill the master cylinder with only DOT 3 or 4 brake fluid. 3) Bleed brake system of an air manually as follows: A) Extend coupler forward to gain access to the 1/2" hole on the top of the coupler housing (see Fig. 2) Insert a flat head screwdriver into the access hole and push on the end of the pushrod assembly (Item #8) activating the master cylinder until the brake fluid within master cylinder stops bubbling. B) Attach bleeder hose to bleeder valve on one of the wheels and submerge the other end of the hose into a transparent container partially filled with clean brake fluid. Loosen bleeder valve one turn and while watching hose in transparent container use screw driver to pump master cylinder as long as air bubbles continue to leave the hose. When bubbles stop, close bleeder valve, move to next wheel and repeat process until all brakes have been bled properly. (Note: Check fluid level in master cylinder frequently while bleeding brakes. Refill as necessary to keep level above half full.) 4) When bleeding is completed, refill master cylinder (Item #2) and reattach the cap (Item #4). Make sure the pushrod assembly is moved to its furthermost forward position (towards the front of the coupler) by pushing down and forward on the rod. (Note: The end of the pushrod should line up with the front of the 1/2" access hole.) After installation, endure coupler operation is not impaired in any way. Do not use if coupler operation is impaired. 7

10 OPERATING INSTRUCTIONS Failure to secure vehicle, trailer, and/or load before latching/unlatching/adjusting coupler may result in property damage and/or serious bodily injury. TO LATCH COUPLER TO HITCH BALL: 1) Make sure load is secure. 2) Open coupler locking lever. While holding locking lever open, lower the coupler over the hitch ball until ball is fully seated into the ball pocket of the coupler (See Fig. 3). 3)Move locking lever to the closed position (See Fig. 4). DO NOT force handle down. If handle does not close easily, trailer and tow vehicle ma be misaligned. Re-align as necessary. Check that latch is engaged by lifting up on back of locking lever (See Fig. 5). Also, check that the hitch ball is fully seated and ball clamp is below the ball. If the ball is not seated WITH lever in the closed position AND safety latch engaged, DO NOT TOW. Repeat the above steps. 4) OPTIONAL: Place a pin or lock in hole shown (See Fig. 5) A lock can be used in place of the pin as a theft deterrent. TO UNLATCH COUPLER FROM HITCH BALL: 1) Load may have shifted during transit, resulting in a negative tongue load. Use caution when unlatching coupler, as tongue may rise unexpectedly when unlatched. If lock or pin is in lever, remove it before removing coupler from hitch ball. 2) Open locking lever. With locking lever fully open, raise coupler off of hitch ball. 3) Return handle to closed position after clearing the hitch ball. ENGAGING MANUAL LOCKOUT LEVER: The purpose of the manual lockout lever is to control the brake pressure being applied to your trailer when you are backing up. Having the actuator in the extended position will make it easier to engage the lockout lever. To engage the lockout lever (Item #23), move the lever back and upwards until the front of the lever nests into the round spacer (Item #22) (see Fig. 6). This will prohibit movement of the actuator when backing up. The lockout lever will fall out of the lockout position when you drive forward again. FULTON Performance Products 8 50 Indianhead Dr., P.O. Box 8 Mosinee, WI / / FAX 715/ fulton@fultonperformance.com F2959 (A-7922) 07/02

11 OPERATING INSTRUCTIONS (CONT.) SERVICING BREAKAWAY ASSEMBLY: A thorough inspection of the breakaway assembly is required if it is applied at any time. Damaged parts must be replaced. If there is any damage to the lanyard itself the entire pushrod assembly will need to be replaced. To disengage breakaway mechanism, first release the brake line pressure by briefly opening a bleeder valve. Extend coupler forward to gain access to the 1/2" hole on the top of the coupler housing (see Fig. 7). Insert a flat head screwdriver into the access hole and push down on the pushrod assembly ((Item #8) and pivot the pushrod towards the front of the coupler. Make sure the pushrod assembly is moved to its furthest forward position (towards the front of the coupler, see Fig 8) by pushing down and forward on the rod. (Note: The end of the pushrod should line up with the front of the 1/2" access hole.) Inspect and replace parts as needed. MAINTENANCE ACTUATOR MAINTENANCE: 1) Frequently check brake fluid level (fluid must be DOT approved, clean and uncontaminated). 2) Make sure mounting bolts are properly tightened. 3) Inspect entire actuator, replace any bent, worn or damaged parts immediately. 4) Be constantly aware of systems braking quality, make periodic checks as described in the brakes owners manual. Consult certified brake specialist to make necessary adjustments or repairs. Failure to do so could result in loss of braking. COUPLER MAINTENANCE: 1) Maintain a film of automotive grease in the ball pocket, ball clamp (front & back), ball clamp spring, where link pin enters housing, and where the housing contacts the bracket hardware. 2) Maintain a film of oil on the pivot points and safety latch spring using SAE 30 WT. motor oil. 3) Keep the ball pocket and mechanism clean because dirt, paint, etc. can hinder proper operation. When parking or storing your trailer, keep the bracket and coupler off the ground so dirt and/or other foreign material will not build up in the coupler ball pocket. LIMITED ONE YEAR WARRANTY Warranty. Fulton Performance Products, Inc. ( We ) warrants to the original consumer purchaser ( You ) that the product will be free from defects in material and workmanship for a period of one year under normal use and service, ordinary wear and tear excepted. If the product does not comply with this warranty, We will replace the product without charge to You and within a reasonable time or, at Fulton s option, refund the purchase price. This warranty is not transferable. Limitations in the Warranty. The warranty does not cover the following: (a) normal wear and tear; (b) damage through abuse, neglect, misuse, or as a result of any accident or in any other manner, (c) damage from misapplicaton, overloading, or improperly installed; (d) improper maintenance; (e) a product altered in any manner by anyone other than us. Obligations of Purchaser. To make a claim, contact us at 50 Indianhead Drive, Mosinee, WI (715) , identify the product, and follow the instructions that will be provided. Any returned product that is replaced or refunded becomes the property of Fulton. You will be responsible for shipping costs to us. Please retain your purchase receipt to verify date of purchase. This must be produced to honor warranty claim. Remedy Limits. Repair or replacement is the purchaser s sole remedy under this or any other warranty on the product, whether express or implied. We shall not be liable for service or labor charges incurred in removing or replacing a product or any incidental or consequential damages of any kind. We expressly disclaim any implied warranty of merchantability or fitness for particular purpose after the three-year warranty period. Some states do not allow the exclusion of incidental or consequential damages or limitation of an implied warranty so the above exclusion and limitation may not apply to you. Legal Rights. This warranty gives you specific legal rights, and You also may have other rights which vary from state to state. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON ANY PRODUCT SHALL BE LIMITED TO THREE YEARS FRO THE DATE OR RETAIL PURCHASE BY YOU. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to You. FULTON Performance Products, Inc. 50 Indianhead Dr., P.O. Box 8 Mosinee, WI / / FAX 715/ fulton@fultonperformance.com F2959 (A-7922) 07/02 9

12 Installation Instructions and Service Manual Model 66 Actuator* for Trailer Brakes 6600 lbs Capacity Part #47200/ Drum Brake Ready Part #47201/ Disc Brake Ready *US Patent No. 6,375,211 MODEL 66 ACTUATOR INSTALLATION INSTRUCTIONS IMPORTANT: READ AND UNDERSTAND THE ENTIRE INSTRUCTION/ASSEMBLY PROCEDURE BEFORE INSTALLING YOUR BRAKES AND ACTUATOR. The Model 66 works by the "surge" or "push" of the trailer toward the tow vehicle. This automatically synchronizes the trailer brakes with the tow vehicle axle brakes. When the trailer pushes against the tow vehicle, the actuator telescopes together and applies the force to the master cylinder, supplying hydraulic pressure to the brakes. The built in dampening shock absorber retards the telescoping shock against the hitch ball by depending on the brake fluid in the master cylinder. Low levels of brake fluid will signal the tow vehicle operator to add brake fluid via hitch ball knocking. Be sure to comply with regulations for brakes in your state. Brake laws sometimes are minimum standards and you may wish to add additional brakes to your trailer. Read your tow vehicles owner s manual on towing capacity and other towing recommendations before installing brakes or this actuator. The Model 66 Actuator is completely assembled and ready to bolt into place (Tongue sizes: 3 x3, 3 x4 & 3 x5 ). 1. Bolt the actuator to the tongue-using grade 5 bolts 1/2 inch in diameter, 4 inches long. Lightweight tongues, less than 11 gauge, require spacer tubes inside the tongue for reinforcement. Attachment strength should equal or exceed than 1-1/2 times trailer G.V.W.R. 2. Hydraulic brake lines should be installed on the trailer as described in the installation manual supplied with the brakes. Note: Some disc brakes require the use of flexible brake lines at the connection POINT on the brake caliper. Follow brake manufacturer instructions. 3. Tie Down's actuators feature a shock dampener that uses brake fluid from the master cylinder. The dampener must be primed before bleeding or using trailer. To prime the dampener, fill the master cylinder with DOT 3 brake Fluid. Push the coupler into the housing and slowly pull out 3 times, then refill master cylinder. 4. Use only DOT-3 heavy-duty hydraulic fluid in the Model 66 actuator. Use a pressure type brake bleeder to bleed brakes. (This type of brake bleeder is available at your local automotive jobber.) Follow manufacturer's directions. Or, manually bleed the brakes using a heavy-duty flat blade screwdriver inserted in the hole provided on top of the actuator near the front. Insert the screwdriver and use a pumping action to activate the master cylinder in order to bleed the brakes. See page 8 for more details. To bleed master cylinder and brakes, install bleeder hose on first wheel cylinder to be bled; if tandem axle trailer, bleed closest axle first, and the closest brake on that axle first. Use a loose end of hose from the bleeder valve submerged in a glass container of brake fluid to observe bubbling (hose must be submerged into clean brake fluid to keep air from traveling back into the brake cylinder). Loosen the bleeder screw located in the wheel cylinder one turn, the system is now open to the atmosphere. The bleeding operation for that brake is complete when bubbling stops. Be sure to tighten bleeder screw securely. 10 Instructions #15359 TIE DOWN ENGINEERING 5901 Wheaton Drive Atlanta GA, (404) FAX (404)

13 Each wheel cylinder must be bleed until all air is out of the lines. Replenish the brake fluid during the bleeding process so the level does not fall below half full level in the master cylinder reservoir. When bleeding and testing is completed, make sure master cylinder is filled to 3/8" below the top of the reservoir and filler cap is securely in place. 5. When using drum or disc brakes on tandem axle trailers, both axles must be installed with brakes. Failure to install brakes on both axles will result in loss of braking performance, overheating of brakes & wheel hub, and significantly reduce brake pad life. 6. Road test trailer a short distance to activate the actuator several times. This will fill the reservoir of the master cylinders shock dampening system. Check fluid level again. Remember, low brake fluid levels will result in hitch ball knocking. 7. When testing is completed, make sure master cylinder is filled to 3/8" below the top of the reservoir and filler cap is securely in place. Road test again to make sure brakes work properly. RATED CAPACITY Maximum Actuator Capacity: 6600 lbs. Gross Load, 660 lbs. Maximum Tongue Load The actual in-service rating is limited to that of the ball and hitch being used or the trailer manufacturer's G.V.W.R. shown on the certification label, whichever is lower (Note: GVWR is the Gross Vehicle Weight Rating which includes the trailer and the load weight as a Total Gross Weight). HITCHING TRAILER 1. The vehicle, towing hitch and ball must have a rating equal to or greater than trailer GVWR. 2. Model 66 will accept 2" trailer hitch balls only. Trailer balls larger than 2.00 or out of round will not fit the coupler or may result in coupler failure. Balls smaller than can cause shock loading and sudden disconnection. Make certain ball latch is in correct position to retain the hitch ball. Push latch back until safety latch engages plate below latch. Insert safety pin into forward hole as a safety lock for the hitch ball coupler prior to towing. Do not tow trailer if coupler is damaged. 3. Connect safety cables or chains using crossed pattern under tongue, or follow trailer manufacturer's directions. 4. Connect actuator breakaway cable S-hook to the tow vehicle only. Do not connect S-hook to the safety cables or chains. 5. The breakaway system is designed to only operate after the trailer detaches from the tow vehicle and the safety chains have failed. The breakaway is not a parking brake. Do not use as such. 6. If the breakaway is accidentally applied while un-hitching, insert a flat bladed screwdriver into the spring clip slotted hole under the actuator and pry down to release. 7. Any control devices that restrict operation of the actuator cannot be used. This includes certain sway control devices. The actuator must be free to telescope in response to braking requirements. 8. Equalizing or weight distributing hitches may be used, allow six to eight inches free chain length. DANGER: Tongue weight beyond rating limits will interfere with performance of actuator, and braking system, and the tow vehicle. 9. The actuator is designed for use with Free-Backing trailer brakes. To block braking action, (in order to back up) with other types of brakes, use an electric solenoid. For trailer movement when brakes are not required, place the safety pin in the upper hole on the side of the actuator to block movement of the actuator. DANGER: Failure to remove pin will also prevent forward braking. Pin must be in the lower, forward hole as a safety lock for the hitch ball coupler latch when towing at all times. MAINTENANCE 1. Always check the brake fluid reservoir before using trailer. Make sure it is at least half full. If not, re-fill to 3/8 inch below the top of the reservoir with DOT 3 brake fluid. Check for leaks and repair as required. Never reuse brake fluid. 2. To extend coupler and ball life, coat both with a thin coating of grease. This will also eliminate squeaking. Wipe clean and renew film each time trailer is used. 3. Examine the actuator for bent parts or wear each time the trailer is used. Replace parts as necessary. 4. There are no user adjustments on the actuator. 5. Actuator travel (shown by coupler roller path) over one inch indicates a need to adjust the brakes or add fluid to the reservoir or a need to bleed the brakes and check connections for leaks. Adjust per instructions found in brake installation manual. In general, back-off adjusters on drum brakes from locked position, as required. Adjust Free-Backing brakes by rotating in forward direction only. Failure to adjust may result in loss of braking. Disc brakes do not require adjustment, check for pad wear. 11

14 6. While towing, if the actuator appears to be knocking against the hitch ball while starting or stopping, check brake fluid reservoir and fill if below 3/8 full from the top. Dampening shock absorber requires sufficient brake fluid in order to retard movement against hitch ball during towing. - DISC BRAKE USE When installing disc brakes to use with part #47200/86167 actuator, a check valve inside the actuator must be disabled. See disc brake installation instructions. If you do not properly disable the check valve, pressure will remain in the system causing the disc brakes to drag, overheat and fail. Part #47201/86165 actuator, has a disabled check valve for use on disc brakes - DO NOT use part #47201/86165 on drum brakes. Actuator and brakes should always be flushed with fresh water after using trailer in corrosive conditions. This includes salt water, fertilizers and other corrosive materials. Before storing trailer remove brakes and clean thoroughly. It is also wise to repack the bearings at the same time. Failure to properly and adequately maintain the actuator could cause serious damage, injury or death. The breakaway system is not designed to operate if the trailer does not separate completely from the tow vehicle, or if the tongue goes under the rear of the tow vehicle. In the event that the breakaway system is used, check all system components (cable, S-hooks, etc.) for proper working order. Replace any damaged parts with genuine Tie Down parts only. When re-setting the breakaway system keep hands and fingers clear as you re-set the mechanism, hydraulic pressure held in the system may cause the assembly to snap back suddenly. AVOID sharp turns, which can cause the actuator to bind or jackknife against the tow vehicle or cause a bend in the tongue. Either can damage the actuator causing brake failure. AVOID towing trailer across large bumps or dips that may over stress the connection between the trailer and tow vehicle, as this could result in damage to the actuator. DO NOT REUSE BRAKE FLUID. Always use fresh DOT 3 fluid from a fresh container. Failure to maintain proper levels of fluid in the reservoir will cause brake failure. Failure to install the hitch pin before towing can result in accidental opening of the coupler hitch latch which can lead to the trailer coming off of the hitch ball causing serious damage, injury or death. If pin will not fit into the front lower hole, the coupler is not attached properly. Re-set coupler on hitch ball. A minimum of 5% tongue weight and a maximum 10% tongue weight of the trailer GVWR must be located on the hitch ball. The Trailer tongue should be parallel to the ground. Too much weight can cause premature brake actuation and loss of control of the towing vehicle. To little tongue weight can cause the trailer to fishtail, resulting in loss of control of the tow vehicle and trailer (total trailer weight GVWR includes weight of the trailer plus load). A loose fit between the coupler and hitch ball can cause the actuator and hitch ball to separate, causing serious damage, injury or death. Check coupler every time prior to towing and at each stop on long trips. Always make certain that coupler latch safety pin is securely installed into coupler latch. When using drum or disc brakes on tandem axle trailers, both axles must be installed with brakes, Failure to install brakes on both axles will result in loss of braking performance, overheating of brakes & wheel hub, and significantly reduce brake pad life. NEVER ALLOW THE COUPLER LATCH SAFETY PIN TO REMAIN IN THE REVERSE LOCKOUT POSITION HOLE. AFTER REVERSE MANEUVERING, ALWAYS INSERT COUPLER LATCH SAFETY PIN BACK INTO COU- PLER LATCH. FAILURE TO REMOVE SAFETY PIN FROM REVERSE LOCK OUT POSITION HOLE WILL PRE- VENT FORWARD MOVEMENT BREAKING WHICH CAN RESULT IN SERIOUS PROPERTY DAMAGE, INJURY OR DEATH. 12

15 TIE DOWN ENGINEERING LIMITED WARRANTY Limited Warranty TIE DOWN ENGINEERING Inc ( TIE DOWN") warrants its products to be free from defects in material and workmanship for one year from date of delivery to the original purchaser when properly installed, used and maintained by the purchaser. This warranty does not apply to damage or loss caused by any or all of the following circumstances or conditions: Damage caused during installation. Parts, accessories, materials or components used with or replacing any TIE DOWN braking system not obtained from or approved in writing by TIE DOWN. Misapplication, misuse and failure to follow the directions or observe cautions and warnings on installation, operation, application, inspection or maintenance specified in any TIE DOWN quotation, acknowledgement, sales literature, specification sheet or installation instruction and service manual ("applicable literature"). Use of product in any other application other than those described in TIE DOWN s product information materials. If any TIE DOWN products are found upon TIE DOWN's examination to have been defective when supplied, TIE DOWN will either: credit the purchaser's account for the purchase price of the TIE DOWN product; replace the TIE DOWN product; or repair the product. TIE DOWN has sole discretion in choosing which option to provide. For this LIMITED WARRANTY to apply, TIE DOWN must receive notice of the alleged defect within 30 days of either the discovery of the alleged defect or the expiration of the warranty period, whichever is earlier. Any claim not made within this period shall conclusively be deemed waived. If requested by TIE DOWN, purchaser shall return the alleged defective product to TIE DOWN for examination at purchasers expense. TIE DOWN will not pay for expenses incurred in returning a product to TIE DOWN without TIE DOWN's prior written authority. TIE DOWN shall not be liable for any other expenses purchaser incurs to remedy any defect. Purchasers waive subrogation on all claims under any insurance. Limitation of Liability: It is expressly agreed that the liability of TIE DOWN is limited and TIE DOWN does not function as an insurer. THE REMEDIES SET FORTH IN THIS WARRANTY SHALL CONSTITUTE THE EXCLUSIVE REMEDIES AVAILABLE TO THE PURCHASER OR USER AND ARE IN LIEU OF ALL OTHER REMEDIES, EXPRESS OR IMPLIED. THE LIABILITY OF TIE DOWN, WHETHER IN CONTRACT, IN TORT, UNDER ANY WARRANTY OR OTHERWISE, SHALL NOT EXCEED THE PURCHASE PRICE OF THE PARTICULAR PRODUCT MANUFACTURED, SOLD OR SUPPLIED BY TIE DOWN. To Obtain Technical Assistance: To enable TIE DOWN to respond to a request for assistance or evaluation of customer or user operating difficulty, please provide at a minimum the following information by calling : Model number, serial number and all other data on the specific component which appears to be involved in the difficulty. The date and from whom you purchased your TIE DOWN product. State your difficulty, being sure to mention at least the following: Application, Nature of load involved, and Weight of the load. Field Service If field service at the request of the purchaser is rendered and the difficulty is found not to be with TIE DOWN's product, the purchaser shall pay the time and expense (at the prevailing rate at the time of service) of seller's field representative(s). Charges for service, labor and other expenses that have been incurred by the purchaser, its customer or agent without prior written authorization of TIE DOWN will not be accepted. TIE DOWN ENGINEERING 5901 Wheaton Drive Atlanta GA, (404) FAX (404)

16 Instructions for Bleeding Tie Downs Model 66 & 80 Actuators Tie Down's actuators feature a shock dampener that uses brake fluid from the master cylinder. The dampener must be primed before bleeding or using trailer. To prime the dampener, fill the master cylinder with DOT 3 brake Fluid. Push the coupler into the housing and slowly pull out 3 times, then refill master cylinder. To pump master cylinder, insert a flat tip screwdriver into the round hole near the front of the actuator cover. (picture 1) Screwdriver tip will fit into the slot provided in the emergency brake bracket as shown. Push the screwdriver forward and back to pump the master cylinder. (picture 2) IMPORTANT: Never go past 90 degrees (screwdriver straight up) when "pumping" the master cylinder (picture 3). Moving past 90 degrees will cause the emergency brake bracket to "set", locking into place creating constant pressure in the brake lines. If you find that the screwdriver will not go in place as shown when starting to pump the master cylinder, or you move the screwdriver past 90 degrees and feel it "snap into place", you must unlock the emergency brake bracket as shown in pictures 4 and 5. Pictures 4 & 5 show the underside of the actuator. If the oval slot where the emergency brake release tab comes out is "silver" (picture 5) and the release tab is pushed forward, this indicates that the emergency stop bracket is "set" and must be released before bleeding brakes or using the trailer. If the oval hole is "dark" (picture 4) and the release tab is free to move back, the emergency brake is ready to go, including bleeding and using the trailer. To release the emergency brake bracket, (pictures 6 & 7) insert a brake adjustment tool (looks like a bent screwdriver) into the slot on the release tab (on bottom side of actuator) and pull down until a "click" noise is heard indicating the bracket is released. Optional: two screw drivers using one to pull down and one to place under the other for leverage. TIE DOWN ENGINEERING 5901 Wheaton Drive Atlanta GA, (404) FAX (404)

17 INTRODUCTION Your trailer is equipped with the Model A-60 Hydraulic Brake Actuator. Trailer brakes will automatically energize whenever the tow vehicle's brakes are applied. They will develop stopping (deceleration) force in direct proportion to the stopping force generated by the tow vehicle. This actuator is designed for use with a 2" hitch ball. The hitch ball and tow vehicle must be rated to handle the actual Gross Vehicle Weight (GVW) of the trailer and load. Please read and familiarize yourself with this handbook. Also, review and understand the guidelines and requirements for towing published by the tow vehicle manufacturer and the trailer manufacturer. CAUTION For your peace of mind and safety, make sure to have your questions answered before towing the trailer. Please keep this handbook in your tow vehicle or with your trailer for future reference. Contact your dealer or our customer service department if additional information is desired. Before towing, be sure to read and perform the actuator related safety checks listed in this handbook. You the user are responsible for the consequences of inadequate maintenance, deliberate misuse, alteration or damage to the actuator. OPERATING INSTRUCTIONS THEORY OF OPERATION Trailer braking is controlled by the A-60 actuator mounted on the tongue of the trailer. When the tow vehicle brakes are applied, the 'surge' or 'push' of the trailer toward the tow vehicle automatically energizes and synchronizes the trailer brakes with the tow vehicle brakes. The actuator telescopes together applying force to a piston inside of a master cylinder, which in turn, generates hydraulic pressure that is routed to the brakes. TOWING At constant speed, the brake actuator master cylinder piston is in the free (extended) position; no hydraulic pressure is developed. The shock absorber subdues intermittent application of the trailer brakes when towing on rough roads. FIGURE 2 ACTUATOR COMPRESSED (STOPPING) BREAKAWAY PROTECTION The breakaway cable is connected to the tow vehicle. If the trailer accidentally becomes detached while towing, this cable activates the braking mechanism, thereby applying and holding pressure on the trailer brakes. The breakaway mechanism shall not be used as a parking brake and must be manually reset after activation. BACKING UP The actuator will compress to some degree when backing up. Depending on the type of brakes and terrain, accessories may be installed if necessary to keep brake line pressure from building up to the point at which the brakes energize and inhibit backing. Many trailers with disc brakes require an electrical solenoid control, energized by the tow vehicle back-up light circuit. When energized, brake line pressure does not build up during backing. REQUIREMENTS - EQUIPMENT ACTUATOR The Model A-60 actuator maximum load rating is 6000 pounds. It can support a maximum static tongue load of 750 pounds. The maximum load rating is for the total weight of the trailer fully loaded including all gear and includes tongue weight. TOW VEHICLE Review the tow vehicle owner's handbook and trailering guide for information on towing capacity, requirements for brakes, use of weight equalizing hitches and other towing recommendations. Make sure your outfit complies with the gross combined weight rating (GCWR) limits specified by the tow vehicle manufacturer. BRAKE LAWS Brake laws vary from state to state. Be sure you understand and comply with regulations. Make sure your outfit has adequate brakes and keep them property adjusted and in good working condition. Brake laws usually set minimum standards. You may wish to consider a better braking capability depending on the tow vehicle, miles driven and towing terrain. HITCH The tow vehicle's hitch must have a rating equal to or greater than the trailer GVWR. FIGURE 1 ACTUATOR EXTENDED (RUNNING POSITION) Do not use an underrated ball. Use only a quality machined or forged ball with a smooth surface finish. STOPPING As the tow vehicle decelerates, the trailer moves forward toward the tow vehicle. The actuator compresses, applying force through an overload spring to the master cylinder piston in direct proportion to the tow vehicle braking force. The piston strokes inward against the hydraulic fluid, creating pressure that is transmitted to the brakes through brake line tubing. The shock absorber assures smooth application and release of the brakes. HITCH BALL The hitch ball must have a rating equal to or greater than the trailer GVWR. The actuator coupler will only accept 2" diameter balls. Make certain a 2" diameter ball of the correct load rating is used. Balls must be within the limits of 1.970" " diameter when measured in all directions. Balls larger than 2.000" or out of round will not fit the coupler socket. Balls smaller than 1.970" can cause shock loading and a sudden disconnection could result at worse case. Hitch balls may be purchased from your dealer or UFP. 15

18 HITCH HEIGHT For proper tow vehicle and trailer hookup and towing performance, the tow vehicle and trailer are to be level with respect to the ground after hitching up. If your trailer is not level, equipment is available to raise or lower the hitch ball. A weight equalizing hitch or load support suspension equipment may also be required to keep the tow vehicle level and to properly load each axle. SAFETY CHAINS Adequate safety chains must be used and conform to the Society of Automotive Engineers (SAE) J684 standard, "TRAILER COUPLING AND HITCHES - AUTOMOTIVE TYPE". The strength rating of each length of safety chain shall be equal in minimum break test load to the gross weight of the trailer including its load. Make sure that your safety chains are fastened to the frame of the trailer and to the hitch or tow vehicle frame. Safety chains fastened directly to the actuator mounting bolts, the hitch ball or to the bumper, are not acceptable and will not pass vehicle inspections. Connect safety chains using a crossed pattern under the tongue. version is available for operating 2 sets of 8 1/2" drum brakes and 2 sets of UFP 10" disc brakes. Contact factory for further information. CAUTION If you are retrofitting disc brakes onto a trailer previously fitted with drum brakes, a check valve inside the actuator master cylinder must be disabled. See the disc brake installation instructions. It you do not disable the check valve, the disc brakes will remain pressurized, causing them to drag and overheat. Some trailers do not have adequate brakes for the operating conditions encountered. This will increase stopping distance and cause premature brake lining wear or overheating. You may wish to discuss this subject with your dealer. HITCHING UP FIGURE 3 TYPICAL DOUBLE SAFETY CHAIN INSTALLATION SWAY CONTROL DEVICES Trailer sway control devices that restrict operation of the actuator must not be used. The actuator must be free to telescope in response to braking requirements. WEIGHT DISTRIBUTING HITCHES Weight distributing (equalizing) hitches may be used. Chain must be vertical (straight up and down) under pulling load (actuator extended). Excessive tongue weight beyond actuator rating must be avoided as it will reduce brake performance and could damage the actuator. Follow hitch manufacturer's instructions. It is mandatory to install either the hitch pin (supplied) or a padlock (1/4" or 5/16" shank) into the coupler side hole before towing. This will prevent any accidental opening of the coupler latch. If latch inadvertently opens, the trailer could jump off the hitch ball. Serious bodily injury and/or equipment damage could occur. Hitch pin should fit easily into hole. If not, coupler latch is not completely closed. On each occasion coupler is attached to ball, make certain ball is completely engaged in coupler ball socket and handle will not open without first pushing button to side. Failure to do so could result in an accident and/or serious personal injury. If hitch pin is damaged or lost, contact UFP for a free replacement. TO OPEN THE COUPLER Remove hitch pin from hole in the side of the coupler. Push button on top of handle to the side. While holding button to the side, raise handle by lifting front with two fingers. The coupler should unlatch easily. If not, the ball may be oversized or eggshaped, foreign matter could be lodged in coupler ball socket or there is excessive upward or forward force on the coupler with respect to tow vehicle. Examples include tongue jack forcing front of trailer up or trailer pushing against tow vehicle. Correct as necessary. FIGURE 4 TYPICAL WEIGHT DISTRIBUTING HITCH INSTALLATION BRAKES The actuator is to be used only with brakes specifically designed for trailer service. It should not be used with any custom built, one-of-a-kind brakes because such combinations have not been tested and evaluated. The actuator is designed for use with one or two sets of either 10" or 7" drum brakes. It can also be used with one set of 8 1/2" or 12" drum brakes. The basic actuator may be used with one set of UFP 10" disc brakes. A special FIGURE 5 OPENING COUPLER 16

19 TO CLOSE COUPLER Place coupler over the ball, lower coupler and close handle. You will hear a distinct "click". Handle should close with finger pressure. If handle will not close freely, ball is not fully inserted into socket, is oversized or eggshaped. DO NOT FORCE HANDLE. As a unique safety feature, the coupler latch should not close unless the ball is properly seated into the coupler socket. If necessary, replace ball with a quality unit that meets SAE specifications. Check before towing to see if coupler is locked by lifting up on latch handle without pushing button to side. If handle opens, latch mechanism has been damaged. DO NOT TOW TRAILER. Contact factory for replacement parts. DO NOT move trailer if latch handle will not remain closed or with the handle open. BRAKE LOOKOUT CAP This mechanical control is an available option on the Model A-60 actuator. It allows trailers to be backed up over soft ground or up inclines without fully engaging the brakes. The control mechanism is designed to disengage when the trailer is pulled forward after backing up. Therefore it must be manually reset prior to each back up. OPERATING BRAKE LOCKOUT CAP 1. To operate lockout cap, the actuator must be fully extended. This can be done by pulling the trailer forward slowly. 2. With the lockout cap in the TOW (forward) position, depress the button in the front of the cap and rotate the cap clockwise toward the BACK- ING position until it stops. The button should remain down. 3. Back the trailer. To close handle without ball, if necessary for storage, first push safety pawl inside coupler back and then slowly close handle. FIGURE 6 CLOSING COUPLER 4. If the trailer cannot be maneuvered to the final position and needs to be pulled forward, there are two options: a) Pull the trailer forward and allow the actuator to extend. The control cap will rotate (reset) and you will have to turn it back to the BACKING position in order to back up. b) If you have backed up an incline, allow the tow vehicle to move forward slowly so the actuator remains compressed. This keeps the control in the engaged (BACKING) position so you can back up again. BACKING UP When you back up, the actuator will start to compress, generating hydraulic pressure in the system. As the pressure builds, the brakes will energize to various degrees under various operating conditions. Under most conditions, backing up will not energize drum brakes enough to interfere with backing. Available brake lockout hardware options allow you to control the pressure buildup so that energizing of brakes does not interfere with backing up. BRAKE LOCKOUT BRACKET A simple mechanical lockout is included on some models to prevent the actuator from compressing when you back the trailer. The brake lockout bracket is useful in situations where you need to back over soft ground or up a hill. Use it as follows: 1. Insert the brake lockout into slot behind roller pin on side of main body. CAUTION If the actuator is uncoupled from the tow vehicle after backing up, manually extend the actuator to disengage the lockout and return the control cap back to the tow position. REMOVING BRAKE LOCKOUT CAP 1. Make sure the actuator is fully extended. 2. With the cap in the TOW position, depress the button and rotate the cap counter clockwise toward the REMOVE position until it stops. 3. Lift the cap up to remove it and gain access to the master cylinder reservoir. 2. Slide the brake lockout completely forward in slot. Washer will keep brake lockout from falling out while backing up. When you pull the trailer forward and the actuator extends, the brake lockout should fall out of the slot. This ensures that the actuator will function when stopping. Before towing, make sure the brake lockout is removed from the slot otherwise brakes will not energize. Before towing trailer, check that the lockout cap is in the proper operating condition, the cap button is up and cap is in the normal TOW position. If for any reason cap does not reset or function properly remove cap from trailer. Failure to do so may inhibit normal trailer braking performance. FIGURE 7 INSTALLING BRAKE LOCKOUT BRACKET FIGURE 8 BRAKE LOCKOUT CAP 17

20 AUTOMATIC BRAKE LOCKOUT An electrically operated automatic pressure control is recommended if the trailer is equipped with disc brakes. Whenever you back up, a 12 volt electrical signal from the tow vehicle backup light circuit energizes the pressure control unit. Hydraulic pressure is prevented from building up so the brakes will not come on. The electrical control may also be used with drum brakes. To retrofit, the existing master cylinder in the actuator will have to be replaced. Consult factory. BREAKAWAY CABLE Secure the breakaway cable solidly to the bumper or frame of tow vehicle as close to center as possible (do not attach to safety chains). The cable must hang clear of the trailer tongue and be long enough to permit short radius turns without pulling the cable. Do not loop S-hook over breakaway cable to attach it. CAUTION If the breakaway cable is accidentally pulled, determine cause and correct. ALWAYS reset to prevent damage to brakes. Inadvertent setting of the brakes by pulling the breakaway cable is the single most common mistake users make. To prevent light pulls from accidentally setting trailer brakes, a small metal clip has been installed on breakaway cable in front of the indicator bead. The clip will not inhibit the action of the breakaway mechanism during actual breakaway conditions. However, if breakaway should occur the clip will be destroyed and should be replaced. Spare clips are attached to the cover of this manual. To retract the breakaway cable, fully extend the actuator and push up on the pushrod release bracket located on the underside and behind the ball socket to allow the bead to retract into the actuator. This will release the trailer brakes. Install new clip on breakaway cable in front of bead. FIGURE 10 STROKING THE PUSHROD TO RELEASE BRAKES Note: If brakes can not be released using above method or if pushrod release bracket will not move, it is damaged beyond serviceability. Contact UFP for repair parts. SAFETY CHECKS BEFORE TOWING ACTUATOR CONDITION Examine the actuator for evidence of external damage, bent parts or excessive wear. Replace parts as necessary. Check to determine that mounting bolts (if equipped) are tight. COUPLER The release handle in the coupler portion of the actuator closes freely with finger pressure when the coupler is properly seated onto the hitch ball. COUPLER CHECK PROCEDURE To make certain the coupler portion of the actuator is securely latched onto the ball, take a moment, look under the coupler and make a visual check. An alternate check is to extend the trailer tongue jack to the ground and lift the tow vehicle and trailer combination 2" to 4". If the ball does not disengage, the actuator is securely attached. If ball does disengage, reset ball in coupler and recheck. FIGURE 9 CHECKING AND RESETTING BREAKAWAY CABLE If pushing up on the bracket does not release the brakes or if it is hard to push, insert a screwdriver into the 5/16" hole behind the bracket. Use screwdriver to stroke push rod backwards to relieve load on bracket. Push up on bracket and hold up while releasing screwdriver. The pushrod release bracket should now move freely and brakes should be released. Check to see it the actuator is reset. Extend the actuator fully. Remove the cap from the top of the actuator and pull the plug from top of the reservoir cover. While looking at fluid in the reservoir, manually compress actuator. In the first 1/8" of stroke the fluid in the reservoir should "splash" or "ripple" slightly. If it does, the actuator is working property. If ball disengages from coupler, or latch opens without pushing button first, DO NOT TOW TRAILER - CONTACT FACTORY. Note: Under some conditions the coupler may not open or close if trailer tongue is positioned to cause an excessive upward or forward force with respect to tow vehicle, (parking on a downhill grade for example) or if shank of hitch ball is very large. Correct the problem. TONGUE WEIGHT Improper weight distribution can cause a trailer to "fishtail" (sway from side to side) and the coupler to rattle (up & down) as it moves down the highway, putting excessive strains on both trailer and towing equipment, and potentially causing an accident. The most effective way to guard against this is to make sure that the weight on your trailer is properly distributed. 18

21 It is extremely important that at least 5% to 10% of the total weight of your loaded trailer be located at the trailer hitchball when the tongue is parallel to the ground. This will help prevent fishtailing. A bathroom scale can be used for this determination. For example, if the gross weight of trailer, boat and gear is 4000 lbs, the weight on the tongue must be a minimum of 200 lbs. The importance of an adequate down load on the hitch ball cannot be overemphasized. If the weight on the hitch ball does not fall within the proper range, you should take immediate steps to reposition the load. If only a small adjustment is required, you may be able to solve the problem simply by shifting some of the gear in your boat (gas tank, anchor, fishing tackle) from back to front or vice versa. If this is not adequate, the undercarriage of some trailers (axle or axles) can be moved backward or forward, as required. BREAKAWAY CABLE Check the breakaway cable periodically to make sure it has not been damaged. Check the location of the indicator bead and clip. The clip should be in place and the bead should not be outside the actuator. Accidental application will cause brakes to drag and heat up. SAFETY CHAINS Make sure that your safety chains are properly attached to the tow vehicle per the instructions supplied by trailer manufacturer. SAE recommendations are listed in Requirements - Equipment section. FLUID LEVEL Check the fluid level in the master cylinder reservoir if you detect evidence of brake fluid leakage. Refill as required. HITCH BALL Make sure a 2" diameter ball of correct load rating is used. A film of clean grease on the ball will extend coupler and ball life and eliminate squeaking. Wipe ball clean and renew film periodically. TOW VEHICLE HITCH The hitch an the tow vehicle must be of the proper load rating and in sound condition. If hitch is of the receiver type, make certain receiver pull pin is in place and safety pin is installed. TRAILER JACK Trailer jack must be fully retracted and caster wheel removed (if necessary) before towing. MAINTENANCE AND SERVICE INSTRUCTIONS CAUTION If you are not skilled in the following procedures, we recommend you contact your dealer for this service. If you have any questions contact our customer service department at PERIODIC INSPECTION AND MAINTENANCE In order to ensure efficient operation, the following checkpoints should be observed annually or every 2000 miles, whichever occurs first. 1.Check for any hydraulic leaks in the brake system. Be sure all tube fittings are tight. Periodic checks must be made on all hoses, brake line tubing and fittings to guard against cuts, worn hoses and loose fittings which may cause leaks in trailer brake hydraulic system. Replace deteriorated and damaged parts as necessary. 2. Check brake adjustment (not necessary for disc brakes) after first 300 miles and every 2000 miles thereafter. Proper adjustment of brakes is extremely important for peak stopping capability. If brakes are in need of adjustment, we recommend that you follow the manufacturer's instructions or the steps outlined in this booklet. 3. Check for wear on hitch ball. Ball diameter must be in the range of 1.970" " when measured in all directions. If ball is worn, it is UNSAFE and must be replaced. It could cause improper brake performance, separation of ball and actuator, or noisy and jerky trailer operation. 4. Check safety chains and attachment points for damage or wear. Repair or replace as necessary. 5. Check brake fluid in the master cylinder reservoir. To gain access to the reservoir, remove the cap on top of the actuator. Clean area around master cylinder plug. Use a screwdriver to carefully pry off plug. Make sure rubber seal around opening is in good condition. Clean brake fluid off level indicator on plug. Re-install and remove plug. Brake fluid should just touch the end of the level indicator. 6. Check for foam or bubbles in the brake fluid. If either are present, drain fluid from master cylinder and replace only with new brake fluid of the same type, (DOT 3 or 4). In order for brakes to function properly all air must be expelled from the brake system. If bleeding is necessary, follow MANUAL BLEEDING OF THE BRAKE SYSTEM instructions as outlined in this booklet. AUTOMATIC BRAKE LOCKOUT (if equipped) The electrical lead from the solenoid valve must be connected to the tow vehicle backup light circuit. A "click" should be heard when the tow vehicle is shifted into reverse and the backup lights come on. To check: Have someone listen for the sound while operator is in the cab. Keep one foot on the brakes to avoid accidentally backing up. ELECTRICAL WIRING Plug in connector and check signal, brake and running lights. PARKING AFTER USE After parking the trailer ALWAYS manually extend the actuator to keep moisture from coming in contact and corroding the master cylinder bore. If trailer has been immersed in salt water, rinse off trailer and flush out brakes with fresh water. FIGURE 11 MASTER CYLINDER RESERVOIR PLUG NOTE: It is imperative that the system be filled with only ONE type of brake fluid. Different types do not mix. DOT 3 and 4 are used by most manufacturers. Follow instructions on brake fluid container. 7. Check the breakaway cable for worn or frayed cable strands. End fittings should be checked for damage. Replace as necessary. 8. Check coupler latch operation for excessive wear and fit on ball. 19

22 An extremely loose fit may allow coupler portion of actuator and ball to separate causing serious bodily injury and/or equipment damage. Check fit on ball as outlined in COUPLER CHECK PROCEDURE in the "SAFETY CHECKS BEFORE TOWING" section. 9. Inspect tow hitch per tow hitch manufacturer's instructions for corrosion or damage. Repair or replace components as necessary. 10. Check coupler mechanism for smooth operation. If button is hard to push or latch handle does not spring open after being disengaged, lubricate points on coupler latch mechanism indicated by arrows in Figure 12. FIGURE 12 COUPLER LUBRICATION POINTS 11. Check actuator travel. Excessive actuator travel (over one inch) when brakes are applied indicates a need to adjust the brakes (not necessary with disc brakes) or air in the brake lines. 12. Check actuator for excessive wear. If the outer member is rubbing against the inner member, wear marks will show on top of coupler just forward of outer member. Contact factory for replacement parts. EXTENDED STORAGE MAINTENANCE (Over one year) The following preventive maintenance is recommended for extended periods of storage. 1. Check brake system for proper fluid level in master cylinder. If fluid level is extremely low, air may be trapped in brake lines. Bleed all lines if necessary and fill reservoir to proper level. 2. Lubricate all links and pivots to prevent rusting. If equipped with drum brakes and storage is in a humid environment, remove wheel and drum assemblies and spray a good anti-corrosion compound (CRC Formula 5-56, for example) under rubber boot on forward end of brake wheel cylinder. Also, spray springs, adjuster and anchor pin. CAUTION Avoid spraying drum and brake lining surfaces. 3. Grease bearings, fill hub cavities and reinstall wheel and drum assemblies. 4. Top off bearing protectors, if equipped, with grease. 5. Make sure breakaway system has not been set, and actuator is fully extended. 6. If possible, store away from excessive moisture. 20

23 TROUBLESHOOTING ACTUATOR AND BRAKE PROBLEMS If any of the following problems develop, the trailer must be immediately stopped and the proper corrective action taken before the trailer is put back into service. Failure to do so may lead to loss of proper trailer braking capability, or damage to the trailer and load. PROBLEM: COUPLER LATCH HANDLE DOES NOT OPEN OR CLOSE EASILY POSSIBLE CAUSE REMEDY Oversize hitch ball Ball not fully inserted in ball socket. Trailer and tow vehicle are not level with each other, or are facing downhill. Excessive corrosion Check ball size at several positions, ball should be within 1.970"-2.000" in diameter. Replace if necessary. Check for proper ball size, (see above) and positive tongue load. Check to see if tongue jack is fully retracted. Make sure there are no foreign objects or excessive paint inside coupler cavity. Reposition tow vehicle and trailer or block trailer tire and extend actuator. Lubricate or replace parts as necessary. If the latch handle does not close freely, DO NOT tow the trailer until cause of the problem is located and eliminated. Forcing latch handle closed will make opening latch handle extremely difficult. PROBLEM: SQUEAKING, CLUNKING AND CLATTERING AT ACTUATOR POSSIBLE CAUSE Hitch ball requires lubrication. REMEDY Lubricate with conventional multipurpose lubricant or commercial lubricant made for hitch balls. Loose hitch ball Loose hitch Loose mounting bolts (if equipped) A worn or too small hitch ball Worn shock absorber Air in brake lines allowing actuator to travel too far. Trailer is equipped with "free backing brakes. Inspect hitch ball and tighten. Inspect hitch and repair. Inspect brake actuator mounting bolts and tighten as necessary, (70-80 ft-lbs). Replace hitch ball with a quality unit that meets SAE specifications. Replace shock absorber. Check for leaks, re-bleed brakes. Clunking noise is typical for these types of brakes as long as braking performance is normal. 21

24 Leaky hub grease seal. PROBLEM: GREASE LEAKING OUT BACK SIDE OF BRAKE DRUM OR ROTOR Replace grease seal and wheel bearings if damaged. Clean drums and other hardware. Replace brake shoes if contaminated with grease. Pack wheel bearings. PROBLEM: WHEN BRAKING, BRAKES REPEATEDLY COME ON AND RELEASE, BRAKING IS NOT SMOOTH. THIS CONDITION IS CALLED CHUCKING Worn out shock absorber in actuator. Loose hitch or hitch ball. Not enough tongue weight or shocks on tow vehicle too soft. Air in the brake lines. Brakes out of adjustment. Replace the shock absorber. Correct as necessary. Correct as necessary. Bleed the brake system. Adjust the brakes property. Contaminated brake linings. Fix cause of contamination (leaky wheel cylinder or hub grease seal. Replace linings and clean braking surface on drum or rotor. PROBLEM: BRAKES DO NOT OPERATE, POOR BRAKE PERFORMANCE POSSIBLE CAUSE Worn out brake shoes or disc brake pads. REMEDY Replace brake shoes/pads on both sides of axles and check drums/rotors for wear or damage. Foreign material in the brake unit assembly. Insufficient amount of hydraulic fluid Broken lines or pinched line. Seized actuator master cylinder. Prevents piston from stroking. Corrosion/rust keeps brake from operating. Inadequate brakes for load or driving conditions. Clean thoroughly. Replace shoes and linings if contaminated. Fill reservoir and bleed brakes. Check for leaks. Replace faulty lines and bleed brakes. Replace actuator master cylinder. Replace damaged components or entire brake assembly as required. If you have a tandem axis trailer add a second set of brakes. Incorrect adjustment of drum brake. Broken components in brake assembly. Leaky or seized brake wheel cylinder. DRUM BRAKES ONLY Adjust all brakes. Replace faulty parts and re-adjust brakes. Replace/rebuild wheel cylinder and replace brake shoes (if contaminated with brake fluid). Clean drums and other hardware, readjust brakes and bleed brake system. 22

25 POSSIBLE CAUSE Drum brake adjusted too tightly. PROBLEM: ONE BRAKE OVERHEATING REMEDY Readjust, check all brakes. Disc brake caliper does not permit brake pads to release. Leaky or seized brake wheel cylinder. Damaged or frozen brake mechanism. Check caliper. Sections must be free to move apart. If frozen, remove and free up. Caliper piston may freeze up and prevent pads from retracting. Clean contaminants out of piston cavity. Replace piston, seal and protective dust boot Bleed system. Replace/rebuild wheel cylinder and replace brake shoes (if contaminated with brake fluid). Clean drums and other hardware, readjust brakes and bleed brake system. Rebuild or replace brake unit. PROBLEM: BOTH BRAKES OVERHEATING Isolate the problem to actuator or the brakes as follows: 1. Fully extend actuator. 2. Remove master cylinder reservoir plug. 3. Check that reservoir is property filled. 4. Manually push the actuator inner member in or use a screwdriver to stroke pushrod. (Be sure to depress the pushrod release button after stroking pushrod). 5. In the first 1/8" of stroke, the reservoir fluid will either remain dead calm or swirl around. If the fluid swirls: Fluid is allowed to return to reservoir when actuator is extended. Actuator is functioning properly, troubleshoot brakes. POSSIBLE CAUSE Drum brakes misadjusted. Adjust brakes properly. REMEDY Trailer stored with actuator compressed; both brakes to freeze up. rust has caused Remove brakes. Clean, repair or replace components as necessary. Check valve in master cylinder not properly punctured, (disc brakes only). Inadequate brakes for towed load or driving conditions. Pinches or kinks in brake lines. Puncture check valve. Re-bleed brake system. If you have a tandem axle trailer add a second set of brakes. Check brake lines and replace as necessary. It fluid does NOT move: Brake system is remaining pressurized and there is an actuator problem. Troubleshoot actuator. POSSIBLE CAUSE Pulled breakaway cable, pushrod not reset REMEDY Reset breakaway cable, install clip. For each of the following the actuator inner member must be removed. Follow the instructions in DISMANTLING AND ASSEMBLY OF ACTUATOR. Fluid return hole in master cylinder clogged or mispositioned. Troubleshoot. Replace parts as necessary. Corrosion in master cylinder freezing up piston or not allowing it to fully retract, usually caused by trailer stored with actuator compressed. Other malfunction or damage keeping the master cylinder from retracting. 23

26 DISMANTLING AND ASSEMBLY OF ACTUATOR DISMANTLING ACTUATOR Note: Read and understand this section before attempting to disassemble inner member. 1. Extend actuator and remove cap from top. 2. Unscrew brake line fitting from rear of master cylinder. Note: Brake fluid escaping from master cylinder and brake line will damage paint. Care should be taken to protect painted surfaces. 3. Remove one retaining ring and washer from each of the two roller pins located on side of actuator main body and slide pins out. 4. Pull on breakaway cable to remove inner member. This ensures that all components will come out attached together. Internal components can now be removed and dismantled for inspection, maintenance or repair. Entire inner member can be replaced. FIGURE 14 ACTUATOR, SIDE VIEW ACTUATOR ASSEMBLY Before the inner member can be inserted into the main body all internal components must be assembled and placed in their proper position. 1. For ease of assembly, assemble inner member upside down. 2. Check that shock absorber, reservoir cover plate, diaphragm, and plug are assembled to the master cylinder. 3. Insert ball end of breakaway cable through hole in front of inner member, thread through latch assembly and around outside of cable guide rod located on the side of master cylinder. Ball end of cable can now be inserted into hole on cable attachment plate and slid over into slot. Note orientation of cable attachment plate. 4. Insert square end of push rod assembly into hole in cable attachment plate. Insert round end of push rod assembly through rubber boot and into master cylinder piston. 5. Lightly grease rear rollers and hold them in the pockets in the sides of the master cylinder while inserting entire assembly into the inner member from the back end. While inserting assembly make sure push rod enters hole in push bracket. The tab on the safety release bracket will have to be depressed to allow push rod assembly to fully enter hole in push bracket. The cable attachment plate should sit flush with the push bracket if properly assembled. 6. Make sure breakaway cable is correctly routed and is not wrapped around or hung up on any components. 7. While supporting the master cylinder, turn inner member assembly over and lightly grease front rollers and insert them through the openings on top of inner member. Note: Before inserting rollers make sure breakaway cable runs on top of shock absorber eye ring. 8. Slide actuator inner member into outer member and line up roller pin holes on rear of actuator first. Insert lightly greased roller pin. 9. Push or pull inner member to line up holes in rollers with hole in shock absorber eye-ring and insert lightly greased roller pin. 10. Pull on inner member to the fully extended position. With slack taken out of breakaway cable, check that the cable clip is in place next to the indicator bead. Push up on safety release bracket tab to reset breakaway system. 24

27 11. Assemble washers and retaining rings on roller pins. 12. Connect brake line fittings and install cap. 13. Bleed brake system according to instructions outlined in MANUAL BLEEDING OF THE BRAKE SYSTEM section. FIGURE 15 COMPONENT LOCATION (Inner Member) MANUAL BLEEDING OF THE BRAKE SYSTEM BOTTOM VIEW NOTE: ORIENTATION OF CABLE ATTACHMENT PLATE IS TOWARD SIDE OF INNER MEMBER CAUTION If you are not skilled in performing the following procedures, have a qualified service shop to perform the job. Check that all hydraulic fittings are secure. Read and understand all instructions before starting. Two people are required for manual bleeding. 1. Remove the master cylinder reservoir plug and fill the reservoir with brake fluid. Use either DOT 3 or DOT 4 automotive brake fluid. Follow instructions on brake fluid container. Avoid shaking brake fluid container and pour fluid slowly to minimize air entrapment. Let fluid in reservoir stand until completely free of air bubbles. 2. IMPORTANT: Before bleeding brake lines, bleed the actuator master cylinder. Insert a screw driver through hole in bottom of inner member and use short strokes to pry on pushrod (while holding safety release bracket up) until no air bubbles are seen coming from small orificed hole in the bottom of the master cylinder reservoir. 3. Start bleeding procedure on the brake furthest from master cylinder. 4. At the brake assembly, connect a transparent bleeder hose to bleed screw fitting on wheel cylinder and submerge free end into a container partially filled with brake fluid. Do not reuse this fluid. 5. The first person strokes the pushrod slowly while holding safety release bracket up. The second person opens the bleed screw fitting. He then closes the bleed screw fitting BEFORE the first person SLOWLY releases the pushrod. Repeat this procedure until the fluid expelled from the bled hose is free of air bubbles. Remember to always tighten the bleeder screw before releasing pushrod. During this procedure, the master cylinder reservoir fluid level must be maintained at no less than 1/2 full. 6. Repeat steps 4 and 5 for the other brake and the brakes on the front axle, if equipped with tandem brake axles. 7. If installation is tandem axle with brakes on both axles, repeat bleeding procedure on rear axle brakes for the second time to assure purging of all air in system. 25

28 8. As a final check after bleeding is completed, stroke pushrod and check to be sure brake system is pressurized by attempting to rotate a tire. 9. Push up on the safety release bracket to ensure that pushrod is in released position. 10. After bleeding has been completed, re-check fluid level in master cylinder. Fill the master cylinder reservoir to indicator on reservoir plug. Do not overfill. IMPORTANT: DO NOT USE BRAKE FLUID DRAINED FROM BRAKE SYSTEM TO RE- FILL MASTER CYLINDER RESERVOIR AS SUCH FLUIDS CONTAIN CONTAMINANTS FROM SYSTEM WHICH MAY RESULT IN FAILURE IN BRAKE FAILURE OR COSTLY REPAIRS. FIGURE 16 STROKING PUSHROD TO BLEED BRAKES BREAKAWAY CABLE CLIP INSTALLATION INSTRUCTIONS The breakaway cable clip is installed on the breakaway cable to prevent inadvertent pressurization of trailer brakes if cable is lightly pulled accidentally. Should the breakaway cable be pulled, during emergency situations, the clip will be destroyed. The breakaway system must be reset by pushing up on the tab located under coupler and the clip must be replaced. To install clip, open latch handle and pull enough cable out of coupler body to make installation of clip easier. Clip must be installed on cable in front of indicator bead as shown below. Hold clip with pliers and insert over cable. Use a second set of pliers to gently close the opened end of clip. Clip should be free to move on cable. CAUTION The breakaway system reset tab must be pushed up after clip installed and anytime the cable has been pulled. 26

29 TWO YEAR LIMITED WARRANTY A-60 BRAKE ACTUATOR The actuator is guaranteed against defects in materials and workmanship under normal use and service for a period of two years after the date of trailer purchase by the first owner. Limitations of Coverage This warranty does not cover: Normal wear and tear, including corrosion. Damage caused by accidents, overload, abuse, modification or improper use of product. This warranty is limited to defective parts replacement only. Charges for installing replacement parts, damage incurred to other equipment as well as incidental or consequential damages connected therewith are excluded. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to you. Repair or Replacement Procedure If a failure or defect occurs during the warranty period, promptly contact warrantor's (UFP) customer service department. Until such notice is received, warrantor will not be responsible for any repair or replacement costs. UFP, at its option, may require return of the component in question to the factory, transportation charges prepaid. UFP will replace, FREE OF CHARGE, either the entire actuator assembly or the part that proves defective, at its option. Any part found not to be defective will be returned freight collect with an explanation. Installation of parts and adjustment of brake systems MUST be performed by a skilled brake mechanic and service manual instructions must be followed. Vehicle Identification Number (VIN) The VIN is a 17 digit number located on the trailer identification label. The label is located on the left side of the trailer. Be sure to include the VIN number in all communications with Warrantor. Purchaser's Rights This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Product Improvement UFP has a policy of continuous product improvement. We reserve the right to change or improve the design of our products without assuming an obligation to modify any product previously manufactured. 135 Sunshine Lane San Marcos, CA (760) Fax (760)

30 Service Information for 28 TRAILERING WITH DISC BRAKES Disc brakes offer several advantages over drum brakes that you will appreciate. Disc brakes have improved resistance to fade on downhill grades. They are self adjusting, so as pads wear, braking efficiency is not reduced. They recover quickly after being submerged. They require less maintenance, are easier to flush out, and are less susceptible to water induced corrosion. Your trailer's brakes are designed to energize automatically when the tow vehicle's brakes are applied. These are known as "surge brakes". When the vehicle slows down or stops, the forward momentum (surge) of the trailer against the hitch ball develops hydraulic pressure in a master cylinder inside the trailer brake actuator. Hydraulic lines are used to transfer pressure to the brakes and engage them. Follow the tow vehicle manufacturer's guidelines with respect to towing capability, hitch requirements, and other towing considerations. OPERATING TIPS Check Your Brake System Before Each Trip 1. Follow the pre-towing instructions that came with your actuator. 2. Make sure there are no leaks in the hydraulic system. 3. A surface rust will build up on the rotor brake surface if the trailer isn't used for a week or more. The brake pads will wipe off the rust in the first few miles of travel. If the trailer has been idle for several months, or has been frequently submerged in salt water and the brakes not flushed out, severe corrosion can occur. Review the maintenance instructions in the following section. When Starting Out 1. The trailer should tow easily. If it seems hard to pull or wants to swing toward one side, a rotor may not be rotating freely. Investigate and solve the problem. 2. Try your brakes at slow to moderate speeds and develop the "feel" to sense they are functioning property. On The Road Drive carefully, obey speed limits and don't follow too closely. When towing a trailer, even with brakes, you will need extra distance to stop. Allow for it. On long, gentle downhill grades, try to avoid downshifting. Running in a low gear (which uses the engine as a brake) can actuate the trailer's surge brakes continuously for the duration of the grade, causing them to overheat. A better procedure is to slow down before the start of the downgrade run and maintain a controlled downhill speed with repeated application and release of tow vehicle (and thus trailer) brakes. This technique permits the brakes to cool down between applications. This will help ensure reserve braking capacity in an emergency. On moderate and steep sections of road, downshifting into lower gears may be necessary and desirable to help control speed. Again, slow down before the grade and keep vehicle

31 speed under control. Do not stay on the brakes continuously because they can overheat. Don't hesitate to pull over when possible during or after severe braking situations to let everything cool down. Running a stretch of highway where you don't brake is the quickest way to cool down the brake system because a high volume of air flows thru the vented rotors and over the brake pads to cool them. It you decide that stopping capability is not what it should be: 1. Have the tow vehicle and trailer brakes checked for proper operation. 2. Review tow vehicle manufacturer's recommendations and instructions for towing. 3. If the trailer has only one set of brakes, consider adding a second set. Towing conditions, tow vehicle/trailer combinations impose many variables. Make sure your outfit is safe and that you feel comfortable with your particular circumstances before you begin your trip. Before Launching If the brakes are hot, it is a good idea to let them cool down. The sudden change in temperature when submerging very hot calipers and rotors stresses all parts and could cause damage. Upon Return Home If you have been into saltwater, flush rotors and calipers thoroughly with fresh water to minimize subsequent corrosion. Back-up Feature We offer an electrically operated valve that is mounted on the actuator and is connected to the tow vehicle back-up lights. Whenever they are energized, the valve opens and prevents pressure buildup in the system. Otherwise, you could not back up. Most trailer manufacturer's use this valve. If you try to back up and can't, check the valve. When it is energized (by shifting into reverse) you can hear a noticeable "click" sound. If you don't, check for an electrical problem. Storage Whenever you park the trailer, make sure the actuator is fully extended. This position relieves pressure on the brakes. Actuators sometimes freeze up in the compressed position from corrosion. The next time out, the brakes will drag and overheat. ROUTINE MAINTENANCE Hose Them Off If you have been in saltwater, the single most important maintenance step for disc (or drum) brakes is to flush them thoroughly with fresh water. Watch For Corrosion Light surface rust on rotors is common and not a problem as discussed elsewhere. Extremely thick, heavy rust on rotor surfaces will not allow the wheel assembly to rotate freely, resulting in heat buildup and premature wear on components. Clean or replace components as necessary. We recommend you check for rust damage at least annually. More frequently if used in very humid environments, or in saltwater. Pad Wear Pads must be replaced when 3/32" (.094") or less of the pad friction material is left. If you are not familiar with disc brake pad replacement, have this work performed by a qualified service shop. Improper pad replacement may decrease braking effectiveness, potentially causing an accident from not being able to stop the tow vehicle combination within an acceptable distance. Rotor Damage Rotors should be resurfaced by a qualified brake specialist if extreme galling or wear marks are present. Rotors must be replaced if the distance between brake surfaces becomes less than 0.882" (22.4mm) for DB-42 Model due to wear or machining. Otherwise, brake effectiveness and rotor integrity will be reduced resulting in loss of brakes. Check pad and rotor condition at least annually. Actuator and Hydraulic Line Service Follow actuator manufacturer's suggested service routine. Always be sure hydraulic fluid is clean. Be sure that fluid level is within 1/2 inch of top of reservoir. Do not fill beyond that level. Brake systems use DOT 3 hydraulic fluid. Check for leaks in the brake lines and fittings. Leaks will lead to loss of trailer braking ability. Repair or replace as necessary. Replacement Parts All replacement parts can be purchased from the trailer manufacturer or UNIQUE FUNCTIONAL PRODUCTS. Replacement pads, pistons and dust boots can also be purchased from auto part stores: YEAR MODEL Kia Sephia NOTE: Use only organic, non-metallic pads. Metallic pads will rust and depreciate rotor surface. 29

32 TWO YEAR LIMITED WARRANTY These disc brakes are guaranteed against failure attributable to rust or defects in materials and workmanship under normal use and service for a period of two years after the date of trailer purchase by the first owner. Limitations of Coverage This warranty does not cover: Normal wear and tear. Damage caused by accidents, overload, abuse, modification or improper use of product. This warranty is limited to defective parts replacement only. Charges for installing replacement parts, damage incurred to other equipment as well as incidental or consequential damages connected therewith are excluded. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to you. Repair or Replacement Procedure If a failure or defect occurs during the warranty period, promptly contact warrantor's (UFP) customer service department. Until such notice is received, warrantor will not be responsible for any repair or replacement costs. UFP, at its option, may require return of the component in question to the factory, transportation charges prepaid. UFP will replace, FREE OF CHARGE, either the entire disc brake assembly or the part that proves defective, at its option. Any part found not to be defective will be returned freight collect with an explanation. Installation of parts and adjustment of brake systems MUST be performed by a skilled brake mechanic and service manual instructions must be followed. Vehicle Identification Number (VIN) The VIN is a 17 digit number located on the trailer identification label. The label is located on the left side of the trailer. Be sure to include the VIN number in all communications with Warrantor. Purchaser's Rights This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Product Improvement UFP has a policy of continuous product improvement. We reserve the right to change or improve the design of our products without assuming an obligation to modify any product previously manufactured Sunshine Lane San Marcos, CA Fax

33 Before Towing FULTON Performance Products, Inc. P.O. Box 8 Mosinee, WI COUPLER USE, MAINTENANCE, INSTALLATION, & SERVICE INFORMATION All Fulton Couplers Meet or Exceed SAE J684 and VESC V5 Specifications DANGER 1. Check vehicle hitch, ball, and coupler for signs of wear or damage. Replace any parts that are worn or damaged before towing. Clamp hand wheel couplers hand tight only. Assure that the ball clamp is properly nested under the ball and not sitting on top of the ball. Recheck tightness again after towing. 4. Check that trailer safety chains are properly connected. 5. Check that all trailer lighting is hooked up and working correctly. 2. Know your trailer plus added load weight. Do not exceed lesser of coupler, vehicle, ball, or trailer weight ratings. Use only the ball diameter indicated on your coupler. Use of any other ball diameter will create and extremely dangerous condition which can result in separation of the coupler and ball or ball failure. 3. Be sure the coupler is secured to the hitch ball and the lock lever or hand wheel is down tight and locked. Recommended Maintenance 1. Smear ball socket and clamp face with chassis grease. Periodically oil pivot points and sliding surfaces of coupler with SAE 30 wt. motor oil. 2. When parking or storing your trailer, keep the coupler off the ground so dirt will not build up in the ball socket. Weld on Instructions Installation Instructions for Class 1 Couplers Bolt on Instructions Use 1/8" fillet weld as shown below. Use No. E6011 A.W.S. Welding Rod (AC RO DCAP) 1/8" Dia. Set machine AMPS at 105/115 with 18/22 volts. CAUTION After installation is complete, check that coupler operation has not been impaired in any way. 1. Assure coupler internal stop is butted against end of trailer tongue for maximum overlap. 2. The preferred method is to use (4) 3/8" bolts through side holes and torqued to 15/20 ft. lbs. (see illustration below) An alternate method is to use (2) 3/8" grade 5 through bolts and locknuts providing they can be torqued to at least 20 ft. lbs. without excessive deformation of the coupler or the trailer tongue. F-1937 (C-7401) 3/01 31

34 Installation Instructions for Class 2, Class 3, and 34600/34318 Class 4 Couplers Weld on Instructions Bolt on Instructions Use 1/8" fillet weld as shown below. Use No. E6011 A.W.S. Welding Rod (AC RO DCAP) 1/8" Dia. Set machine AMPS at 105/115 with 18/22 volts. CAUTION After installation is complete, check that coupler operation has not been impaired in any way. 1. Assure coupler internal stop is butted against end of trailer tongue for maximum overlap. 2. The preferred method is to use (4) 1/2" bolts through side holes and torqued to 30/35 ft. lbs. (see illustration below) An alternate method is to use (2) 1/2" grade 5 through bolts and locknuts providing they can be torqued to at least 35 ft. lbs. without excessive deformation of the coupler or the trailer tongue. DANGER If housing is deformed, replace complete coupler. Use only genuine Fulton repair kits. DANGER When assembling the coupler make sure the ball clamp is located properly onto the housing rivet as shown below for your style of coupler. Adjustment method for Fas-Lok Couplers With the assembled coupler clamped onto the correct size ball, turn the locknut down just until the spring under the locknut is fully compressed. Then back the locknut off 1/2 to one turn or just enough to enable clamping or unclamping the coupler and ball. F-1937 (C-7401) 3/01 32

35 Hubs, Bearings, Races and Seals Karavan Trailers uses the following sizes of hubs on all of its model trailers. Measurements listed are both spindle size and hub size. Hub Size Bearing, Race & Seal Size Manufacturer s Number 1-1/16 Inner & Outer Bearing 1-1/16 L /2 flange Inner & Outer Race 1-1/16 L Spring loaded dust seal (1.250 I.D O.D.) TB Dexter Torsion Axle Spring loaded dust seal (1.500 I.D O.D.) TB 1-3/8-1-1/16 Inner Bearing 1-3/8 L Bolt UHI Inner Race 1-3/8 L Brake Drums Outer Bearing 1-1/16 L Outer Race 1-1/16 L Spring loaded dust seal (1.750 I.D O.D.) TB 1-3/4-1-1/4 Inner Bearing 1-3/ Bolt UHI Inner Race 1-3/ Brake Drums Outer Bearing 1-1/4 L Outer Race 1-1/4 L Spring loaded dust seal (2.125 I.D O.D.) TB Grease Seals Inspect the grease seals periodically. A visual inspection is sufficient and is done quite easily on a trailer without brakes. It is normal to see a small oil film around the seal area. This should not hurt anything. However if the leakage becomes excessive it is time to replace the seal before too much grease escapes causing bearing failure. Replacement of the seal requires removing the complete hub assembly from the spindle. On axles with brakes you must remove the complete brake drum assembly to inspect the seals. It is very important that you check the seals on brake axles periodically to make sure they are not leaking. Leaking seals allow the grease to get on the brake linings thus causing grabby brakes. Eventually the brake linings will become saturated with grease and will have to be replaced. Karavan an s s Sure e Lube System Karavan uses a Sure Lube system on all of its axles. This system is a well accepted benefit for trailering. Under the rubber dust cap there is a grease zerk. The grease zerk presses into the hole that goes all the way through the center of the spindle and comes out by the back bearing. At that point it greases the back bearing and fills the inside of the hub. It then greases your front bearing. When you see grease come out by the castle nut, your hub and bearing are full. Advanta antages of the Sure e Lube System 1. You can grease the bearings without taking the hubs off. 2. You can change the grease in your hub and bearings by rotating the hub slowly while putting grease in, until you see new grease come out. 3. You can check your hub & grease at any time. 4. You can grease your bearing at any time on long trips. Maintenance of Sure e Lube 1. Once or twice a year (depending on usage) jack your trailer up one wheel at a time. Hold the wheel with both hands and try to rock to check for play in the bearing. If you have play then you need to adjust your castle nut (see bearing adjustment). 2. When greasing bearings look at the old grease when it comes out. If you see small silver like filings it may indicate a problem with your bearings. They should be replaced immediately. 3. It is important to use a pin the same size as the hole to make your Sure Lube system work properly. 33

36 When to Check Trailers often sit idle for extended periods of time so it is a good idea to check all of these before any use. Bearings rechecked and repacked before storage and after immersion in salt water will last longer. Check the lubricant level when the hub is warm. On boat trailers, we suggest that you check just prior to launching to be sure the hub is full of grease when the axle is submerged. Recommended Lubricant Chevron RPM Automotive LC #2 Grease is installed at the factory. Any good marine grade water-resistant grease is recommended. Different types of grease shouldn t be mixed. Bearing Repac packing Ideally, one would not have to be concerned about wheel bearings in that you would not have to get them submerged in the water when loading and unloading. This is not the case in many instances so therefore preventative maintenance is required. This type of maintenance varies so greatly because one individual may back his trailer in and out of the water 300 times a year and tow it 1,500 miles total while another individual may back his in the water six times a year but tow it 7,000 miles. Then we also have an individual that hauls his boat 30 miles, puts it in the water for the summer, and then loads it back up in the fall for the 30 mile trip home. Because of the various types of ways in which people use a trailer it becomes difficult to say every 500 miles repack your bearings of after backing in the water 10 times repack your bearings. Neither of the above can apply. About the only thing that applies is good common sense. Note the following: 1. When water gets in the bearings and is on the steel itself it will rust. So the most important part is get a good grade of wheel bearing grease that will not break down when water is mixed with it. 2. Pack the bearings by forcing the grease into all the small cavities in the bearings. Fill the cavity in the hub with grease. 3. Make sure the grease seals are in usable condition. 4. Keep the bearings and grease free of any dirt or foreign matter. 5. The wheel bearings should be repacked anytime during the year that you plan on storing the trailer for a period of time. 6. The more often you back your trailer in the water, the more chance you stand of getting water in the bearings. You should definitely be packing your bearings more often (at least twice during the season) if this is the situation. 7. Towing a trailer numerous miles has its good points and bad points. Long towings may warm the hub and grease up enough to remove any water it may have collected. However should you then back the warm hubs into the water just after a long tow they will take on water through condensation. It is therefore important that you let them cool before backing into the water. 8. Be sure the bearings are adjusted properly not too tight, or too loose. See Bearing Adjustment. Check the grease in your hubs once a year. In most instances, if a good quality lubricant is used and the lubricant levels are maintained, it may not be necessary to repack the bearings. However, should the grease appear to be contaminated or broken down, remove all of the old grease from the bearings and hubs and completely repack. Remove the rear bearing will most likely cause damage to the rear seal. A new one should be installed when reassembling. Bearing Adjustment The wheel bearings have been preadjusted at the factory. To maximize bearing life, however, we suggest that you check the bearing adjustment after the first 50 miles of use, then every time the bearings are repacked. Bearing adjustment can be checked by jacking up one side of the trailer. Grip the edge of the wheel and see if you can rock it or move it. If you have movement remove the dust cap and the cotter key. While rotating wheel tighten the spindle nut to a recommended 20 inch-pounds of torque if your trailer has 1-1/16" - 1-1/16" bearings or 30 inch-pounds if your trailer has 1-3/8" - 1-1/16" bearings. Do not over tighten. Look for the hole in the spindle through the slots in the spindle nut. If you can see any part of the hole through the slot in the nut turn the nut counterclockwise until the next slot in the nut lines up with the cross hole. Insert cotter key or new L pin. If you cannot see any portion of the hole in the spindle through the slots in the nut, turn the nut counterclockwise until the hole lines up with the first slot available in the nut. Insert cotter key or L pin. This adjustment will give you from one-thousandths to ten thousandths end play, which is in tolerance for proper adjustment. Check wheel again for the movement. If no movement, spin wheel. Wheel should turn easily and have no end play (lateral movement). Bend ends of cotter key or L pin to keep it from coming off. A large cotter pin must be used to fill the hole for the sure lube system to work properly. Position dust cover. Tap lightly on edges to start cover. Then using a screwdriver and alternating sides as you work around the dust cover, tap screwdriver with hammer until the dust cover is completely into the hub and the flange on the dust cover is tight against the hub face. Repeat on other wheels. 34

37 Lighting & Wiring ing Diagram am & Color Code Make sure that all trailer lights are in proper working order. Yellow Wire - Left Stop & Turn Green Wire - Right Stop & Turn Brown Wire - Taillights, Rear Marker Lights, Front & Rear Side Lights White Wire - Ground State and Federal regulations require all types of trailers to be equipped with tail, stop, turn and side marker lights. Trailers over 80 inches wide must have clearance and identification lights. All the necessary lights are supplied by us, the manufacturer, however it is the owner s responsibility to maintain them in good operating condition at all times. Make sure the ground wire is attached to both the trailer and towing vehicle to make a sure, positive ground. Some towing vehicles are equipped with a 4-wire taillight systems. It then becomes necessary to use a four to a three wire converter. Troubleshooting and Maintenance The Karavan electrical system is quite trouble-free especially with the use of the automotive type wire harness that we use. This eliminates shorts in the system due to bad or corroded connections. We suggest however that you use the following precautions for trouble-free trailering: 1. Disconnect the tongue harness from the towing vehicle before backing the trailer into the water. This will eliminate the bulbs from lighting while submerged in the water. Lighting submerged light bulb will cause it to burn out. (This is not necessary if your unit is equipped with waterproof taillights and rear cluster). 2. Carry a spare taillight bulb #1157, which is the large bulb in the taillight. The smaller bulb in the taillight for the sidelight is #57, and is also used in the rectangular amber sidelight. 3. Once a year remove the light lenses and spray or coat the metal components with either WD40 or CRC. A light coat of petroleum jelly also works quite well. 4. Make sure your towing vehicle s electrical system is sufficient to handle the extra load required to power your trailer lights. Check with your local automotive dealer for specifications and any options available to increase the electrical capacity. 5. In order to insure a positive ground connection between the trailer and the towing vehicle, it is important that the white ground wires are secured properly to both the trailer and the towing vehicle. A poor ground connection will cause the taillights to blink and not function properly. Load-Carrying Capacity The serial tag will show the Gross Vehicle Weight Rating (GVWR) which is the load-carrying capacity plus the weight of the trailer itself. NOTE: This trailer is equipped to meet applicable Federal safety standards. Check local and state requirements regarding brakes and any additional equipment that may be required. Any modifications or additions including load equalizing hitches, without written factory consent; usage in an abnormal manner including overloading voids all manufacturers warranties and liability. 35

38 Paint and its Care The finish on your Karavan Trailer is a powder-painted, baked finish. It is a finish, when properly maintained, should remain very eye appealing for years. Touch up paint is available in a bottle with a paint stick or a spray can. All nicks and scratches should be touched up before rusting sets in and starts to deteriorate the finish. Should the trailer become exposed to salt water or towing on salted highways we recommend that you flush it with soap and water as soon as possible. Salt is very harsh on any type of finish and deteriorates it very rapidly. Recommended Torquing Procedur ocedure e for f Mounting Wheels : Maintain proper torque on lug nuts or wheel bolts. Failure to do so may result in serious injury or property damage. 1. After dismounting old wheel, remove all dirt, rust, grease and oil from stud threads. Do not lubricate threads. 2. Position wheel on trailer. Inspect to insure full contact between mounting surface (seat pads) of wheel and mounting surface of hub or brake drum. 3. Start wheel nuts on studs. 4. Finger tighten top nut, then rotate wheel so that the number 2 nut is at top and finger tighten. Finger tighten remaining nuts in numerical (crisscross) order; always tighten nuts in top position. 5. Repeat Step 4, rotating wheel and finger tightening nuts until all nuts are snug. 6. Tighten nuts in same fashion as described in Steps 4 and 5. Nuts should be torqued to ft. lbs. Retorque nuts after 50 miles of driving and periodically thereafter. 7. After wheels (with tires) have been mounted, visually inspect to insure noninterference with body or other component parts. Be sure to inspect wheels in all possible positions (extreme turns, etc). NOTE : Check the fit of your lug wrench, an oversize wrench results in mutilated lug nuts. 36

39 Changing Tire It is desirable that you carry a jack that will work on your trailer in the event that you have a flat tire. A small board or block can also be very beneficial in the event you are jacking on soft dirt or hot asphalt. the jack (depending on style) may be placed under the side frame in back of the wheel or also under the axles. Safety Chains CAUTION: Avoid sharp turns. This could bend, create extreme stress or fracture either the coupler or the trailer tongue. The safety chains on your unit are an added insurance that it will not become detached from the towing vehicle. Your trailer hitch on the towing vehicle should have two holes or rings for fastening the safety chains, preferably one on each side of ball hitch. It is strongly recommended that you crisscross the chains under the tongue, the chain on the left side of the trailer attached to hole or ring on the right side of the ball hitch, and vice versa. This prevents the trailer tongue from dropping to the road should the coupler or ball hitch fail. The chains should be rigged as tight as possible with just enough slack to allow tight turns to be made. This can be accomplished by twisting the chain hook in a clockwise or counterclockwise direction thus twisting the link spacings and making the chain shorter. Also by keeping your chains as short as possible you prevent them from dragging on the road and wearing the chain links. NOTE: If for any reason you find it necessary to replace a safety chain, do not use or substitute any lighter weight chain than supplied with your trailer. All chain attachments such as hooks, s-hooks, etc. must be equally as strong as the chain itself. Trailer Trailer Weight GVWR in Minimum Braking Strength in Pounds Class Pounds II 1,000 to 3,500 3,500 III 3,500 to 5,000 5,000 IV 5,000 to 7, V 7,600 to 16, Tie Downs It is very important that your recreational vehicle is supported properly by the trailer. It is also important that your recreational vehicle stays positioned on the trailer while towing. This is accomplished by securing your load to the trailer by some type of tie down. 37

40 1 Bow Tie Down: Karavan Trailers offers one of the best winch post assemblies as far as adjustment and stability are concerned. However for added security, you may want to use a separate tie down to tie the bow eye both downward and also forward. This should guard against any sudden stops or starts. This also guards against winch or winch strap failure (on Boat Trailers). 2 Rear Tie Down: It is very important that the transom of your boat is resting fully and securely on the supports provided and that it remains that way while trailering. The two most common types of tie downs are the transom tie down strap or else the gunwale tie down. Either system works well and holds your boat solidly on the trailer. Places to fasten the gunwale tie downs are provided in either the light brackets or the side frame brackets (on Boat Trailers). Tires & Tire e Pressur essure The most common cause of trailer tire trouble is under-inflation. It is important therefore that you always maintain full air pressure, as indicated by the tire manufacturer on the tire s sidewalls or on the trailer manufacturer s certification label. Always check air pressure when the tires are cold, before you ve moved the trailer. Tires heat up and the air pressure increases after traveling only a short distance. When your trailer tires become worn or damaged, replace them promptly with the same type, size and capacity (not necessarily the same brand) as the original tires, For example: some trailers are not designed for use with radial tires. If the original tires on your trailer were not radials, do not replace them with radials (radials can be used as long as they have the proper carrying capacity). For safety and convenience, it is recommended that you always carry a spare wheel and tire. Check your state laws in regards to spare wheels, most states require you to carry a spare at all times. Most tire manufacturers have the air pressure molded on the tire sidewall. Listed below are the tire sizes with their respective carrying capacities and tire pressures. Bias-Ply Tires Tire Size Load Range Ply Rating Max Load lbs. Inflation P.S.I. Cold 4.80 x 8 B x 12 B x 12 C x 12 B x 12 C x 8 B x 8 C ST175/80D B ST175/80D C ST205/75D B ST205/75D C ST215/75D C ST225/75D C ST225/75D D x 16 E x 8 B x 8 B x 8 C x 8.0 x 10 C x 8.0 x 10 E Radial Tires Tire Size Load Range Ply Rating Max Load lbs. Inflation P.S.I. cold ST175/80R C ST205/75R C ST215/75R C Important Many tire manufacturers have toll free numbers, which you may call should you have a problem with one of their products. (See inside front cover). 38

41 LIMITED WARRANTY HIGHWAY / NON-HIGHWAY TIRE & WHEEL WARRANTY Carlisle Tire & Wheel Company ( Carlisle ) warrants, subject to the terms, conditions and limitations stated herein, tires & wheels to be free from defects in materials and workmanship. Carlisle s liability for tires and wheels shall be limited to replacement of any defective tire or wheel plus any applicable taxes. Carlisle s Warranty 1. The Carlisle Tire & Wheel Warranty ( Warranty ) applies only to the original purchaser for two years from the date of purchase. a) The warranty period for the coating of the wheel is ninety (90) days from the date of purchase. 2. The Warranty is void if the tire or wheel fails due to damage from improper inflation pressures, exceeding the maximum speed limit, or overloading the tire beyond the maximum load capacity stated on the sidewall. 3. The Warranty does not cover incidental or consequential damages including, but not limited to, lost time, inconvenience, loss of vehicle use, cost of towing or transportation, related property damage or consequential damages of any type or nature. 4. The Warranty does not cover mounting and balancing charges. 5. The Warranty is void if a covered tire is worn past last 3/32 of tread depth at any point on the tread contact surface. 6. The Warranty does not apply to the following: a) repaired tubes, tires or wheels b) tires or wheels used in racing and competition c) tires or wheels subjected to road hazards, overloading, underinflation, improper mounting, fitment to incorrect rim, purposeful abuse or chemical contamination d) tires or wheels which have been patched, unplugged or repaired or into which liquid balancers or sealants have been introduced e) cosmetic irregularities 7. Carlisle makes no expressed claims of expected tire wear. Variables that affect tire wear are driving conditions, load and tire inflation pressure. To obtain warranty adjustments or warranty information contact your Carlisle dealer or call Carlisle s Product Services Department at or fax to Claims must be made within 30 days of discovery of irregularity. Carlisle reserves the right to inspect all products before making adjustments. THERE ARE NO WARRANTIES EITHER EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. CARLISLE SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUEN- TIAL DAMAGES. NO REPRESENTATIVE OF CARLISLE TIRE & WHEEL COMPANY HAS AUTHORITY TO MAKE ANY REPRESEN- TATIONS OR PROMISES EXCEPT AS STATED HEREIN. Some states do not permit limitations on the period of time an implied warranty lasts and do not permit the exclusion of limitation of incidental or consequential damages, thereof, the above limitations or exclusions may not apply. This warranty provides specified legal rights. Other rights may vary from state/province to state/province. NOTE: All specifications subject to change without notice. Rev. 4/01 Carlisle Tire & Wheel Company 25Windham Boulevard Aiken, South Carolina THE LOADSTAR WORRY FREE WARRANTY FOR HIGH SPEED TRAILER TIRES Eligibility You are eligible for the benefits of this policy if you are the owner and original consumer of new LOADSTAR tires, bearing Dept. of Transportation prescribed tire identification numbers, only on the vehicle on which they were originally installed according to the vehicle manufacturer s or LOADSTAR recommendations. What is Warranted and for How Long Your tires are warranted against failures due to defective materials and workmanship. (A) Tires are eligible for warranty if presented not more than four years past manufacturing date and has a minimum of 2/32nd" tread remaining. (B) Free Replacement For (Bias or Bias/Belted) High Speed Trailer Tires. If a LOADSTAR tire fails due to defective materials or workmanship during the first 10 % of treadwear, or the first year, the tire will be replaced with a new comparable LOADSTAR tire without charge. (C) Treadwear Prorated Replacement. Tires not qualifying for free replacement will be replaced with a new, comparable tire based upon the percentage of tread that has been worn. The price you pay will equal the percentage of original, usable tread worn, multiplied by our then current Predetermined Adjustment Price. Owner pays mounting charge. Definition of Comparable Tire A comparable new LOADSTAR tire may either be the same line of tire, or, in the event the disabled tire is out of production or unavailable, the same basic or equal construction and quality with different sidewall or treadwear configuration. If a higher priced tire is accepted as replacement, the difference in price will be paid by the owner. Computing Treadwear Treadwear is computed as a percentage of the original, usable tread. The original, usable tread does not include the last 2/32nd inch of tread depth. What is Not Covered By The Warranty Failure due to fire, accident, malicious mischief, improper inflation, improper use, running flat, overloading or road hazards. Examples of road hazards include nails, glass and other foreign objects and natural and man-made defects or obstacles such as excavations, construction, potholes and chuckholes. Damages caused by road hazards include cuts, snags, punctures, scuffs, carcass bruises and impact breaks. Premature or irregular wear due to improper inflation or alignment or balance. Tires presented by other than the original consumer. 39

42 Tires with weather cracking which were purchased more than (4) four years prior to presentation for adjustment. If you have no proof of purchase date, tires manufactured (4) four years prior to presentation are not covered. Loss of time, inconvenience, loss of use of the vehicle, costs of towing or transportation, or consequential damages of any type or nature. Any implied warranty, including merchantability or fitness, is limited to the duration of this written warrenty or (4) years, whichever is less. Balancing or mounting charges. *NOTE: This limited warranty is the entire warranty given by LOADSTAR and LOADSTAR s complete obligation is as set forth herein. No one has authority to imply, suggest, agree, represent, warrant or promise contrary to the terms hereof. Owner s Obligation You must present the tire to any LOADSTAR Tire Distributor or participating dealer in the U.S.A. To obtain no charge adjustment for tires, you must present proof of purchase date (such as trailer dealer or tire retailer invoice). You are responsible for payment of all taxes, as well as retailer charges for services that you request but are not covered by the warranty. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. NOTE: Some states do not allow the exclusion or limitation of incidental or consequential damage or how long an implied warranty lasts, so the limitations or exclusion may not apply to you. Adjustment Procedures Unserviceable LOADSTAR tires adjustable under the terms of this policy should be returned to a LOADSTAR tire Distributor. 1.) Check National Distributor Directory for the nearest LOASTAR Tire Distributor. Call the nearest distributor. They can tell you where the nearest dealer would be located. 2.) Call 1-(800) , 9AM-5PM weekdays for the nearest distributor. If There is No LOADSTAR Tire Dealer Available 1.) Purchase a tire of like quality and price. 2.) Return the LOADSTAR tire to the nearest distribution center, UPS. collect. 3.) IMPORTANT You Must include the following: A.) Invoice for replacement 40 B.) Original invoice C.) Current information Name: _ Address: Phone Number: Date Tire Removed: Reason Removed: _ Trailer Make: Model : Year: 4.) Fill out this information and tape securely to the tire along with a mailing label addressed to the distributor. 5.) When the LOADSTAR Distributor receives the tire he will examine it, adjust it under the terms of the LOAD- STAR warranty and send you a complete explanation and check (if applicable). Important Safety Information Any tire, no matter how well constructed, may fail due to improper maintenance or service factors, creating a risk of property damage and serious or fatal injury. For your safety, comply with the following: 1.) Check air pressure monthly when tires are cold. Use an accurate tire air pressure gauge. Do not reduce pressure when tires are hot. Proper inflation is essential. Underinflation produces flexing of sidewalls and builds up heat to the point that premature tire failure may occur. Overinflation can cause the tire to be more susceptible to impact damage. 2.) Never overload your tires. The maximum load capacity and maximum inflation pressure are molded into the sidewall of your tire. Overloading builds up excessive heat and can lead to early tire failure. 3.) Avoid damaging objects (chuckholes, glass, rocks, curbs, etc.) which may cause internal tire damage. Continued use of a tire that has suffered internal damage, which may not be visible externally, can lead to dangerous tire failure. Determination of internal damage will require dismounting of the tire and examination by trained tire personnel. 4.) Property damage and serious or fatal injury can also result from the following causes: Improper tire mounting and inflation procedures may cause the tire beads to break with explosive force during installation of the tire on the rim. Tire and rim must match in size. Rim parts must match by manufacturer s design. Clean rim. Lubricate rim and beads. Do not exceed the maximum recommended pressure to seat the beads. ONLY SPECIALLY TRAINED PERSONS SHOULD MOUNT TIRES. Use of worn out tires (less than 2/32nd" remaining tread depth) increases the probability of tire failure. Excessive speed creates heat buildup in a tire, leading to possible tire failure.

43 Towing Your Trailer Caution! Check the following items each time before towing trailer. 1. Be sure all parts, bolts and nuts are tight. 6. Do not exceed trailer capacity. 2. Secure load to trailer with BIA approved 7. Be sure all lights are operating and are disconnected tiedowns. before backing into water. 3. Check tire pressure when tire is cold. Check 8. Coupling ball - make sure you are using the size and adjust wheel bearings if necessary after marked on the trailer coupling and coupling must be first 50 miles of use. securely latched to the ball. 4. Inspect and repack wheel bearings at least 9. Cross safety chains under tongue and secure to twice a year and before storing. towing vehicle. 5. Check that the Bed Locking Pin is in place. 10. Check brake operation. Launching While you are waiting for your turn at the ramp, you should prepare your boat for launching. Attach a bow line to your boat and detach trailer tie-downs. If your boat is an outboard or stern drive, tilt up the lower unit. To avoid flooding and swamping your boat, before launching be sure the hull drain plug is in place and tight. Back Trailer to the Ramp Have someone stand to one side of the ramp to direct you. Backing up a trailer can be tricky. A good way to simplify the procedure is to grasp the steering wheel with one hand at its lowest point (at 6 o clock). When you want the trailer to go right, move your hand on the wheel to the right; to make the trailer go left, move your hand to the left. Launching Back your trailer into the water until the front step of fender is at water level. This is a water level guide, which you can use on most ramps, however on extremely flat ramps you will want to back in further. On steeper ramps you will not want to back in as far. The other controlling factor is the style boat you have. Experimenting at this point will give you the best conditions for launching and loading your boat. Set parking brake and gear shift. Unlock winch and push boat slowly but firmly off the trailer into the water. Be sure you (or your partner) have a firm hold on the bow line. A more controlled launching can be achieved by letting you boat roll off the trailer with the winch rope attached. This is a slower process of unloading but is definitely more controlled. Loading your y Boat Again, back the trailer into the water following the same instructions as just stated for launching. 1. Prepare your boat for winching on the trailer. Bring your boat over to the trailer with the mooring rope. With the winch in the neutral lock position grab the winch rope and unwind the winch, Hook winch rope into eyelet on boat. Place winch latch into lock position for cranking boat on trailer. Winch slowly at first giving the boat time to swing around into position. This is necessary especially with a cross-current or cross wind. Crank boat completely onto trailer. Hook bow eye safety chain. 2. Some boaters prefer to drive their boats on the trailer. One thing to keep in mind is that you should not back into the water too deep. If you are in too deep the trailer looses all of its centering capabilities because your boat is floating on the water above the trailer. Loading your unit several times will give you a better feel for the depth to back your trailer in. Drive your boat on carefully and try to hit the center of the trailer as much as possible. If you do not hit the center of the trailer, just keep slight pressure on the boat at slow throttle and drive the boat like you would a car. If you do not hit the center of the trailer, turn your boat so the front will go to the right, reverse the procedure if you are to the left of center. Keep turning until you feel the boat slide or drop into the center. Line the front of the boat up so it is headed right into the bow stop on the winch stand, adjusting it by turning the rear of your boat like a car. 41

44 FULTON Performance Products Marine Trailer Jack Owner s Manual Read and understand all instructions before installing and/or using product. NEVER allow anyone unfamiliar with the operating instructions to use this product. Read and understand all instructions provided by the manufacturer of the products(s) that this jack will be installed on. Installation of these Fulton jacks must conform to the following mounting instructions only. Fulton is not responsible for accidents, occurrences, injuries and losses to or of any person or property wherever which arises as a result of Purchaser s alterations, modifications, assembly, reassembly, or installation of this product. When cranking jack or coupling trailer, secure trailer from rolling. These jacks are designed for vertical loading, excessive side forces must be avoided Refer to product to obtain rated capacity. If uncertain contact Fulton Performance Products. These jacks are designed for mounting to square or rectangular trailers only. Theses jacks are not intended for mounting to trailers with round tongues. Assure the correct mounting hole pattern is for your trailer tongue size. The gap between the mounting bolts and the trailer tongue is not to exceed 1/16" In both the vertical and horizontal positions, the plunger must be positioned in the detent hole in the mounting bracket. When manually moving trailer over rough or unpaved surfaces, crank to lowest practical position to minimize bending stress on jack. Operator use caution never to position any part of your body under any portion of the jack or the load being supported. Disregard could cause property damage and/or serious bodily injury. Inspect snap ring groove and remove any coating or foreign material from the groove before inserting snap ring. Make sure snap ring is properly seated in the groove before each use. Make certain that the plunger pin is properly locked into the detent hole in the mounting bracket before raising of lowering the trailer tongue. When manually moving trailer over rough or unpaved surfaces, crank to lowest practical position to minimize bending stress on jack. Do not attempt to weld bolt-on brackets or straps to the trailer. These items are zinc plated and will emit toxic fumes when welded. Special brackets are available for weld-on applications. Failure to follow these warnings and instructions may result in property damage and/or serious bodily injury. MOUNTING INSTRUCTIONS Before mounting your trailer jack, check for interference from recessed ball mounts, trailer coupler, hitch or hitchplates and/or vehicle bumper. Rotate the jack handle to check that the swing is not obstructed. If the jack is of the swing-away or swivel design, check the unit in both vertical and horizontal positions. When the swing-away jack is in the horizontal or storage position, there should not be any interference from structural members of the trailer or trailer coupler. On all jacks check that proper ground clearance has been achieved and will not contact the towing vehicle when in a tight turn. If the jack is not installed correctly, any interference (steep inclines, angled turns etc.) may cause non-repairable damage to the jack and/or trailer. After installation is complete, check that jack operation has not been impaired in any way. Bolt-On Mounting Instructions (Fig 1 - Illustration shown is for a 3" or 4" high trailer frame. If trailer has a 5" frame, mount bracket rotated 90 degrees) 1) Place the jack against the trailer tongue and positions the mounting straps (A) on the opposite side of the tongue. Place the straps so the flat side is against the tongue. Make sure the holes in the bracket and straps are in line. 2) Insert the four bolts (B) through the bracket and straps (two bolts on the top of the tongue and two below the tongue). Position the jack so the at the top bolts rest directly on the top of the tongue and the bottom bolts are as close to the tongue as possible. The gap between the mounting bolts and the trailer tongue is not to exceed 1/16". 3) Secure with locknuts (C). Torque the nuts to 25 ft-lbs. 4) Check for clearance of handle swing, trailer light cables, and coupler clearance. Weld-On Mounting Instructions - Fig 2 (Bracket shown is a snap ring style. Bolt-thru style will be orientated and welded the same.) 1) All welding operations must be performed by an AWS certified welder. 2) Place the weld-on mounting plate, Item #27 or #44, against the trailer tongue with the flange locating against the bottom and weld as shown in Fig 2, using four 1" long, 3/16" fillet welds. 3) Snap Ring Style - Assemble the jack to the mounting plate by placing the jack over the grooved extruded opening on the mounting plate. Fasten by placing the snap ring into the groove. Make certain that the snap ring is properly seated in the groove. 4) Bolt-thru Style - Assemble the jack to the mounting plate by placing the jack into the recessed opening on the mounting plate. Insert the bushing, Item #41, through the jack mounting bracket and tighten the locknut, Item #42, until there is no movement in the bushing. 5) Check for clearance of handle swing, trailer light cables, and coupler. 42

45 ASSEMBLY INSTRUCTIONS Handle Assembly - Fig 3 - Place one spacer over the 3/8" x 4.25" bolt. Lightly grease split tube spacer, then place the bolt and tube spacer assembly through the split tube spacer. then place the bolt and spacers through the roller. Insert the bolt through the handle. Install the 3/8" locknut onto the bolt and tighten. Adjust the nut so that the bolt no longer turns freely. A minimum of two full bolt threads must be visibly extend through the nut. Caster Wheel Assembly - Grease the outside of the wheel spacer, Item #19, using a standard automotive grease, and insert it into the wheel, Item #18. Place the wheel and spacer into the yoke and align the holes in th wheel with the holes in the yoke. Insert the 1/2" x 3" bolt, Item #20, through both sides of the yoke. Make sure the threads of the bolt are to the outside of the yoke when the yoke hangs down in the trailering position. Install the 1/2" locknut, Item #21, and tighten until yoke is just tight enough against the metal spacer to keep the spacer from rotating. Do not over-tighten, this can cause spacer deformation and binding of the wheel. The wheel must still spin freely. OPERATING INSTRUCTIONS Rotate the jack handle clockwise to raise,or counter-clockwise to lower the jack. NOTE: If the caster wheel does not have ground contact, it is necessary to keep the caster from rotating when cranking the jack handle. SWING-AWAY SWIVEL JACK OPERATION This style jack is designed to be swiveled into a horizontal or storage position (see Fig. 4) In both the vertical and horizontal positions, the plunger must be securely in position in the mating hole in the mounting bracket. To place the jack into the horizontal position allow about 2" of ground clearance beneath the footplate or caster wheel. Pull the plunger pin out of the opening and swivel the jack. Rotate either left or right until the plunger pin snaps into the proper mounting bracket hole. NOTE: To avoid damaging the handle while trailering in the horizontal position, secure the handle to the jack with a bungee cord or a rope. To return jack to the vertical position, pull the plunger pin out of the hole and rotate to the vertical or lifting position. At this point, the jack can be pulled or pushed until the plunger pin snaps into the mating hole in the mounting bracket. MAINTENANCE The internal gearing and bearing of the jack must be kept lubricated. Using a needle nose applicator, pump a small amount of automotive grease through the lubrication opening. The lubrication opening can be found on the side of the jack tube, right above the support plate (see Fig. 5). Rotate the jack handle to distribute the grease evenly. Lightly grease the inner tube of the jack using the same type of grease. A light weight oil must be applied to the handle unit at both sides of the tube. The axle bolt and nut assembly of the caster wheel must also be lubricated with the same light weight oil. HOW TO ORDER PARTS Always replace broken, bent or worn parts before using this product. Use only Fulton Performance Products parts or parts of equal quality for repair. Replacement parts are available through Fulton Performance Products Customer Service Dept., Please specify product model number, name of parts, and part number. LIMITED WARRANTY Fulton products are warranted to the original consumer purchaser to be free from defects in material and workmanship under normal use and service, ordinary wear and tear expected, for a period of three (3) years from date of purchase as shown on customer s receipt. This warranty shall not apply to any defects caused by: (I) physical abuse of goods or any components or acts of vandalism by any persons other than Fulton, it s employees, agents, or subcontractors; (II) alterations, modifications, additions, or repairs made during the applicable warranty period by anyone other than Fulton employees, agents or subcontractors; (III) improper installation or use contrary to Fulton s instruction; or (IV) accidents or damage resulting from fire, water, wind, hail, lightning, electrical surge or failure, earthquake, theft or similar causes or contributed to by the negligence of Fulton or it s employees, agents, or subcontractors. FULTON Performance Products 50 Indianhead Dr., P.O. Box 8 Mosinee, WI / / FAX 715/ fulton@fultonperformance.com F2512 (K-7570) 7/01 43

46 : Fishtailing caused from improper tongue weight on the tow vehicle hitch ball can cause loss of control of the tow vehicle and result in serious injury or property damage. Weight Distrib ibution Establishing a trailer with the proper GVWR is very important. But once that has been established and you have the load on the trailer it is equally important that you have the proper distribution of the weight on the trailer. By that we mean you should have 5 to 10% of the total weight of your loaded trailer on the hitch coupler which is called tongue weight. This should be checked when the tongue is parallel to the ground. A bathroom scale can be used to determine this, or go to a truck scale. EXAMPLE: The gross vehicle weight of trailer and load is 2,000 pounds. The tongue weight should not be less than 100 pounds nor more than 200 lbs. Too light of tongue weight can cause the trailer to fishtail (sway from side to side) as you travel down the highway. this creates excessive strains on the towing vehicle, hitch and also the trailer itself. It can very easily cause an accident. To adjust for too light tongue weight the axle/axles must be moved backward on the trailer allowing more weight to be carried on the tongue. This is accomplished by loosening the U-bolts on most models. Adjustments should be made until the tongue weight falls within the 5 to 10% recommended range. If only a slight weight adjustment is required it s possible you may be able to move gear to compensate the difference. Some towing vehicles require less tongue weight than others. The 5 to 10% guide lines will hold quite true to form until you get into larger size loads anywhere from 4,000 pounds on up. At this point it becomes necessary to strike a happy medium of sufficient tongue wight to tow properly and yet not too much tongue weight as to create undue stress on the towing vehicle, hitch and hitch coupler. Check hitch rating to be sure of it s capacity or when buying a hitch make sure it will carry the load. The weight-distribution hitch may be recommended to you by the dealer for heavier units. If this type system is installed all responsibilities will become those of the owner of the unit, not those of Karavan Trailers, Inc. Listed are several items you must consider should you install this type system. First off, make sure they are installed properly. Care should be used so that they are not overloaded to the point the undue strain is applied to both the trailer and towing vehicle. This type system dampens the action of the surge hydraulic brake systems thus causing the brakes either not to be applied as soon as possible or may cause them to be partially applied at all times especially when being towed. This leads to overheated brakes plus excessive brake shoe wear. It may also lead to bearing failures because the heat build up will disintegrate the grease in the bearings. Wheel Size Karavan uses different wheel sizes on its trailer line as listed in the chart below. Spare wheels may be purchased from Karavan dealer or else an automotive supply house with the given information. Read the numbers from the tire and count lug bolts to determine rim size. Rim Size (inches) No Of Studs Bolt Circle Diameter Common Automotive (inches) Rim /2 Ford, Chrysler /2 Ford, Chrysler /2 Ford, Chrysler /2 Ford, Chrysler /2 Ford, Chrysler 15 5 & 6 5-1/2 Ford, Chrysler 16 6 Ford, Chrysler 16.5 x /2 Ford, Chrysler Winch h and Winch h Post P Assembly y for f Boat Trailers The winch post assembly on your trailer is very easily adjusted up and down and front and rear on the trailer. Once the boat is positioned on the trailer as desired the winch post assembly should be adjusted so the rubber bow stop is located just above the bow eye on the boat. The rope, strap or cable will then run below the bow stop when loading and unloading the boat. When the boat is pulled on the trailer against the bow stop, the bow eye will be held securely directly under the bow stop, thus keeping your boat from moving forward or backward especially when the brakes are applied suddenly. Make sure the bow eye safety chain is hooked in the bow eye at all times except when loading or unloading. 44

47 FULTON Performance Products, Inc. Marine Trailer Winch Owner s Manual Always inspect the strap, rope, or cable, and hook before each use. Never use strap, rope, or cable that is worn, frayed, or kinked. Never let anyone stand in or behind a boat while pulling with the winch. Do not stand near the winch strap, rope, or cable, because it can whip violently if it should break. Read and understand all instructions before using product. NEVER allow anyone unfamiliar with the operating instructions to use this product. Winches are not designed to secure boats to trailers while towing. Boat tie downs should be used for this purpose. If you cannot crank the winch with one hand, you are probably overloading the winch! High forces may be created by the use of a winch thereby creating potential safety hazards. Never let go of the handle until you are sure the ratchet pawl is properly set and supporting the load. If not, the handle can spin dangerously backwards. A clicking ratchet pawl when lowering the load will not support the load. Winches that are equipped with a two way ratchet pawl system allow the convenience of bringing the line or strap onto either the top or bottom of the winch drum. IN NO CASE WILL THE RATCHET PAWL SYSTEM HOLD THE LOAD WHEN IT IS BEING LET OUT OR LOWERED. This winch is not designed to be a human or equipment hoist and should never be operated when there are persons positioned on or under the load being moved. The cable keeper or rope threading alone will not support the load. Never let the cable or rope all the way out. Always keep a minimum of three complete wraps of the cable or rope around the drum hub. On two speed winches make sure that the ratchet pawl is properly engaged to hold the load before attempting to change gears. Failure to follow these instructions may result in serious injury and/or property damage. WINCH APPLICATIONS All Fulton Trailer Winches meet or exceed SAE Standard J1853. Fulton trailer winches are designed for use on boat trailers. To insure safer boat loading: The rated load capacity of the winch should be at least equal to two times the maximum pull on the winch strap, rope, or cable required to load the boat on the trailer. A general guide is for the winch rating to equal the total boat weight, including equipment. The breaking strength of the strap, rope, or cable should be at least 1 1/2 times the winch rating. Breaking strengths of the hook should be 1 1/2 times the breaking strength of the strap or rope and 1 1/4 times the breaking strength of the cable. Single Speed Winches Easy to use one way ratchet pawl on T600, T900, and P1200 allows free wheeling in the OFF position. A convenient two way ratchet pawl on the T1100, T1300, T1500, T1602, T1801, and T1802 offers the option of wrapping the line on the drum from either direction. (See the above warnings.) Two Speed Winches Larger boats load easily with Fulton two speed winches. One speed is for quick pull, and the other speed pulls heavy loads with less effort. Fulton two speed winches allow changing speeds without removing the handle, except for the T3700. Lift the shift lock lever and move the handle in or out to change speeds. When in the neutral position, the T3700 must have the crank handle disengaged. Free wheeling line play-out without a spinning handle makes for safer operation. Optional hand brake may be purchased separately and can be installed after the winch is mounted. (the hand brake is standard on T2605B and T3700 models.) OPERATING INSTRUCTIONS Single Speed Winches To pull line off: First place the ratchet pawl in the reverse or neutral position. To pull line off the winch, extreme caution must be exercised. Be certain that all persons and objects are clear of the area to insure that the will not be struck and injured by a spinning winch handle as you pull line off the winch. To pull line/load in: First, ALWAYS ENGAGE THE RATCHET PAWL IN THE HOLD POSITION, on the T1100, T1300, T1500 this is done by aligning the engage arrow on the ratchet lever with the alignment marks on the frame. Before moving a load, make sure that the ratchet pawl snaps into engagement. Now turn the handle in the appropriate direction. When turning the handle you should always hear a clicking sound indicating the ratchet pawl is working properly. IF THE CLICKING SOUND SHOULD EVER STOP, DO NOT LET GO OF THE HANDLE BECAUSE THE HANDLE CAN SPIN DANGEROUSLY BACKWARDS. Lower or move the load to a safe resting place before letting go of the handle. To let line/load in: First, take a firm grip of the handle, then push the ratchet pawl to the reverse or neutral position. You may have to turn the handle slightly (pull line in) to free the ratchet pawl. Keep a firm grip on the handle and turn slowly. Never let go of the handle when letting out or lowering a load. If you want to stop and rest, always engage the ratchet pawl first, then let go of the handle gradually to make sure the ratchet pawl is holding the load. A clicking ratchet pawl when letting line/load out will not support the load. 45

48 Two Speed Winches Fulton two speed winches, model numbers T T3205 change gear ratios by sliding the gear input shaft. The T3700 winch changes gear ratios by changing the handle to a different input shaft. When changing gears on the T T3205, make sure that the ratchet pawl is properly engaged to hold the load before attempting to change gears. After the input shaft has been shifted to obtain the desired gear ratio, make sure the shift lock lever is firmly in place in the groove on the input shaft before operating the winch. To pull line off: For model numbers T T3205, shift input shaft to neutral position and engage shift lock when pulling line off drum. Place the ratchet pawl in the neutral position to pull line off the winch. For T3700, push in the handle lock clip and slide the handle until lock clip snaps into the outer groove in the pinion shaft. Check position by turning handle to make sure the shaft does not turn with the handle. To pull line/load in: Follow the instructions for single speed winches. Note on the T3700, reengage the handle so that the lock clip snaps into the inner groove of the selected pinion shaft. Hand Brake Operation For two speed winches equipped with the optional hand brake, when lowering a load you can push down on the hand brake lever and this will help let the line out more smoothly. This will reduce the effort required on the winch handle when letting line out, but NEVER let go of the winch handle. IN AN EMERGENCY, if the handle does spin backward, NEVER try to grab the handle. MAINTENANCE The spur gears should have a film of grease on them at all times. Maintain a film of grease on outside diameter of drum spacer or drum support bolt for extended service life. Maintain a few drops of automotive engine oil on ratchet pawl mechanism and bushings for extended service life. The ratchet pawl mechanism must be clean and free of dirt, paint, ice, etc., as these conditions will prevent the ratchet pawl from operating properly. Use only Fulton Performance Products parts or parts of equal quality for repair. Call (715) to obtain Fulton Performance Products parts. LIMITED WARRANTY Fulton products are warranted to the original consumer/purchaser to be free from defects in material and workmanship under normal use and service, ordinary wear and tear excepted, for a period of three (3) years from date of purchase as shown on customer s receipt. This warranty shall not apply to any defects caused by: (I) physical abuse of goods or any component or acts of vandalism by any persons other than Fulton, its employees, agents, or subcontractors; (II) alterations, modifications, additions, or repairs made during the applicable warranty period by anyone other that Fulton employees, agents or subcontractors; (III) improper installation or use contrary to Fulton s instruction; or (IV) accidents or damage resulting form fire, water, wind, hail, lightning, electrical surge or failure, earthquake, theft or similar causes not caused or contributed to by the negligence of Fulton or it s employees, agents, or subcontractors. 46

49 *1 - Capacity Rating - Based on direct lift on first layer of line on the drum. Capacity is reduced as line builds up on the drum. *2 - Maximum Mechanical Advantage - Based on first layer of recommended line on the drum. For maximum efficiency use only the amount of line required. *3 - Only winches that are designed to accommodate steel cable should use steel cable. Cable keeper kits are included with the winches specifying steel cable. *4 - Brake kit 1619 available as option - not furnished. Due to our continuing efforts to improve Fulton products, product design and specifications are subject to change without notice. The winch stand must be of adequate strength, and equal size to the base of the winch frame. Use three 3/8 diameter hardened bolts in the slots of the base. Flat washers should be used under the heads of the bolts. Install cable, strap or rope onto the drum in such a way that the ratchet pawl is operating (clicking) as the line is being wound onto the winch. Only winches that are designed to accommodate steel cable should be used with steel cable. INSTALLATION INSTRUCTIONS STRAP Fulton winches have the drums drilled for a strap cross bolt when using strapping (See Fig. 1). A hardened bolt, grade 5 or better, s recommended for strap mounting. Tighten the nut just to where end play in bolt is taken up. Overtightening can deform drum. For winches having a strap anchor included, pass the strap loop under cross bolt, insert strap anchor, then pull tight (See Fig. 2). ROPE Attaching rope to the winch drum requires no bolts, nuts, or rope keepers. Two ways of threading the rope through the drum side are shown (See Fig. 3). Maintain at least three complete wraps of rope around drum hub when under load. CABLE Pass cable through the hole in the drum side. Wrap cable around the drum hub one turn. Continue inserting cable one inch past clap location. Place keeper (clamp) washers and nuts on the outside of the drum (see Fig. 3). Top entry shown, bottom entry would be opposite. Maintain at least three complete wraps of the cable around drum hub when under load. 47

50 TRAILER WARRANTY LIMITED WARRANTY PRE DELIVERY SERVICE Damage to any trailer components may occur during transporting to the dealer. Normally, any defect or damage occurring during assembly or in loading is detected and corrected at the factory during the inspection process. The dealer will repair any uncorrected factory defects or transit damage before the trailer is delivered to you. This warranty does not cover alteration of the trailer, or failure caused by such alteration. Karavan Trailers and Distributor/Dealers reserve the right to make trailer modifications or changes at anytime without incurring any obligation to make the same changes on trailers previously built and/or sold by them. WARRANTY PRE-AUTHORIZATION All warranty returns must be approved by Karavan s customer service representative. Only original production parts installed by Karavan Trailers will be accepted for warranty consideration. Any parts returned other than parts used in Karavan production will be returned to customer at customer s expense. YOUR LEGAL RIGHTS UNDER KARAVAN S LIMITED WARRANTIES All Karavan limited warranties are the only expressed written warranties made by Karavan applicable to Karavan Trailers. These limited warranties give you specific legal rights and you may also have other rights which will vary from state to state. Depending on the state in which your trailer is registered you may have some implied warranties. These implied warranties are limited, to the extent allowed by law, for the time period covered by Karavan Trailers written warranties. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you. SUBSEQUENT BUYER/OWNER The Karavan Trailer warranty is only extended to the first buyer/owner of the trailer. This is defined as the first legal owner of the Karavan Trailer other than an authorized distributor or dealer who has brought the trailer from Karavan for resale to the public. WARRANTY INFORMATION If you experience any difficulties or defects with parts of the trailer please look for the manufacturers name on the part and contact them directly. The following is a list of Karavan s current vendors from whom parts are purchased. Vendor Phone # Part Buchanan Industries Blue Rollers, Endcaps, Keel Pads CH Yates Rubber Rollers Fulton/Wesbar Lights, Wire Harness, Actuators, Brakes, Couplers, Winches, Jacks Tie Down Engineering Actuator, Hubs UFP Hubs, Brake Drums, Actuators, Disc Brakes SST Bearing Bearings & Seals Atwood Mobile Actuators, Brakes Rockwell American Springs Global Advantage Safety Chains Dexter Torsion Axles Carlisle Tires Kenda Tires Nankang Tires 48

51 PLACE STAMP HERE KARAVAN TRAILERS P.O. BOX 27 FOX LAKE, WISCONSIN