Premier Manufacturing Co. 536BK Operating manual

IMPORTANT
Read these instructions completely before installing, using or
attempting to repair this product. If you have any questions,
call Premier at [phone] or [phone].
Installation, Inspection, Operation
& Maintenance Guide
MANUFACTURING CO.
THE FIRST NAME IN QUALITY COUPLINGS
Model 536BK
Front End Assembly

premier manufacturing company 1-800-255-5387 • www.premier-mfg.com
Page 2
Selecting The Right Equipment
Step 4: Browse Premier Product Catalog
Step 3: Considering Operating Conditions and Environments
Step 2: Determine “Tongue Weight Capacity”
Step 1: Determine “Gross Trailer(s) Weight”
Whatever your application, selecting the proper equipment for the job is very important. Proper selection along
with regular inspection and maintenance will help keep operating costs minimal while providing long life to each
component. Below are general guidelines for selecting Premier Couplings and Drawbar Eyes. If you feel that your
application is unique, please give Premier a call so that we may help you through the selection process.
Follow these four steps to ensure proper selection of Premier Couplings and Drawbar Eyes.
Step 2:
Determine “Tongue
Weight Capacity”
(Maximum occurring tongue weight)
Step 3:
Add Margin of Safety
(Dependent upon your equipment
and operating environment)
Step 4:
Browse Premier
Product Catalog
(Based on Steps 1 - 3)
Step 1:
Determine “Gross
Trailer(s) Weight”
(GVWR(s) of towed trailers)
“Gross Trailer(s) Weight” is usually determined by the Gross Vehicle Weight Rating (GVWR). This information is
attached to the trailer by the trailer manufacturer.
For “Double Trailer” configurations, only the rear trailer is considered
when selecting your Premier Coupling or Drawbar Eye. In this example, a
Coupling and Drawbar Eye with a “Gross Trailer Weight” rating of 40,000 lbs.
(18,143 kg) would be the minimum rating acceptable for normal, over-the-
road applications (see Tongue Weight section below).
For “Triple Trailers”, only the two most rearward trailers are
considered in selecting your Premier Coupling or Drawbar Eye.
In this example, a Coupling and Drawbar Eye with a “Gross
Trailer Weight” rating of 80,000 lbs. (36,287 kg) would be the
minimum acceptable for normal, over-the-road applications
(see Tongue Weight section below).
Double Trailer Configuration
Triple Trailer Configuration
Example only, each application may vary and should be considered unique.
Example only, each application may vary and should be considered unique.
40,000 LBS 40,000 LBS
40,000 LBS
Environments such as rough uneven roads or off-road use can dramatically increase shock loads to both drawbar
eyes and couplings. In general, increasing the “Gross Trailer Weight” (Step 1:) and “Tongue Weight Capacity”
(Step 2:) by a minimum of 25% will be sufficient for many applications. Even if an application is used off-road
occasionally, the minimum increase necessary for Gross Trailer and Tongue Weight is 25%. Certain types of
equipment and/or operating practices can also dramatically increase loads through equipment binding and/or
improper loading practices. Of special concern is high tongue weight. However, each application is unique and
every environment different, therefore your application may require more than 25%.
Once both “Gross Trailers(s) Weight” (Step 1:) and “Tongue Weight Capacity” (Step 2:) have been determined,
evaluate your operating conditions and apply an appropriate margin of safety.
Browse the Premier Product Catalog and refer to the “Specifications” section of each product. Be sure to review
the “Understanding Premier Load Specifications” section and “Coupling to Drawbar Eye Cross-Reference” sheet
on the next couple pages.
“Tongue Weight Capacity” is the maximum expected weight at
the drawbar eye. If a hinged drawbar is used, the maximum weight
will be approximately 1/2 the overall drawbar weight. If a non-hinged
drawbar is used and the actual tongue weight is not known, you can
approximate the weight by multiplying the GVWR of the towed trailer
by 15%. However, each application is unique and the best practice is
to weigh the tongue when the trailer is loaded to its GVWR.

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premier manufacturing company Page 3
SAMPLE ONLY
Selecting The Right Equipment
Importance of Inspection and Maintenance
Understanding Premier Load Specifications
Weight of Trailer(s) being towed
(see “Selecting Premier Couplings &
Drawbar Eyes”).
Maximum occurring tongue
weight. Static as well as
dynamic loads.
Maximum load on latch
or upper coupling surface
containing drawbar eye.
Latches and upper coupling
surfaces are not designed
for sustained load at this
stated capacity.
The largest x-section in
eyelet portion of eye. Used to
determine compatibility
with coupling.
Minimum inside diameter
of eyelet portion of eye.
Used to determine
compatibility with coupling.
Weight of unit or pair of
units without accessories.
Each Premier product undergoes extensive design and testing prior to being introduced. We use the latest in
Computer Aided Design and Analysis Software as well as physical destructive tests. Premier’s published load
specifications are the maximum load a given product or part will withstand without failure. Premier’s testing
procedures closely follow the Society of Automotive Engineers (SAE) guidelines of Recommended Practice for
testing Couplings and Drawbar Eyes (SAE J847 & J849).
Maximum Gross Trailer Weight:
Maximum Tongue Weight:
Ultimate Latch/Upward Vertical Capacity:
Maximum Eye X-Section:
Minimum Eye Opening:
Unit Weight:
30,000 lbs. (13,607 kg)
4,500 lbs. (2,041 kg)
5,000 lbs. (2,267 kg)
1 13/16 in. (46 mm)
2 in. (51 mm)
12.6 lbs. (5.7 kg)
“Premalloy” - Premier’s Exclusive Alloy
Whether you use Premier Jacks, Couplings, Drawbar Eyes, Hinge Assemblies or any other
Premier product, regular inspection and maintenance are essential for proper function,
keeping repair costs to a minimum and above all, safe and efficient operation.
To determine wear limits, Premier created Wear Gages that help judge the useful
life of couplings and drawbar eyes (details in catalog). In accordance with Premier
and the Federal Motor Carrier Safety Regulations, these were designed to identify
wear at the critical percentages of 18% and 20%, by measuring the cross-
section of coupling hooks (horn) and drawbar eye loops. 18% wear indicates that
the product should be replaced as soon as possible. At 20% wear, the product is no longer in usable condition
and must be taken out of service immediately and replaced. The latch gage bar measures the gap space between
the top of the coupling hook and the closed latch. If the 3/8” latch gage bar can pass between this region, then
the latch components should be considered worn past safe limits and replaced. Please note that these wear gage
specifications are in accordance with Premier Mfg. Co. and the Federal Motor Carrier Safety Regulations (refer to
other manufacturer’s specifications for wear limits on their products).
Premier also provides Installation Guides for each of our major products. These help guide you through installation,
inspection, routine maintenance and part replacement. Another resource is our website at www.premier-mfg.com.
Here you will find Installation Guides, Service Guides, distributor locations, online catalogs, product information,
trade show schedules and links to trucking resources.
“The harder you work it, the harder it gets” best describes how Premalloy performs.
Premalloy actually work hardens at the contact surfaces during normal use, which results in
longer service life. Premalloy is highly recommended for off-road and aggregate type applications
due to its wear resistant characteristics. Many of Premier’s couplings are made from this exclusive
material. As you are browsing the catalog, look for the Premalloy icon next to the product photos
to determine which models are made of this material.

premier manufacturing company 1-800-255-5387 • www.premier-mfg.com
Page 4
Selecting The Right Equipment
Coupling to Drawbar Eye Cross Reference Chart
2* 3 4 5 6/6A 8 11 20 21 22 23 107 108 110 123 125 126 127 200 200L 203 205 207 238DB† 245DB† 245DB-3† 300 304 305 306 307 309 405 407SE 410
16 •••••••••••••••••••••••••••••••••••
24 •
40 •
100†••••••••••••••••••••••••••• •••••
100-4†•••••••••••••••••••••••••••••••••
130 •••••••••••••••••••••••••••• ••••
135NT ••••••••••••••••••••• •••••• •
140 • • •
150 •••••••••••••••••••••••••••••••••
160 •••••••••••••••••••••••••••••••••••
235NT •••••••••••••••••••• •••••• •
240 •••••••••••••••••••••••••••• •••••
240K •••••••••••••••••••••••••••••••••
270 •••••••••••••••••••••••••••••••••
290 •••••••••••••••••••••••••••••••••
360 •••••••••••••••••••••••••••••••••
370 •••••••••••••••••••••••••••••••••
370B •••••••••••••••••••••••••••••••••
470 •••••••••••••••••••••••••••••••••
470H •••••••••••••••••••••••••••••••••
480 •••••••••••••••••••••••••••••••••
570 •••••••••••••••••••••••••••••••••
580 •••••••••••••••••••••••••••••••••••
580J •••••••••••••••••••••••••••••••••
590 •••••••••••••••••••••••••••••••••••
690/690T •••••••••••••••••••••••••••••••••
770 •••••••••••••••••••••••••••••••••
780 •••••••••••••••••••••••••••••••••
790 • •••••••
880 • •••••••
890/890C ••••••••• •••• •••• ••••• •
2200 •••••••••••••••••••••••••••••••••
2300 •••••••••••••••••••••••••••••••••
2300B •••••••••••••••••••••••••••••••••
2400 •••••••••••••••••••••••••••••••••
2400H •••••••••••••••••••••••••••••••••
Couplings
Drawbar Eyes
† Saf-Tite Product
* Industrial Application
CAUTION: Verify that both the coupling’s and drawbar eye’s rated capacities
meet your application(s) requirements.

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premier manufacturing company Page 5
SAFETY WARNING
This product is designed for towing under normal
conditions within the stated gross trailer weight capacity
of the drawbar eye being used. Do not overload or
abuse this product. Overloading or abuse may lead to
property damage, severe injury, or death.
Bushing I.D.:
Bushing O.D.:
Bushing Length:
2 1/4 in. (57 mm)
4 1/4 in. (108 mm)
4 1/2 in. (114 mm)
Model 536BK Front End Assembly
STANDARD INSTALLATION DRAWING
SPECIFICATIONS
PARTS & ACCESSORIES
Parts Included:
- 536 Housing
- 437AK Poly Bushings
- 349SE-SPL Washer
Bushing Replacements
(Use ONLY Premier’s Bushings):
- 437AK (Poly)
Drawbar Eye is NOT included
(Use ONLY Premier’s Drawbar Eyes):
- 207K Drawbar Eye
- 307K Drawbar Eye

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Model 536BK Front End Assembly
INSTALLATION
These instructions are ONLY for Premier 207K and
307K Drawbar Eyes, and Premier 437AK Bushings,
installed in a Premier 536BK Front End Assembly.
Any substitution or use of non-Premier components
in the 536BK Front End Assembly VOIDS ALL
PRODUCT WARRANTY.
Installation Procedure:
1. The 536BK Front End Assembly and its
accompanying drawbar eye must be installed
to comply with the Federal Motor Carrier Safety
Regulations. Specifically, Section 393.70,
Paragraph C: “Towing of Full Trailers.” Prior to
install or operation, consult with local, State and
Federal agencies, as there may be additional
applicable laws governing installation and use
of this product.
2. One of the three attached Welding Procedure
Specifications; GMAW, SMAW or FCAW, must
be followed. Welding should only be performed
by a certified welder skilled in structural welding
practices.
3. All weld locations must be clean, paint free
and void of any moisture, oil, grease, oxides or
loose or thick scale.
4. The front end structure that the 536 Housing
attaches to must be of sufficient strength to
withstand the load rating of the drawbar eye
it is used with. Figure 1 demonstrates one
example of a proper 536 Housing to front
end connection. The critical features of this
example include a minimum of three points of
contact between the front end structure and
the entire cylinder length of the 536 Housing as
well as fillet welds of adequate size and length.
536BK Assembly after Welding
(Premier 207K & 307K Drawbar Eyes only)
(Premier 437AK Poly Bushings only)
5. Allow the finished structure to cool.
6. Slide the 437AK Poly Bushings into each end
of the 536 Housing.
7. Using extreme caution to avoid damaging or
nicking the threads, slide the drawbar eye all
the way through each 437AK Poly Bushing.
8. Clean and lubricate all visible threads.
9. Slide the 349SE-SPL Washer onto the
threaded end of the drawbar eye.
10. Lubricate the open face of the 349SE-SPL
Washer with 30wt. oil where the 416K Locknut
will rotate against it (see Figure 3).
11. Thread the 416K Locknut onto the drawbar eye
just far enough to remove any free play from
the 349SE-SPL Washer.
12. If an initial gap exists between the flat flanged
base of the drawbar eye and the face of the
front 437AK Poly Bushing (see Figure 2), then
slowly tighten the 416K Locknut until the gap
just disappears as shown in Figure 3.
13. Note the location of one of the 416K Locknut
faces relative to a spot on the 536 Housing
(see Figure 3).
14. Tighten the 416K Locknut no fewer than five
complete revolutions from the position shown in
Figure 3.
15. Place the 208SPL Snap Ring in the groove at
the end of the drawbar eye shaft to complete
the assembly as shown in Figure 4. Use
caution when installing the snap ring and make
certain not to over expand it as this will cause
permanent damage to the snap ring.
16. “IMPORTANT WARNINGS!” sticker was
enclosed. This must be attached to the front
end, adjacent to the drawbar eye, visible for the
end user to read.
Please note: All applications vary and this is a
recommended install starting point for bushing
tightness at 70°F ambient air temperature.
Varying conditions and applications may
require a different initial set up.

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Model 536BK Front End Assembly
Figure 1
INSTALLATION
Figure 2
Figure 3

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INSTALLATION
Figure 4
Model 536BK Front End Assembly
1. Visually inspect the drawbar eye for cracks,
impact damage and/or deformation before
each and every use. Do NOT use if any of
these conditions exist.
2. If the original cross-section of the eye loop has
been reduced by 20% or greater, the drawbar
eye is NOT to be used and is considered out-
of-service.
3. Over time, slack may develop between the
bushings and drawbar eye. Therefore, clean
and inspect every 90 days or sooner if your
application dictates, and adjust or replace the
bushings if slack is noted.
4. This product is designed to be operated within
its free rotation limits. It is the responsibility of
the vehicle designer/end user to assure that
these limits are not exceeded (not binding/
jackknife).
5. WARNING: Prior to towing, make certain that
adequately rated safety chains have been
properly connected.
6. Never weld on any Premier drawbar eye in
order to repair damaged or worn areas. Field
and/or shop weld repairs are inadequate and
may further weaken the drawbar eye.
- Never attempt weld repair of damaged or worn drawbar eyes or front
end assemblies
- Clean and inspect drawbar eyes and eye assemblies for damage or
excessive wear before each and every use
- All welds should be performed by a certified welder skilled in structural
welding practices
- Drawbar structure as well as welds attaching front end assembly to drawbar must
be of sufficient strength to withstand the load rating of the drawbar eye
- Do not bind-up (Jackknife) any application as stresses can cause damage to products
or components, resulting in failure and detachment of the trailer while in use
- Do not apply lubricants to the coupling hook or drawbar eye loop, as they can cover
up possible damage and accelerate wear
IMPORTANT GUIDELINES that apply to all Premier Front End Assemblies
INSPECTION / OPERATION / MAINTENANCE

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Model 536BK Front End Assembly
WELDING PROCEDURES
GMAW
SMAW FCAW

(1) VERIFY THAT BOTH COUPLING’S AND
DRAWBAR EYE’S RATED CAPACITIES MEET
YOUR APPLICATION(S) REQUIREMENTS.
(2) DO NOT OVERLOAD COUPLING OR DRAWBAR
EYE.
(3) INSPECT COUPLING, LATCH AND DRAWBAR
EYE FOR CRACKS, BENDING DAMAGE OR
EXCESSIVE WEAR. DO NOT USE IF ANY OF
THESE CONDITIONS EXIST!
(4) CHECK FOR GAP BETWEEN CLOSED LATCH
AND TOP OF HORN OR COUPLING BALL.
DO NOT USE IF GAP IS 3/8 IN. OR MORE.
(5) MAKE SURE COUPLING IS LATCHED AND THAT
LATCH WILL NOT OPEN.
(6) PRIOR TO USE, ALWAYS CONNECT SAFETY
CHAINS OF ADEQUATE STRENGTH FOR
LOAD(S) BEING TOWED.
(7) DO NOT BIND-UP (JACKKNIFE) ANY
APPLICATION AS STRESSES CAN CAUSE
DAMAGE TO THE COUPLING, DRAWBAR EYE,
OTHER COMPONENTS OR ANY COMBINATION
OF THEM. JACKKNIFING MAY RESULT IN
FAILURE OF PRODUCTS OR COMPONENTS,
RESULTING IN DETACHMENT OF THE TRAILER
WHILE IN USE.
(8) DO NOT APPLY LUBRICANTS TO THE COUPLING
HOOK OR DRAWBAR EYE LOOP, AS THEY
CAN COVER UP POSSIBLE DAMAGE AND
ACCELERATE WEAR.
(9) ALWAYS ABIDE BY ALL APPLICABLE STATE AND
FEDERAL REGULATIONS GOVERNING SAFE
AND PROPER TRANSPORTATION.
(10) NEVER STRIKE ANY OF THESE COMPONENTS
WITH A HAMMER OR ANY OTHER DEVICE.
(11) ALWAYS VERIFY PROPER OPERATION
OF LATCHING SYSTEM AND COUPLING
COMPONENTS PRIOR TO DRIVE OFF.
(12) NEVER USE A COUPLING THAT YOU DO NOT
FULLY UNDERSTAND HOW TO PROPERLY
OPERATE AND VERIFY SECURE LATCHING OF.
(13) NEVER REPLACE ANY PART IN ANY OF
PREMIER’S ASSEMBLIES WITH NON-PREMIER
COMPONENTS. DOING SO WILL VOID ALL
WARRANTY AND POTENTIALLY COMPROMISE
THE UNIT’S INTEGRITY, WHICH COULD RESULT
IN PROPERTY DAMAGE, SERIOUS INJURY, OR
DEATH.
ATTENTION !
End Users must read and follow this information.
DISTRIBUTORS & OEM’S: Please ensure that your customers
are made aware of the following information on this page.
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CONTINUE TO NEXT PAGE FOR
IMPORTANT INFORMATION.

WARRANTY: We warrant all Premier products to be free from defects in material or workmanship for one year. We
will repair or replace, at our option, any Premier product which our examination reveals to be defective, provided
that the product is returned to our factory, at Tualatin, Oregon transportation prepaid, within one year of purchase
by the first retail purchaser. Our warranty does not extend to products which have been subject to misuse, neglect,
improper installation, maintenance or application, nor does our warranty extend to products which have been
repaired or altered outside of Premier’s facility unless the repair or alteration has been expressly authorized in
writing by Premier. This warranty is in lieu of all other warranties, express or implied, and excludes
warranties of merchantability, fitness for a particular purpose and otherwise, and in no event will Premier
be liable for incidental, special, contingent or consequential damages.
DISCLAIMER: Although great care has been taken to ensure accurate information throughout this document,
Premier Manufacturing Company must reserve the right to alter any information contained within. These changes
include but are not limited to: Dimensional changes, load capacity and availability of any part or assembly.
© 2009 Premier Manufacturing Company
All rights reserved. Any reproduction of the photographic images or any other portion of this document, including but not limited to the photocopying, or retention and/or storage
in a retrieval system of any kind, is strictly prohibited without prior express written permission from Premier Manufacturing Company.
WARNING!
This envelope contains important
instructions AND MUST REMAIN
ATTACHED TO THIS FRONT END
ASSEMBLY. It may be removed only
by the End User or by an Original
Equipment Manufacturer who
preserves this envelope and instruc-
tions and provides it to the end user.
premier manufacturing company
THE FIRST NAME IN QUALITY COUPLINGS
800-255-5387 [phone]
www.premier-mfg.com
1-800-255-5387 • www.premier-mfg.com
premier manufacturing company Page 12
Revised: 04/09
Model 536BK Front End Assembly
Installation, etc.