Harbor Freight Tools 1090 lb. Capacity 40_1/2 in x 48 in Utility Trailer Product manual
Contents
1. STAKE 1 12 k 3 12 spo ocococo O o o i 109 1 t eo e 3 12 7 FRONT END BACK END RAIL 1 1 2 3 37 3 1 2 SIDE RAIL 1 112 k 4 46 STEEL ANGLE FIGURE I 32 Cut the Stakes Front End Rails Back End Rails and Side Rails to the sizes indicated in the illustration See Figure l 33 Drill 3 8 holes through the Stakes as indicated in the illustration See Figure I Item 90153 For technical questions please call 1 800 444 3353 PAGE 13 3 8 X 1 3 4 HEX BOLT 3 8 FLAT WASHER 3 8 SPRING WASHER 3 8 HEX NUT FLAT WASHER g SPRING WASHER q 1 HEX NUT FIGURE J 34 determine where to drill 3 8 holes in the Front End Rails and Back End Rails place the eight pre drilled Stakes in the eight Stake Slots of the Trailer and mark the Front Back End Rails with a pencil See Figure J 35 Attach the four Side Rails and Front Back Rails to the Stakes using the 3 8 x 2 3 8 Hex Bolts 3 8 Flat Washers 3 8 Spring Washers and 3 8 Hex Nuts See Figure J 36 Attach the Steel Angles to the Side Rails and Front Back Rails using the 3 8 x 1 3 4 Hex Bolts 3 8 Flat Washers 3 8 Spring Washers and 3 8 Hex Nuts See Figure J Item 90153 For technical questions please call 1 800 444 3353 PAGE 14 OPERATING INSTRUCTIONS Only use a 1 7 8 ball hitch not included on the CAUTION towing vehicle Care must be taken when backing up the T2. NEVER ALLOW ADULTS CHILDREN OR PETS TO RIDE IN THE TRAILER BEFORE EACH USE ALWAYS ATTACH THE SAFETY CHAIN 25 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 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 6096 of the load forward of the Axle 12 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 Item 90153 For technical questions please call 1 800 444 3353 PAGE 4 the Trailer and its payload The towing capacity of the hitch is typically stamped on the hitch drawbar a MAKE SURE THE COUPLER 23 AND THE VEHICLE S BALL HITCH not included ARE OF EQUAL MATING SIZE 1 7 8 AND ARE RATED EQUAL TO OR GREATER THAN THE WEIGHT OF THE TRAILER AND ITS PAYLOAD 8 DO NOT EXCEED 45 MILES PER HOUR WHEN TOWING THE TRAILER Excess speed is a major cause of vehicle trailer accidents 9 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 11
3. Green side marker lights Note Some trailer tail lights black will have two leads in stead of three They con wire clip nect to the harness leads the same way brown to 3 brown color to color amp 5 3 ke 9 c Right light green lead Wired same as left side Denotes wire nut connections Wire Color Codes Left Light Yellow Lead Brown Tail and side marker lights Green Right directional and stop light Yellow Left directional and stop light White Ground to trailer frame BEARING PACKING INSTRUCTIONS Important Read and adhere to the following instructions failure to read and obey all of the follow ing 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 disas sembled 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 Allow all pieces to dry completely Make sure that your hands are thoroughly clean and the bearing packer not included is also thoroughly clean Place fresh clean bearing grease in the packer 5 With the grease filled bearing packer in one hand
4. 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 12 MAINTAIN LABELS AND NAMEPLATES ON THE TRAILER These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement 13 REPORTING SAFETY DEFECTS If you believe your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying the manufacturer Changzhou Nanxiashu Tool Company If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you Harbor Freight Tools or the manufacturer To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 202 366 0123 or write NHTSA U S Department 400 7th Street SW NSA 11 Washington D C 20590 You may also obtain other information about motor vehicle safety from the Hotline Item 90153 For technical questions please call 1 800 444 3353 PAGE 5 DON T TIGHTEN YET TO MAKE ASSEMBLY EASIER wait until assembly is complete and all hardware is in place before tight
5. either integrally or separably to the wheel center member or non pneumatic rim Carcass separation means the pulling away of the carcass from the non pneumatic rim or wheel center member Chunking means the breaking away of pieces of the carcass or tread Cracking means any parting within the carcass tread or any components that connect the tire to the wheel center member Curb weight means the weight of a motor vehicle with standard equipment including the maximum capacity of fuel oil and coolant and if so equipped air conditioning and additional weight optional engine Load rating means the maximum load a tire is rated to carry Maximum loaded vehicle weight means the sum of a Curb weight b Accessory weight c Vehicle capacity weight and d Production options weight Maximum tire width means the greater of either the linear distance between the exterior edges of the carcass or the linear distance between the exterior edges of the tread both being measured parallel to the rolling axis of the tire Normal occupant weight means 68 kilograms times the number of occupants Occupant distribution means distribution of occupants in a vehicle Production options weight means the combined weight of those installed regular production options weighing over 2 3 kilograms in excess of those standard items which they replace not previously considered in curb weight or accessory weight including heavy duty brakes ride l
6. and the bearing in the other press the bearing into the grease forcing the grease inside the slots in the bearing continue doing this until every slot in the bearing is completely full of grease 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 Item 90153 For technical questions please call 1 800 444 3353 PAGE 23 Limited 90 Day Warranty Harbor Freight Tools Co makes every effort to assure that its products meet high quality and dura bility standards and warrants to the original purchaser that this product is free from defects in ma terials and workmanship for the period of 90 days from the date of purchase This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities criminal activity improper installation normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take advantage of this warranty
7. rim diameter in inches The markings on the example tire diagram show 12 The markings on your tire may differ U S DOT tire identification number This begins with the letters DOT and indicates that the tire meets all federal standards The next two numbers or letters are the plant code where it was manufactured and the last four numbers represent the week and year that the tire was built For example the numbers 2107 mean the 21st week of 2007 Any other numbers used are marketing codes used at the manufacturer s discretion This information is used to contact consumers if a tire defect requires a recall Maximum Load Rating This number indicates the maximum load in kilograms and pounds that can be carried by the tire Item 90153 For technical questions please call 1 800 444 3353 PAGE 17 Load Index Rating Codes Code Pounds Code Pounds Code Pounds Code Pounds Code Pounds 71 761 79 963 87 1 201 95 1 521 103 1 929 72 783 80 992 88 1 235 96 1 565 104 1 984 73 805 81 1 019 89 1 279 97 1 609 105 2 039 74 827 82 1 047 90 1 323 98 1 653 106 2 094 75 853 83 1 074 91 1 356 99 1 709 107 2 149 76 882 84 1 102 92 1 389 100 1 764 108 2 205 77 908 85 1 135 93 1 433 101 1 819 109 2 271 78 937 86 1 168 94 1 477 102 1 874 110 2 337 Load index This is a measurement of how much weight each tire can support See chart above The markings on the example tire diagram
8. safe operation If abnormal noise or vibration occurs have the problem corrected before further use Do not use damaged equipment 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 Ib EVERY 2 000 TO 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 TO CLEAN use only water and a mild detergent For technical questions please call 1 800 444 3353 PAGE 20 PARTS LIST AND DIAGRAMS PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUALAS AREFERENCE TOOL ONLY NEITHER THE MANU FACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT 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 MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDER
9. Owner s Manual amp Safety Instructions Save This Manual Keep this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures Write the product s serial number in the back of the manual near the assembly diagram or month and year of purchase if product has no number Keep this manual and the receipt in a safe and dry place for future reference ITEM 90153 1090 LB CAPACITY Haul iaster 12 WHEELS 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 the 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 fol low 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 Visit our website at http www harborfreight com REV 12 Email our technical support at tech harborfreight com When unpacking make sure that the product is intact and undamaged If any parts are missing or broken AWARNING please call 1 800 444 3353 as soon as
10. Running Lights 30 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 F 23 the Yellow Brown Wires to the Left Tail Light 29 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 F 24 Run the Green Brown Wires to the Right Tail Light 29A 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 F 25 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 Item 90153 For technical questions please call 1 800 444 3353 PAGE 11 3 4 THICK PLYWOOD MEASURE WIDTH amp LENGTH OF TRAILER FRAME CUT PLYWOOD TO MATCH WIDTH amp LENGTH OF TRAILER FRAME FIGURE G 26 Toattach a bed not included to the frame of the Trailer you will need the following materials and parts Qty 1 3 4 thick Plywood not included Qty 12 3 8 x 1 1 2 Cross Head Bolts not included Qty 12 3 8 Flat Washers not included Qty 12 3 8
11. Spring Washers not included Qty 12 3 8 Hex Nuts not included 27 Carefully measure the width and length of the Trailer frame Then cut the 3 4 the same dimensions as the Trailer Frame See Figure G 28 Drill three evenly spaced 3 8 diameter holes in the inner flange of each side of the Trailer Then drill three corresponding 3 8 diameter holes in each side of the plywood See Figure G 3 8 FLAT WASHER 3 4 THICK PLYWOOD 3 8 SPRING WASHER FIGURE H 3 8 HEX BOLT 29 With assistance place the 3 4 plywood on the Trailer frame and align the predrilled 3 8 holes in the plywood with the pre drilled 3 8 holes in the Trailer frame See Figure H 30 Secure the 3 4 plywood to the Trailer frame using twelve 3 8 x 1 1 2 Cross Head Bolts twelve 3 8 Flat Washers twelve 3 8 Spring Washers and twelve 3 8 Hex Nuts none included See Figure H Item 90153 For technical questions please call 1 800 444 3353 PAGE 12 31 To attach rails not included to the Trailer you will need the following materials and parts 1 x 4 x 46 lumber not included 1 x 4 x 37 lumber not included 1 x 4 x 12 lumber not included 2 x 2 x 3 1 2 Steel Angle not included 3 8 x 1 3 4 Hex Bolt not included 3 8 x 2 3 8 Hex Bolt not included 3 8 Spring Washer not included 3 8 Flat Washer not included 3 8 Hex Nut not included
12. TAKEN 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 REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Parts List Qty ipti Description aty asen 2 CoterPn amm 2 Dotc Te 1 oO 4 Left Side Rail 5 A Right Side Rail Safety Chain Spring Hanger Tail Light Bracket Spring Side Plate License Plate Bracket Left Tail Light Nylon Nut M10 4 in Right Tail Light in 2 2 2 i 2 i 2 2 i 2 i 2 2 1 2 E Washer 3 4 0 2 1 3 2 5 3 1 4 2 1 5 7 7 8 9 1 9A 11 4 30 12 1 31 1 32 14 33 1 2 34 2 1 2 35 2 36 0 3 5 6 7 Item 90153 For technical questions please call 1 800 444 3353 PAGE 21 Assembly Diagram 1 HEX BOLTS 10 X 20 MM NOT SHOWN 19 3 NYLON NUTS M10 NOT SHOWN 20 8 SPRING SIDE PLATES NOT SHOWN 10 HEX BOLTS 14 X 80 MM NOT SHOWN 22 11 NUTS M14 NOT SHOWN 17 LUG NUTS NOT SHOWN 21 COTTER PINS 4 MM NOT SHOWN 24 BOLTS 10 X 90 MM NOT SHOWN 36 R PIN 3 MM NOT SHOWN Item 90153 For technical questions please call 1 800 444 3353 PAGE 22 4 pin connector Wi ri ng Diag ram White ground wire to trailer tongue Brown
13. d tire inflation pressure and the load limit for this vehicle See the Tire Care section starting on the following page for an explanation of tire pressure and see the Vehicle Load Limit section following that for an explanation of load limit Item 90153 For technical questions please call 1 800 444 3353 PAGE 18 TIRE CARE Checking Tire Pressure Note Underinflated tires can decrease handling stopping performance traction tire life and load carrying capability in addition to causing other negative and hazardous effects including tire failure Overinflated tires are at greater risk of an impact break where the tread and casing break when striking a hard edge often opening a huge gash across the tread Incorrect inflation pressure also increases tires wear rate Therefore it is important to keep tires inflated properly Check all tires pressure at least monthly due to the following factors Most tires naturally lose air gradually Tires can suddenly lose air if the tire strikes a pothole curb or other object is usually not possible to determine underinflation of radial tires by visual inspection This vehicle has 60 PSI recommended cold tire inflation pressure The term cold in this manual does not refer to the temperature outside but it refers to the fact that a tire that has not been driven for a period is cooler and therefore has lower pressure than a tire that has been driven on Tires heat up w
14. ening any nut or bolt Leave hardware snug until then ASSEMBLY INSTRUCTIONS Note For additional references to the parts listed on the following pages refer to the Assembly Diagram near the end of this manual Be sure to read the Bearing Packing instructions on the last page of this manual HEX BOLT 2 1 LEFT dm SIDE RAIL MEMBER 5 4 c CROSS MEMBER RIGHT SIDE RAIL 5A NYLON NUT 3 P NOT SHOWN d FIGURE A 1 Lay out three Cross Members 4 the Right Side Rail 5A and the Left Side Rail 5 Then assemble the parts using Hex Bolts 1 and Nylon Nuts 3 See Figure A Item 90153 For technical questions please call 1 800 444 3353 PAGE 6 DON T TIGHTEN YET TO MAKE ASSEMBLY EASIER wait until assembly is complete and all hardware is in place before tightening any nut or bolt Leave hardware snug until then TOW BAR BOLT 1 SPRING SIDE PLATE 8 NYLON NUT 3 SPRING NOT SHOWN HANGER FIGURE B 7 2 Turn the frame assembly upside down Attach the Towbar 6 to the frame assembly using Hex Bolts 1 and Nylon Nuts 3 NOTE Observe the direction in which the Hex Bolts are inserted See Figure B 3 Attach two of the Spring Hangers 7 to the front portions of the Right Side Rail 5A and the Left Side Rail 5 using Hex Bolts 1 and Nylon Nuts 3 Then attach the remaining two Spring Hangers each with a Spring Side Plate 8 to the rear por
15. evelers roof rack heavy duty battery and special trim Tread means that portion of the tire that comes in contact with the road Tread separation means pulling away of the tread from the carcass Vehicle capacity weight means the rated cargo and luggage load plus 68 kilograms times the vehicle s designated seating capacity Vehicle maximum load on the tire means that load on an individual tire that is determined by distributing to each axle its share of the maximum loaded vehicle weight and dividing by two Vehicle normal load on the tire means that load on an individual tire that is determined by distributing to each axle its share of the curb weight accessory weight and normal occupant weight and dividing by 2 Item 90153 For technical questions please call 1 800 444 3353 PAGE 16 Tire Markings Inner diameter in inches Load index and Speedrating European tire Section width DT certificate in inches 74 U S DOT tire identification number Tire ply composition and materials used Maximum permissible 4 inflation pressure Maximum load rating Information not required by U S DOT Section width This number gives the width of the tire in inches The larger the number the wider the tire The markings on the example tire diagram show 4 80 The markings on your tire may differ Inner diameter This number gives the inner diameter of the tire in inches This is also the
16. ft Side Rail 5 See Figure E 18 Attach a Fender 34 to the Right Side Rail 5A and Left Side Rail 5 using Hex Bolts 1 and Nylon Nuts 3 See Figure E TIGHTEN ALL HARDWARE Now that frame is completely assembled retrace all assembly steps and make sure that all hardware is properly wrench tightened Also tighten lug nuts lug bolts to 90 ft Ib Item 90153 For technical questions please call 1 800 444 3353 PAGE 10 WIRE FROM SIDE RUNNING LIGHT 30 LEFT SIDE RAIL 5 LEFT TAIL LIGHT WIRE FROM SIDE RUNNING LIGHT 30 SIDE RAIL 5A RIGHT TAIL LIGHT 29 i 29A BROWN BROWN YELLOW GREEN FIGURE F 19 Toinstall the Wiring Harness on the Trailer use a Self Tapping Screw 31 to attach the White Ground Wire located at the Plug end of the Wiring Harness to the small mounting hole in the Towbar 6 See Figure F 20 Leave about 18 of wire beyond the Coupler 23 and run the Wiring Harness along the inside of the Towbar 6 to the front Cross Member 4 Then split the Yellow Brown Wires from the Green Brown Wires See Figure F 21 Runthe Yellow Brown Wires along the inside of the front Cross Member 4 to the Side Running Light 30 located on the Left Side Rail 5 Then run the Green Brown Wires along the inside of the front Cross Member 4 to the other Side Running Light located on the Right Side Rail 5A See Figure F 22 Connect the Wire Lead from the two Side
17. he Axle 12 Follow the Bearing Packing Instructions as explained on the last page of this manual Insert the Bearing 18 and a 3 4 Flat Washer 19 on the Spindles Screw a Castle Nut 20 tightly onto each Spindle Then back the Castle Nuts off slightly so that the Hubs 15 can just move freely See Figure D Item 90153 For technical questions please call 1 800 444 3353 PAGE 8 DON T TIGHTEN YET TO MAKE ASSEMBLY EASIER wait until assembly is complete and all hardware is in place before tightening any nut or bolt except wheel lugs Leave hardware snug until then COTTER PIN 21 GREASE FITTING 35 LUG NUT 17 LUG NUT 17 3 4 WASHER cd 19 CASTLE NUT TIRE 16 9 20 JT BEARING 18 DUST CAP G 22 8 Place a Tire 16 on each Hub 15 Secure the Tires to the Hubs using four Lug Nuts 17 per Tire NOTE Make sure to tighten torque the Lug Nuts to at least 90 ft lb See Figure D 9 Insert a Cotter Pin 21 through the hole at the end of each Spindle of the Axle 12 and spread the Cotter Pin See Figure D 10 Press each Dust Cap 22 onto each Hub 15 See Figure D FIGURE D 11 With assistance turn the Trailer over so that its Tires 16 are on the floor ground surface 12 Attach the Coupler 23 to the Towbar 6 using Bolts 24 and Nylon Nuts 3 Lock the Coupler Trigger with the Safety Pin 37 Then insert the R Pin 36 through the hole in the Safety P
18. hile being driven on To check or fill to a tire s cold inflation the tire must have not been driven for more than a mile or two for at least three hours If you check a tires pressure when it is not cold the pressure will appear higher than the actual cold tire inflation Steps for Maintaining Proper Tire Pressure T Locate the recommended tire pressure on the vehicle s tire information placard certification label or in the owner s manual This trailer has 60 PSI recommended cold tire inflation pressure 2 Measure and record the tire pressure of all tires 3 If the tire pressure is too high in any of the tires and the tires have not been driven for at least three hours slowly release air by Item 90153 For technical questions please call 1 800 444 3353 gently pressing on the tire valve stem with the edge of your tire gauge until you get to the correct pressure If the vehicle have been driven within the past three hours and the tire pressure is too high on any tires then recheck the pressure once the tires have been allowed to sit motionless for at least three hours 4 If the tire pressure is too low note the difference between the measured tire pressure and the correct tire pressure These missing pounds of pressure are what you will need to add 5 At a service station add the missing pounds of air pressure to each tire that is underinflated 6 Check all the tires to make sure they have the same a
19. in to secure the Safety Pin in place See Figure E next page 13 To attach the Safety Chain 25 to the Coupler 23 insert a Hex Bolt 1 through the center link of the Chain Then use a Nylon Nut 3 to secure the Safety Chain to the Coupler NOTE Make sure the Safety Chain is the same length on each side See Figure E 14 Attach the Tail Light Brackets 27 to the Right Side Rail 5A and Left Side Rail 5 using Hex Bolts 1 and Nylon Nuts 3 See Figure E 15 Attach the License Plate Bracket 28 and Left Tail Light 29 to the Left Side Rail 5 using Hex Bolts 1 and Nylon Nuts 3 See Figure E Item 90153 For technical questions please call 1 800 444 3353 PAGE 9 LEFT 36 SIDE RAIL SAFETY PIN 37 5 ES D v N BOLT 24 LICENSE PLATE NUT 3 BRACKET 30 TAIL LIGHT 29 HEX BOLT 1 NYLON NUT 3 FENDER 34 RIGHT TAIL LIGHT 55 29A HEX BOLT 1 TAIL NYLON NUT 3 BRACKET FIGURE E 27 16 Attach the Right Tail Light 29A to the Right Side Rail 5A using Hex Bolts 1 and Nylon Nuts 3 See Figure E 17 Remove the Lens from a Side Running Light 30 Insert the Wire Lead of the Side Running Light through the center hole of the Right Side Rail 5A Attach the Side Running Light to the Right Side Rail using the Self Tapping Screws 31 Then reattach the Lens to the Side Running Light Repeat this Step for the remaining Side Running Light and the Le
20. ir pressure If the tires pressure was not measured cold then the pressure should be rechecked with the tires cold as soon as possible Tire Size To maintain safety only purchase new tires of the same size as the original tires Look at the Tire and Loading Information Placard the Specifications Chart in this manual or the sidewall of the tire being replaced If you have any doubt about selecting the correct size consult a tire dealer Tire Tread The tire tread provides traction that prevents your vehicle from slipping especially if the road is wet or icy Tires are unsafe and should be replaced when the tread is worn down to 1 16 Measure tread depth using a tread depth indicator not included Tire Rotation Every 5 000 miles the left and right tires should be switched This will cause the tires to wear more evenly and last longer PAGE 19 Tire Balance and Alignment The tires need to be balanced to prevent vibration when driving This involves attaching small weights to the rim to offset small differences in rim and tire weight The tires also need to be aligned properly Alignment is the orientation of the tires to the road surface and their being parallel This helps the tires to wear evenly and provide better traction Both tire balance and alignment require specialized equipment that is not provided with this vehicle Tire Repair To properly repair a punctured tire the hole needs to be proper
21. ly plugged and patched from the inside of the tire Tread punctures can be repaired if they are not too large Sidewall punctures should not be repaired the tire needs to be replaced if the sidewall is damaged Tires should be removed from the rim to be inspected before being plugged and patched A qualified mechanic should remove the tire from the rim perform the repair and remount the tire VEHICLE LOAD LIMIT Steps for Determining Correct Load Limit Locate the statement The weight of cargo should never exceed XXX kilograms or XXX pounds on your vehicle s placard That figure equals the available amount of cargo and luggage load capacity Determine the combined weight of luggage and cargo being loaded on the vehicle That weight may not safely exceed the available cargo and luggage load capacity If the trailer s load exceeds the cargo and luggage load capacity then the trailer be unsafe resulting in hazardous effects such as Trailer s tires will not be able to maintain traction properly and stopping distance will be increased significantly INSPECTION MAINTENANCE AND CLEANING Item 90153 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 connection and any other condition that may affect its
22. ly use accessories intended for use with this product Approved accessories are available from Harbor Freight Tools 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 equipment 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 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 SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS TO AVOID PERSONAL INJURY AND OR PROPERTY DAMAGE DO NOT EXCEED THE TRAILER S MAXIMUM CAPACITY PAYLOAD OF 1 090 LBS BEFORE EACH USE ALWAYS EXAMINE THE TRAILER FOR PROPER TIRE 16 AIR PRESSURE DAMAGED TAIL LIGHTS 29 29A DAMAGED SIDE RUNNING LIGHTS 30 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
23. n Handle firmly to make sure the Trigger is locked in place and the Handle cannot move Replace the Safety Pin and R Pin See Figure K Make sure to attach each side of the Safety Chain 25 equally to the towing vehicle s rear bumper or frame See Figure K 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 30 and Tail Lights 29 29A at least every 100 miles Carry emergency flares and fire extinguisher if required for operation in your state Carry extra bulbs and fuses if towing the Trailer at night over long distances Item 90153 For technical questions please call 1 800 444 3353 PAGE 15 TIRE INFORMATION Tire Terminology Glossary Accessory weight means the combined weight of automatic transmission power steering power brakes power windows power seats radio and heater to the extent that these items are available as factory installed equipment Carcass means the tire structure except for the tread which provides the major portion of the tire s capability to deflect in response to the vertical loads and tractive forces that the tire transmits from the roadway to the non pneumatic rim the wheel center member or the vehicle and which attaches to the vehicle or attaches
24. possible Copyright 2003 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in Read this material before using this product any shape or form without the express written consent of Harbor Freight Tools Failure to do so can result in serious injury Diagrams within this manual may not be drawn proportionally Due to continuing SAVE THIS MANUAL improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included CONTENTS SPECIFICATIONS m 3 GENERAL SAFETY WARNINGS AND PRECAUTIONS 3 SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS 4 ASSEMBLY INSTRUCTIONS 2c 2 cccccccecsnsceccsssnssssessccescassescecsosnseesssecessnssers 6 OPERATING INSTRUCTIONS esiscccscsscrecveesectundenvendescecevecececouewasssaubeessyee 15 TRE INFORMATION 16 Tire Terminology Glossary eeeeeeeeeeeeeeeeeeeee eene nnn nnn nnne nnn 16 Inu me reer 17 Tire Inflation and Load Lai as ae osama Sino deis eat oni Seno Urt cc 18 1l le cie 19 Checking Tire PEGSSUFG n cece ces cote tuna 19 Steps for Maintaining Proper Ti
25. railer only back up the trailer on a NOTE To reduce friction between the hitch ball and straight path If the Trailer is allowed to turn off the straight path while backing up the Trailer Coupler 23 apply a layer of heavyweight grease could jackknife causing severe damage to the over the hitch ball trailer and to the towing vehicle Temporarily remove the R Pin 36 and Safety Pin 37 Then pull up on the Trigger and lift up on the Handle See Figure K TRIGGER ADJUSTMENT NUT SAFETY NOT INCLUDED CHAN FIGURE K With assistance place the Coupler 23 over the vehicle s hitch ball and pull back on the Trigger and push down on the Handle until the Trigger locks in the slot 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 IMPORTANT If there is play tighten the Adjustment Nut until no play is present After unlocking the Handle the Nut retaining plate holding the adjusting nut in place needs to be pressed back while the Nut is tightened After Nut is tightened the retaining plate needs to fit in place against the flats of the Nut to prevent it from moving This adjustment should be done by 2 people If the Adjustment Nut is too tight the Handle will not lock After the Adjustment Nut is properly adjusted pull back on the Trigger and push down on the Handle until the Trigger locks in the slot Pull up o
26. re 19 pi 1 c 20 NI ec 20 I3 cule 20 Tire Balance and 20 20 VEHICLE LOAD LIMIT 21 Steps for Determining Correct Load 21 INSPECTION MAINTENANCE AND CLEANING 21 PARTS LIST AND nennen 22 Parts CNS e 22 Assembly DISgrar iii ern ects tee eee 23 Wiring Diagram sesasine eee no Pe er noe eee ee ee eee 24 Item 90153 For technical questions please call 1 800 444 3353 PAGE 2 SPECIFICATIONS 4 80 x 12 4PR 1 7 8 Class 40 1 2 x 48 Safety Chain 1 Link Welded 7 32 Diameter x 42 L w S Hooks Lights amp Wiring 12 VDC DOT Approved GENERAL SAFETY WARNINGS AND PRECAUTIONS 1 KEEP WORK AREA CLEAN AND DRY Cluttered damp or wet work areas invite injuries 2 KEEP CHILDREN AWAY FROM WORK AREA Do not allow children to handle this product 3 STORE IDLE EQUIPMENT When not in use tools and equipment should be stored in a dry location to inhibit rust Always lock up tools and equipment and keep ou
27. show 71 The markings on your tire may differ Note You may not find this information on all tires because it is not required by law Speed Rating The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time This does not indicate that the vehicle Tire Speed Rating Codes or rims can safely reach or maintain that speed These MPH Code MPH Code MPH ratings are listed to the right The markings on the F 50 U 124 example tire diagram show M The markings on your G 56 H 130 tire may differ Note You may not find this information J 62 V 149 on all tires because it is not required by law K 68 Z 149 au L 75 W 168 e Tire Composition and Materials Used The M 81 Y 186 number of plies indicates the number of layers of rubber coated fabric in the tire In general the greater the number of plies the more weight a tire can support Tire manufacturers also must indicate the materials in the tire which include steel nylon polyester and others Maximum Permissible Inflation Pressure This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions Tire Inflation and Load Limit MODEL 90153 TIRE SIZE COLD TIRE PRESSURE FRONT 4 80 4 00 12 410 kPa 60 PSI Tire and Loading Information Placard Location The Tire and Loading Information Placard displays the col
28. t of reach of children 4 DO NOT USE THIS PRODUCT IF UNDER THE INFLUENCE OF ALCOHOL OR DRUGS Read warning labels on prescriptions to determine if your judgement or reflexes are impaired while taking drugs If there is any doubt do not attempt to use this product 5 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 6 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 T DO NOT OVERREACH Keep proper footing and balance at all times to prevent tripping falling back injury etc 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 Item 90153 For technical questions please call 1 800 444 3353 PAGE 3 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 REPLACEMENT PARTS AND ACCESSORIES When servicing use only identical replacement parts On
29. the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the complaint must accompany the merchandise If our inspection verifies the defect we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement We will return repaired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state Haul Master 3491 Mission Oaks Blvd PO Box 6009 Camarillo 93011 800 444 3353
30. tions of the Right Side Rail 5A and the Left Side Rail 5 using Hex Bolts 1 and Nylon Nuts 3 See Figure B Item 90153 For technical questions please call 1 800 444 3353 PAGE 7 DON T TIGHTEN YET TO MAKE ASSEMBLY EASIER wait until assembly is complete and all hardware is in place before tightening any nut or bolt Leave hardware snug until then U BOLT 13 AXLE 12 LEFT SIDE RAIL 5 SLIPPER SPRING 9 9 COTTER PIN 33 SPRING BN SPRING HANGER 7 PLATE L 14 HEX BOLT 10 B COTTER 33 HEX BOLT 10 NYLON NUT 3 d FIGURE C 4 Place the Slipper Springs 9 in the Spring Hangers 7 Secure the Slipper Springs to the Spring Hangers using Bolts 10 and Nuts 11 Then insert a Cotter Pin 33 through the hole in the end of the Bolts and spread it See Figure C 5 Place the Axle 12 on top of the Slipper Springs 9 Position a Spring Plate 14 under the Slipper Springs Place two U Bolts 13 over each end of the Axle and each Slipper Spring Then insert the U Bolts through the holes in the Spring Plates and secure the Spring assembly using Nylon Nuts 3 See Figure C 6 Attach the Grease Fitting 35 to the Hub 15 NOTE Every 2 000 to 3 000 miles of use make sure to lubricate the Hub assembly with a heavy duty bearing grease See Figure D next page 7 Carefully slide the Hubs 15 over the Spindles each end of t
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