HEAVY DUTY TRAILER
MODEL 40597
ASSEMBLY AND OPERATING
INSTRUCTIONS
WARNING!
IMPORTANT INFORMATION
This trailer’s Hitch Coupler MUST be
properly secured to the hitch ball of the towing
vehicle. After assembly and attachment, pull
up and down on the Hitch Coupler to make
sure the hitch ball is fitting snugly in the Hitch
Coupler. There must be no play between the
hitch ball and Hitch Coupler. If there is play,
tighten the Adjustment Nut until no play is
present. If the Adjustment Nut is too tight, the
Handle will not lock. Carefully read and follow
the complete instructions in this manual
BEFORE setup or use.
If the Coupler is not secured
properly, the ball could come loose
while the trailer is in motion, possibly
causing property damage, SERIOUS
PERSONAL INJURY, or DEATH.
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
©
®
Copyright 2003 by Harbor Freight Tools . All rights reserved. No portion of this
manual or any artwork contained herein may be reproduced in any shape or form
without the express written consent of Harbor Freight Tools.
For technical questions, please call 1-800-444-3353.
REV 10/04
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reflexes are impaired while taking drugs. If there is any doubt, do not attempt to
use this product.
5.
6.
USE EYE PROTECTION. Wear ANSI approved safety impact eye goggles when
assembling this product. ANSI approved safety impact eye goggles are available
from Harbor Freight Tools.
DRESS SAFELY. Do not wear loose clothing or jewelry, as they can become
caught in moving parts. Wear a protective hair covering to prevent long hair from
becoming caught in moving parts. If wearing a long-sleeve shirt, roll sleeves up
above elbows.
7.
DO NOT OVERREACH. Keep proper footing and balance at all times to prevent
tripping, falling, back injury, etc.
8.
9.
INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.
STAY ALERT. Watch what you are doing at all times. Use common sense. Do
not use this product when you are tired or distracted from the job at hand.
10.
CHECK FOR DAMAGED PARTS. Before using this product, carefully check that
it will operate properly and perform its intended function. Check for damaged
parts and any other conditions that may affect the operation of this product.
Replace or repair damaged or worn parts immediately.
11.
REPLACEMENT PARTS AND ACCESSORIES: When servicing, use only identi-
cal replacement parts. Only use accessories intended for use with this product.
Approved accessories are available from Harbor Freight Tools.
12.
13.
14.
MAINTAIN THIS PRODUCT WITH CARE. Keep this product clean and dry for
better and safer performance.
MAINTENANCE: For your safety, service and maintenance should be performed
regularly by a qualified technician.
USE THE RIGHT TOOL FOR THE JOB. Do not attempt to force small equip-
ment to do the work of larger industrial equipment. There are certain applications
for which this equipment was designed. It will do the job better and more safely
at the capacity for which it was intended. Do not modify this equipment, and do
not use this equipment for a purpose for which it was not intended.
15.
WARNING: The warnings, precautions, and instructions discussed in this
manual cannot cover all possible conditions and situations that may occur. The
operator must understand that common sense and caution are factors, which
cannot be built into this product, but must be supplied by the operator.
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SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS
1.
2.
TO AVOID PERSONAL INJURY AND/OR PROPERTY DAMAGE, DO NOT
EXCEED THE TRAILER’S MAXIMUM WEIGHT CAPACITY OF 1,800
POUNDS .
BEFORE EACH USE, ALWAYS EXAMINE THE TRAILER FOR PROPER TIRE
(part #81) AIR PRESSURE, DAMAGED TAIL LIGHTS (parts #80, #82), DAM-
AGED SIDE RUNNING LIGHTS (part #83), LOOSE BOLTS AND NUTS,
STRUCTURAL CRACKS, BENDS, AND ANY OTHER CONDITION THAT MAY
AFFECT ITS SAFE OPERATION. Do not use the Trailer even if minor damage
appears.
3.
4.
NEVER ALLOW ADULTS, CHILDREN, OR PETS TO RIDE IN THE TRAILER.
BEFORE EACH USE, ALWAYS ATTACH THE SAFETY CHAIN (part #11) OF
THE TRAILER TO THE TOWING VEHICLE. Make sure the Safety Chain is
attached to the towing vehicle with the same length for each side. Do not allow
the Safety Chain to drag on the ground.
5.
6.
ALWAYS CHECK TO MAKE SURE THE PAYLOAD BEING TRANSPORTED IS
PROPERLY AND SAFELY SECURED IN THE TRAILER. Load the Trailer
evenly from side to side with 60% of the load forward of the Axle (part #9).
MAKE SURE THE TOWING VEHICLE IS CAPABLE OF TOWING THE
TRAILER AND ITS PAYLOAD. Make sure the hitch on the towing vehicle is
capable of towing the Trailer and its payload. The towing capacity of the hitch is
typically stamped on the hitch drawbar.
7.
MAKE SURE THE COUPLER (part #1) AND THE VEHICLE’S HITCH BALL
(not included) ARE OF EQUAL MATING SIZE (2”) AND ARE RATED EQUAL
TO OR GREATER THAN THE WEIGHT OF THE TRAILER AND ITS PAYLOAD.
8.
9.
DO NOT EXCEED 45 MILES PER HOUR WHEN TOWING THE TRAILER.
Excess speed is a major cause of vehicle-trailer accidents.
THE TAIL LIGHT BULBS SUPPLIED WITH THIS TRAILER ARE FOR A 12
VOLT DC ELECTRICAL SYSTEM ONLY. Do not attempt to power the Light
Bulbs with any other type or voltage electrical current.
10.
WHENEVER POSSIBLE, PARK THE TRAILER ON A FLAT, LEVEL, PAVED,
SURFACE AND CHOCK BOTH TIRES TO KEEP THE TRAILER FROM
ACCIDENTLY MOVING.
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11.
12.
TRAILER LICENSING NOTICE: Some states may consider this Trailer a vehicle
requiring registration, licensing, and titling. Check with your State Department of
Motor Vehicles for information and guidance on registering, licensing, and titling
the Trailer.
MAINTAIN LABELS AND NAMEPLATES ON THE TRAILER. These carry
important information. If unreadable or missing, contact Harbor Freight Tools for
a replacement.
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts List (page 19) are
included. If any parts are missing or broken, please call Harbor Freight Tools at the
number shown on the cover of this manual as soon as possible.
ASSEMBLY INSTRUCTIONS
NOTE: For additional references to the parts listed on the following pages, refer to the
Assembly Diagram (page 20).
1.
On a flat, level, surface, lay out one Front Left Side Rail (part #3), one Front
Right Side Rail (part #4), one Front Cross Member (part #5), and two Cross
Members (part #20). Assemble the parts, using the Bolts (part #47), Flat Wash-
ers (part #70), Spring Washers (part #66), and Nuts (part #61). (See Figure A.)
TO CENTER OF TRAILER
CROSS MEMBER
(#20)
FRONT RIGHT SIDE RAIL
(#4)
CROSS MEMBER
(#20)
47
61
66
70
FRONT LEFT SIDE RAIL
(#3)
FRONT CROSS
MEMBER
(#5)
TO FRONT OF TRAILER
FIGURE A
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2.
Attach the Right Angle Iron (part #23A) to the Front Right Side Rail (part #4) and
attach the Left Angle Iron (part #23) to the Front Left Side Rail (part #3), using
the Bolts (part #52), Spring Washers (part #67), and Nuts (part #62).
(See Figure B.)
3.
4.
Attach one Connecting Rail (part #2) to the Front Left Side Rail (part #3) and
another Connecting Rail to the Front Right Side Rail (part #4), using the Bolts
(part #47), Spring Washers (part #66), and Nuts (part #61). (See Figure B.)
Insert the two “L” Latches (part #29) through the two Connecting Rails (part #2)
and Front Cross Member (part #5). Secure the “L” Latches using the two “R” Pins
(part #30). (See Figure B.)
5.
Attach the “T” Plate (part #24), Chain (part #11), and Coupler (part #1) to the two
Connecting Rails (part #2), using the Bolts (part #48), Flat Washers (part #70),
Spring Washers (part #66), and Nuts (part #61). (See Figure B.)
FRONT RIGHT SIDE RAIL (#4)
RIGHT ANGLE IRON (#23A)
47
61
66
FRONT
LEFT
SIDE
RAIL
(#3)
“R” PIN (#30)
52
62
67
“L” LATCH
(#29)
FRONT CROSS
MEMBER (#5)
CONNECTING
RAIL
47
61
66
70
LEFT ANGLE IRON
(#23)
(#2)
“R” PIN (#30)
COUPLER
(#1)
“L” LATCH (#29)
CONNECTING
RAIL
“T” PLATE
(#24)
48
61
66
70
(#2)
CHAIN (#11)
FIGURE B
6.
7.
Lay out one Rear Left Side Rail (part #21), one Rear Right Side Rail (part #22),
and three Cross Members (part #20). Assemble the parts, using the Bolts
(part #47), Flat Washers (part #70), Spring Washers (part #66), and Nuts
(part #61). (See Figure C, next page.)
Assemble the front portion and the rear portion of the Trailer, using the Bolts
(part #48) on the top flanges, the Bolts (part #85) on the lower flanges, Flat
Washers (part #70), Spring Washers (part #66), and Nuts (part #61).
(See Figure D, next page.)
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TO REAR OF TRAILER
REAR RIGHT SIDE RAIL
(#22)
CROSS MEMBER
(#20)
CROSS MEMBER
(#20)
47
61
66
70
CROSS MEMBER
(#20)
REAR LEFT SIDE RAIL
(#21)
TO CENTER OF TRAILER
FIGURE C
48
61
66
70
48
61
66
70
FRONT PORTION
85
85
85
85
48
48
61
66
70
REAR PORTION
61
66
70
FIGURE D
8.
Attach the Left Spring Hanger (part #6) to the Front and Rear Left Side Rails
(parts #3, #21), using the Bolts (part #46), Flat Washers (part #70), Spring Wash-
ers (part #66), and Nuts (part #61). Then, attach the Right Spring Hanger
(part #7) to the Front and Rear Right Side Rails (parts #4, #22), using the Bolts
(part #46), Flat Washers (part #70), Spring Washers (part #66), and Nuts
(part #61). (See Figure E, next page.)
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REAR RIGHT
SIDE RAIL
(#22)
FRONT RIGHT
SIDE RAIL
(#4)
REAR LEFT
SIDE RAIL
(#21)
FRONT LEFT
SIDE RAIL
(#3)
LEFT SPRING
HANGER (#6)
46
61
66
70
FENDER
(#26)
54
63
46
61
66
70
54
63
70
66
61
SPRING
PLATE
(#27)
AXLE (#9)
HUB (#12, #75, #79)
WHEEL (#81)
FENDER
SEAT
ASSY.
(#25)
47
61
66
LEAF
SPRING
(#8)
NOTE:
PRIOR TO USING,
LUBRICATE THE
HUB ASSEMBLY.
(#12, #75, #79)
“U-BOLT (#28)
BEARING (#76)
WASHER (#34)
DUST COVER (#33)
NUT (#64)
COTTER PIN (#72)
See note on Page 9
FIGURE E
9.
Attach the two Fender Seats (part #25) to the Left and Right Spring Hangers
(parts #6, #7), using the Bolts (part #47), Spring Washers (part #66), and Nuts
(part #61). Then attach the two Fenders (part #26) to the two Fender Seats,
using the Bolts (part #47), Spring Washers (part #66), and Nuts (part #61).
(See Figure E.)
10.
11.
Attach the two Leaf Springs (part #8) to the Left and Right Spring Hangers
(parts #6, #7), using the Bolts (part #54), and Nylon Nuts (part #63). Insert a
Cotter Pin (part #72) through the holes in the end of the Bolts and spread the
Cotter Pins. (See Figure E.)
With assistance, turn the Trailer upside down. Place the Axle (part #9) on top
of both Leaf Springs (part #8). Place the two Spring Plates (part #27) below
the Leaf Springs. On each end of the Axle, insert two U-Bolts (part #28)
downward over the Axle and through the mounting holes in each of the Spring
Plates. Then secure the Axle and Leaf Springs, using Flat Washers (part #70),
Spring Washers (part #66), and Nuts (part #61). (See Figure F, next page.)
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12.
13.
Insert a Hub (part #12) onto the spindle at each end of the Axle (part #9). Insert
the Bearings (part #76) onto the spindles of both ends of the Axle. Insert a
Washer (part #34) onto each spindle of the Axle. Then secure the Hub and
Bearing assemblies, using the Nuts (part #64). (See Figure F.)
NOTE: Back the Nuts (part #64) off slightly so the Hubs (part #12) can just
move freely. Insert a Cotter Pin (part #72) through the hole in the ends of the
spindles of the Axle (part #9) and spread the Cotter Pins. (See Figure F.)
COTTER PIN (#72)
AXLE (#9)
LUG NUT
(#86)
WHEEL
(#81)
BEARING (#76)
WASHER
(#34)
DUST
COVER
(#33)
HUB (#12)
GREASE FITTING
Greasing Wheel Bearings: Prior
(#75)
to the installation of the hubs
upon the axle, the inner and
outer wheel bearings should be
packed with a quality bearing
grease. Follow theBearing
NUT (#64)
COTTER PIN (#72)
TIRE (#81)
Packing Instructionsas explained
on the last page of this manual.
LUG NUT (#86)
FIGURE F
14.
15.
16.
Place a Wheel/Tire Assembly (part #81) onto each Hub (part #12). Secure each
Wheel/Tire assembly firmly to the Hubs, using the Lug Nuts (part #86)
NOTE: Make sure the Lug Nuts are torqued to at least 90 Ft.-Lbs.
With assistance, turn the Trailer right side up and allow itsTires (part #81)
to rest on the floor/ground surface.
Remove the Lens from a Side Running Light (part #83). Insert the Wire Lead of
the Side Running Light through the center hole of the Front Left Side Rail
(part #3). Attach the Side Running Light to the Front Left Side Rail, using the
Self Tapping Screws provided with the Wiring Harness (part #84) kit.
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Then, reattach the Lens to the Side Running Light. Repeat this Step for the
remaining Side Running Light and the Front Right Side Rail (part #4).
(See Figure G.)
17.
Attach a Tail Light Bracket (part #31) to the Rear Left Side Rail (part #21), using
the Bolts (part #47), Spring Washers (part #66), and Nuts (part #61). Then,
repeat this Step to attach the remaining Tail Light Bracket to the Rear Right Side
Rail (part #22). (See Figure G.)
18.
19.
Attach the License Plate Bracket (part #32) and Left Tail Light (part #80) to the
Tail Light Bracket (part #31) on the Rear Left Side Rail (part #21), using the Bolts
(part #47), Spring Washers (part #66), and Nuts (part #61). (See Figure G.)
Attach the Right Tail Light (part #82) to the Tail Light Bracket (part #31) on the
Rear Right Side Rail (part #22), using the Bolts (part #47), Spring Washers
(part #66), and Nuts (part #61). (See Figure G.)
RIGHT TAIL LIGHT (#82)
47
61
66
TAIL LIGHT BRACKET (#31)
LEFT
TAIL
LIGHT
(#80)
REAR RIGHT
SIDE RAIL
(#21)
REAR LEFT
SIDE RAIL
(#21)
47
61
66
FRONT RIGHT
SIDE RAIL
(#4)
TAIL
FRONT LEFT
LIGHT
BRACKET
(#31)
SIDE RAIL
(#3)
LICENSE
PLATE
BRACKET
(#32)
FIGURE G
SIDE RUNNING LIGHT (#83)
20.
To install the Wiring Harness (part #84), temporarily loosen one Bolt (part #47)
that is located on the Coupler (part #1). To ground the Wiring Harness, bare
about 1” of the end of the White Ground Wire to expose its copper strands. Wrap
the exposed copper strands around and under the head of the loose Bolt. Then,
retighten the Bolt.
IMPORTANT: Make sure the surfaces of the Coupler and Bolt are clean
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in order to provide a proper grounding surface for the exposed portion of
theWhite GoundWire. (See Figure H.)
21.
22.
Leave about 18” of wire beyond the Coupler (part #1), and run the Wiring
Harness along the inside of the Connection Rail (part #2) to the Front
Right Side Rail (part #4). Then, split theYellow/Brown Wires from the Green/
BrownWires. (See Figure H.)
Run the Yellow/Brown Wires along the inside of the Front Cross Member
(part #5) to the Side Running Light (part #83) located on the Front Left Side
Rail (part #3). Then, run the Green/Brown Wires along the inside of the Front
Right Side Rail (part #4) to the other Side Running Light. (See Figure H.)
WIRING HARNESS
CONNECTOR PLUG
WHTE GROUNDWIRE
BOLT
(#47)
BROWN
GREEN
BROWN
YELLOW
WIRE LEAD
FROM
SIDE RUNNING LIGHT
(#83)
WIRE LEAD
FROM
SIDE RUNNING LIGHT
(#83)
YELLOW
RED
GREEN
RED
RIGHT
TAIL
LIGHT
(#82)
LEFT
TAIL
LIGHT
(#80)
BROWN
BROWN
BLACK
BLACK
FIGURE H
See Wiring Diagram on Page 12.
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WIRING DIAGRAM FOR RUNNING LIGHTS
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23.
24.
Connect the Wire Lead from the two Side Running Lights (part #83) to the Brown
Wire on each side of the Trailer. Then, insert Wire Clips along the entire length of
the Side Rails of the Trailer to hold down the Wiring Harness. (See Figure H.)
Run the Yellow/Brown Wires to the Left Tail Light (part #80). Strip the ends of
the Wires about 3/4”. Connect the Yellow Wire to the Red Wire of the Left Tail
Light. Then, connect the Brown Wire to the two Black Wires of the Left Tail Light.
(See Figure H.)
25.
Run the Green/Brown Wires to the Right Tail Light (part #82). Strip the ends of
the Wires about 3/4”. Connect the Green Wire to the Red Wire of the Right Tail
Light. Then, connect the Brown Wire to the two Black Wires of the Right Tail
Light. (See Figure H.)
26.
27.
NOTE: It is recommended that only a qualified technician perform the electrical
service that may be needed to enable your particular make/model vehicle to
power the Trailer’s 12 volt DC lighting system.
To attach a bed (not included) to the frame of the Trailer, it is recommended to
use the following parts:
A. Qty. 1:
B. Qty. 18:
C. Qty. 18:
D. Qty. 18:
E. Qty: 18:
3/4” x 4’ x 8’ Plywood (not included).
3/8”Cross Head Bolts (not included).
3/8” Flat Washers (not included).
3/8” SpringWashers (not included).
3/8” Hex Nuts (not included).
(See Figure I, next page.)
28.
29.
Measure the distance between the eight Stake Slots located on the outer edges
of the Trailer frame. Then, corresponding to the measurements, cut eight
3-1/2” x 1” slots in the edges of the 3/4” plywood. (See Figure I.)
Place the 3/4” squarely on the Tailer frame. As shown in the diagram, drill
eighteen mounting holes through the 3/4” plywood and the frame with a 3/8” high
speed metal drill bit. (See Figure I.)
30.
31.
Use the 3/8”Cross Head Bolts, 3/8” Flat Washers, 3/8”SpringWashers, and 3/8”
Hex Nuts to secure the plywood bed to the Trailer frame. (See Figure I.)
To attach rails (not included) to the Trailer, it is recommended to use the follow-
ing parts:
A. Qty. 8: 1.6” x 3.5”x 27” wood strips (not included).
B. Qty. 6: 0.75”x 3.5” x 48” wood strips (not included).
C. Qty. 6: 0.75”x 3.5” x 94.5” wood strips (not included).
D. Qty. 4: 0.175” x 2” x 2” x 3.5” Steel Angle (not included).
E. Qty. 16: 3/8” x 1-3/4” Hex Bolt (not included).
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3-1/2”X 1”SLOTS
3/8” DIA.
MOUNTING
HOLES
STAKE SLOT
3/4”PLYWOOD
3/8”CROSS HEAD BOLT
3/8”FLATWASHER
3/4”PLYWOOD
3/8”SPRINGWASHER
3/8” HEX NUT
FIGURE I
F. Qty. 8: 3/8” x 2-3/8” Hex Bolt (not included).
G. Qty. 48: 3/8” x 2-3/8” Hex Bolt (not included).
H. Qty. 72: 3/8” Spring Washer (not included).
I. Qty. 112: 3/8” Flat Washer (not included).
J. Qty. 72: 3/8” Hex Nut (not included).
(See Figure J, next page.)
32.
33.
34.
Cut the Stakes, Front End Rails, Back End Rails, and Side rails to the sizes
indicated in the illustration and drill 3/8” diameter mounting holes where shown.
(See Figure J.)
To determine where to drill 3/8” holes in the Stakes, place the eight Stakes in the
eight Stake Slots of the Trailer frame and mark with a pencil.
(See Figure J, and Figure K, next page.)
Attach the Side Rails and Front End/Back End Rails to the Stakes, using
3/8” x 3-3/8” Cross Head Bolts, 3/8”Flat Washers, and 3/8” Nuts.
(See Figure K, next page.)
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DIMENSIONS
SHOWN IN
INCHES.
6.5
27
2
6.5
6
2
2
1.25
STAKE
FRONT END
BACK END RAIL
2
2
8
8
2
2
24
SIDE RAIL
3/8” DIAMETER
18.5825
50.835
94.5
2
18.5825
2
1.25
3/8” DIAMETER
CONNECTING PLATE
FIGURE J
FIGURE K
BACK END
RAIL
SIDE RAIL
3/8”SPRINGWASHER
STAKE
3/8” NUT
3/8”SPRINGWASHER
3/8”WASHER
3/8” NUT
SIDE
RAIL
3/8”FLATWASHER
FRONT
END
RAIL
3/8” FLAT
WASHER
CONNECTING
PLATE
3/8” X 3-3/8”
CROSS HEAD BOLT
3/8” X 1-3/4” CROSS HEAD BOLT
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35.
36.
37.
Attach the Connecting Plates to the Side Rails and Front End/Back End Rails,
using 3/8” x 1-3/4” Cross Head Bolts and 3/8” Nuts. (See Figure K)
With assistance, lift the Trailer rail over the Trailer and lower the Stakes into the
Stake Slots of the Trailer.
To construct and attach a spare tire carrier (not included) it is recommended to
use the following parts:
A. Qty. 2: 3/8” x 12”threaded Bolts (not included).
B. Qty. 2: 3/8” Flat Washers (not included).
C. Qty. 2: 3/8” Spring Washers (not included).
D. Qty. 2: 3/8” Nuts (not included).
38.
39.
NOTE: It is recommended that only a qualified technician perform the following
procedures.
Measure the distance (on center) between two mounting holes located on the
Wheel (part #81). Then, corresponding with the pre-measured distance, mea-
sure and drill two 3/8” diameter holes through a Connecting Rail (part #2).
(See Figure L.)
MEASURE DISTANCE
BETWEENTWO
MOUNTING HOLES.
WHEEL (#81)
FIGURE L
DRILLTWO 3/8”HOLES HERE.
40.
Align two of the mounting holes in the Wheel (part #81) with the two previously
drilled 3/8” holes in the Connecting Rail (part #2). Secure the Wheel to the Con-
necting Rail, using the two 3/8” x 12” threaded Bolts, two 3/8” Flat Washers, two
3/8” Spring Washers, and two 3/8”Nuts. IMPORTANT: When securing the Wheel
to the Connecting Rail, make sure the Tire does not touch the ground surface. If
necessary re-align the Wheel to allow at least 8” from the bottom of the Tire to the
ground surface.
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ATTACHING TRAILER TO VEHICLE
OPERATING INSTRUCTIONS
1.
2.
Only use a 2” ball hitch (not included) on the
towing vehicle.
(See Figure M.)
CAUTION
Care must be taken when backing up
the Trailer; only back up the trailer on a
straight path. If the Trailer is allowed to turn
off the straight path while backing up, theTrailer
could jackknife, causing severe damage to the
trailer and to the towing vehicle.
WARNING! The Trailer load should never
exceed 1800 pounds or exceed the
Trailer’s Bed size.
3.
4.
5.
Make sure to have a qualified technician to grease the Hub Assembly
(parts #12, #75, #79) prior to using theTrailer.
NOTE: To reduce friction between the Hitch Ball and Coupler (part #1), apply a
layer of heavy weight grease over the Hitch Ball. (See Figure M.)
With assistance, place the Coupler (part #1) over the vehicle’s Hitch Ball. Pull up
on the Coupler’s Handle while turning the Handle counterclockwise to allow the
Coupler to drop fully onto the Hitch Ball. Turn the Handle clockwise to lock the
Coupler in place. Pull up and down on the Coupler to make sure the Hitch Ball is
fitting snugly in the Coupler. There should be no play between the Hitch Ball and
Coupler. If there is play, tighten the Adjustment Nut until no play is present. If the
Adjustment Nut is too tight, the Handle will not lock.
6.
Make sure to attach each side of the Safety Chain (part #11) equally to the towing
vehicle’s rear bumper or frame.
COUPLER (#1)
HANDLE
SAFETY
CHAIN
(#11)
ADJUSTMENT
NUT
HITCH BALL
(NOT INCLUDED)
FIGURE M
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5.
6.
Connect the Tail Light Wiring Assembly to the towing vehicle’s 12 Volt DC system.
NOTE: Make sure to consult the operator’s manual of the towing vehicle for
proper connection instructions.
When towing the Trailer over long distances stop and check the tightness of all
connections, Side Running Lights (part #83), and Tail Lights (parts #80, #82) at
least every 100 miles.
7.
8.
Carry emergency flares, and fire extinguisher, if required for operation in your
state.
It is recommended to carry extra bulbs and fuses if towing the Trailer at night over
long distances.
INSPECTION, MAINTENANCE, AND CLEANING
1.
BEFORE EACH USE, inspect the general condition of the Trailer. Check for loose
Bolts and Nuts, misalignment or binding of moving parts, cracked, bent, or broken
parts, excessively worn Safety Chain , damaged Tail Lights/Side Running Lights/
Wiring Harness, loose Lug Nuts, loose Hitch connnection, and any other condition
that may affect its safe operation. If abnormal noise or vibration occurs, have the
problem corrected before further use. Do not use damaged equipment.
2.
3.
BEFORE EACH USE, check the Tires for wear and proper inflation (60 PSI).
BEFORE EVERY USE AND AT 500 MILE INTERVALS DURING EVERY TRIP,
check and tighten the Tire Lug Nuts. Torque from 85 to 90 Ft.-Lbs.
4.
EVERY 2,000TO 3,000 MILES OF USE, lubricate the Hub Assemblies with a heavy
weight bearing grease. Follow the Bearing Packing Instructions as explained
on the last page of this manual. After each Hub Assembly is reassembled, tighten
the Castle Nut until the wheel starts spinning with slight resistance. Loosen the
Castle Nut about 1/6 turn from this point. Insert a new Cotter Pin through the Castle
Nut and the hole in the axle. Bend the Pin back, locking it and the Nut in place.
5.
TO CLEAN, use only water and a mild detergent.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE PARTS LIST AND ASSEMBLY DIA-
GRAM INTHIS MANUAL AS A REFERENCETOOL ONLY. NEITHERTHE MANUFACTURER OR DISTRIBU-
TOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYERTHAT HE OR SHE
IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO
REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTUER AND/OR DISTRIBUTOR EX-
PRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY
CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL
RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR RE-
PLACEMENT PARTSTHERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT
PARTSTHERETO.
SKU 40597
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PARTS LIST
Part #
Description
Qty.
Part #
33
Description
Dust Cover
Qty.
1
2
3
4
5
6
7
8
9
Coupler
1
2
1
1
1
1
1
2
1
1
2
5
1
1
1
1
1
2
2
2
4
2
2
2
1
2
2
4
Connecting Rail
Front Left Side Rail
Front Right Side Rail
Front Cross Member
Left Spring Hanger
Right Spring Hanger
Leaf Spring
34
46
47
48
52
54
61
62
63
64
66
67
70
72
75
76
79
80
81
82
83
84
85
86
Washer
Bolt (M10 x 25)
Bolt (M10 x 25)
Bolt (M10 x 30)
Bolt (M14 x 30)
Bolt (M14 x 70)
Nut (M10)
54
3
2
4
69
2
Axle
Nut (M14)
11
12
20
21
22
23
23A
24
25
26
27
28
29
30
31
32
Chain
Nylon Nut (M14)
Nut (M20)
4
Hub
2
Cross Member
Rear Left Side Rail
Rear Right Side Rail
Left Angle Iron
Right Angle Iron
"T" Plate
Spring Washer (10)
Spring Washer (14)
Flat Washer (10)
Cotter Pin (4 x 36)
Grease Fitting
Bearing (7205)
Grease Seal (30 x 52)
Left Tail Light
69
2
37
2
2
4
Fender Seat Assy.
Fender
2
1
Spring Plate
Wheel/Tire Assy.
Right Tail Light
Side Running Light
Wiring Harness
Bolt (3/8" x 1-3/4")
Lug Nut
2
"U" Bolt
1
"L" Latch
2
"R" Pin (3 MM)
Tail Light Bracket
License Plate Bracket
1
4
5
NOTE: Some parts are listed and shown for illustration purposes only, and are not avail-
able individually as replacement parts.
SKU 40597
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ASSEMBLY DIA
GRAM
84:WIRING HARNESS NOT SHOWN.
86:LUG NUTS NOT SHOWN.
82
22
48
61
66
70
47
61
66
70
20
20
4
85
52
62
80
21
20
67
83
85
47
61
66
31
7
23A
47
61
20
47
61
66
47
61
66
70
46
61
66
70
66
5
3
32
26
85
85
47
61
66
70
2
6
54
63
46
1
61
66
70
23
27
54
63
25
83
29/30
12/75/79
8
24
11
NOTE:
2
47
61
66
48
61
66
70
9
81
28
61
66
76
34
64/72
33
PRIORTO USING, LUBRICATE
THE BEARINGSTHROUGHTHE
GREASE FITTING ONTHE
INSIDE OFTHE HUB.
SKU 40597
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Bearing Packing
Instructions
Important
Read and adhere to the following instructions; failure to read
and obey all of the following instructions COMPLETELY will void the
warranty and can result in damage to the trailer, property damage, or
SERIOUS PERSONAL INJURY.
Whenever a hub is disassembled (if a hub on a new unit requires assembly or
a hub is disassembled for maintenance), the following procedure MUST be followed.
1.
Using a suitable solvent, thoroughly clean the bearings and the rest of the parts in
the Hub assembly of all grease, dirt, metal shavings, or any other foreign object.
The parts must be cleaned even if they are new or appear clean.
2.
3.
Allow all pieces to dry completely.
Make sure that your hands are thoroughly clean and the bearing packer (not in-
cluded) is also thoroughly clean.
4.
5.
Place fresh, clean bearing grease in the packer.
With the grease-filled bearing packer in one hand and the bearing in the other, press
the bearing into the grease, forcing the grease inside the slots in the bearing, con-
tinue doing this until every slot in the bearing is completely full of grease.
6.
Finish assembling the hub/wheel assembly as explained in this manual, being careful
not to get any dirt or debris on any part of the assembly.
SKU 40597
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